In 2023 Volumetric Building Companies (VBC) opened a facility in Ireland, to serve the Irish, UK and European markets. We spoke to David Johnson, VBC’s UK Pre-Construction Director about the new opening and the shape of the modular market.
The new facility in County Monaghan, Ireland, brings vast experience in timber panelised solutions with VBC appointing a team of 27 product designers, architectural technicians and support staff to boost its already diverse modular product portfolio, but what was behind this move and what plans are there for the UK market? “The facility in Monaghan is currently a centre of design excellence that originated from a panelised timber background,” says David. “It is already expanding to support global operations across all systems including hot rolled steel 3D modular and timber 3D volumetric modular. Healthcare is a specific focus in Ireland right now.”
Productivity and national barriers
Modular manufacture is often seen as a way to improve construction productivity – that seems to be perpetually low – why is this so difficult to address and how can offsite methods help improve the way we deliver buildings? Key factors contributing to the lack of construction productivity in the UK can be attributed to the skills shortage due to aging workforce, labour shortages post Brexit, material supply impact of COVID-19 and Brexit but what else? “In the UK specifically the construction process is also weighed down by compliance legislation and the planning process with a contracting process that is cumbersome and time consuming,” says David. “Offsite construction offers the ability to deskill much of the construction process and provide a consistent high[1]quality solution in significantly faster timescales. It allows manufacturing facilities to be located in areas where labour is available providing a more robust and dependable workforce and supply chain giving the ability to deliver much more predictable product in known timescales for costs that do not escalate.”
The UK often proudly likes to see itself as a global leader in offsite construction. But differing political, economic, social and business landscapes have massive impacts, what is the UK construction landscape like in comparison to the USA for example – what are the parallels and differences? “The UK is a leader in offsite construction technology, but, compared to other markets, it is not the leader in the large-scale adoption of offsite methods,” says David. “There is still a fundamental distrust of offsite technologies in the UK by clients, developers and funders. This is in part due to some high-profile failures of both projects and businesses but also just a fear of the unknown. From my experience, the US market is more willing to adopt new systems and technologies and trust the systems proposed. Whilst it differs from state to state, the procurement and work winning process is much simpler with less complex contracts. The delivery process requires less onerous planning and code compliance requirements when compared to the UK.”
Platforms – are they the answer?
Standardisation – does it exist? It seems to be mean different things to different organisations and can be a major obstacle when systems fail, so what can be done to overcome these issues? Much faith has been put in the development and adoption of platform solutions, but do these really solve some of these puzzles surrounding offsite? “Standardisation does exist, but it does not have to mean carbon copy buildings,” says David. “Within VBC we have standardised components that have a degree of flexibility modelled in to allow our systems to flex to meet project specific requirements. Provided projects remain within these defined constraints then a project can be deemed to be standard. The issue is when client’s approach modular providers too late in the project gestation period when too many constraints have been applied. This then stifles standardisation and creates a bespoke process that loses many of the benefits of adopting an offsite solution.
“Platform solutions can certainly help but we need to clearly define what is a platform. Since the release of the UK Construction Playbook many businesses are using the word platform to gain favour with Government clients selling only their own system as a platform. A true platform solution must be a public domain solution that is manufacturable by multiple suppliers, that way, the ongoing issues with confidence and compliance can be largely alleviated. To do this, manufacturers should relinquish reliance on their ‘systems’ and be willing to manufacture a universal platform.
“The Government can help by developing a compliance process that is less demanding than those currently in place with a series of standards that – akin to building regulations – provides the confidence clients and investors needs without the burden of expensive and time-consuming project specific compliance testing. They could also develop and mandate a platform solution on government projects that goes further than the current guidance and principles. For UK Government to harness all the manufacturing capacity in the UK, I’m certain that with full factories and guarantees of future pipeline, modular manufacturing businesses would switch to delivering a pre-approved mandated platform system in a heartbeat.
Mindset change
Innovation is more than creating new products but changing the way construction is approached with offsite offering many benefits – maybe not clearly communicated by the offsite sector itself very well – there are many fantastic projects happening overseas, what can be learned from the international way of doing things? “The single biggest issue we have in the UK offsite sector is the comparison with traditional methods of construction,” says David. “There is a tremendous construction history in the UK with some of the longest trading and most established construction businesses in the world. The UK has a fantastic built environment legacy with our architecture and building history revered around the world, but this brings with it an intrinsic and subconscious adherence to traditional build methodologies. The symbiotic relationship between UK construction and bricks and mortar has not waivered.
“Other countries with less established construction histories are demonstrating a willingness to adopt different methods of construction on a much larger scale and are confident in adopting new building systems and technologies. There is also a willingness in other countries to express the modularity of a building and celebrate the new and innovative approach where the UK has a habit of wanting to cloak buildings is a skin that makes them appear traditionally built.”
As all followers of offsite will know, the UK’s volumetric modular sector had a torrid 2023 with some high-profile business failures inevitably affecting client confidence in offsite. Albeit tied to the housebuilding sector – what can be done to restore some confidence into the modular and wider offsite sector? “It has been a very difficult time for UK modular businesses and without support at government level it will not be the end of the tough times,” adds David. “Businesses have not failed due to system issues or technology problems: they have failed due to lack of committed pipeline and consistent workflow. Whilst the UK Government have independent programmes and departments exploring and implementing the use of modular, it is not widespread, and confidence remains with traditional contracting and construction.
“The mindset of the industry must change regarding the definition of what a modular business needs to be successful. Most modular businesses in the UK and around the world are delivering projects that are individual and bespoke. To really unlock the benefits of modular the paradigm shift has to be made to industrialised manufacturing of buildings and put the ‘system’ ahead of the ‘project’ to ensure buildings are developed not just for offsite construction but for offsite manufacture. If this can be supported by a commitment of continuous volume, buildings will be delivered significantly quicker and cheaper with manufactures able to invest in infrastructure and technology to support improvements in speed, quality and cost.
“I appreciate it is a big ask but to bolster confidence in the sector requires a bold move to give large scale manufacturers the volume they need to demonstrate they can be successful, without it, investment will not come, and the UK volumetric modular sector will remain a cottage industry.”
For more information visit: www.vbc.co
Source: Offsite Magazine issue 41
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