If offsite holds the key to construction’s future, we must change the way we approach project design. Craig Johnson, Trimble’s Field Sales Representative – New Accounts, describes why a Design for Manufacture and Assembly (DfMA) approach is so vital.

If we are to deliver on the offsite vision, it is essential that it is considered from the very outset of a project. It is well known that the success of any project will often be determined as early on as the initial concept and design phase, with each completed stage in turn influencing and shaping the next. Indeed, the process stretches far before and beyond the final construction and assembly phase. Only if a project is designed, modelled and detailed with offsite manufacturing and assembly in mind, can the value of these modern methods be realised.

Defining DfMA

Defined as a methodology that focuses on simplifying the design of a product or component to improve its ease of manufacture and assembly, structures designed in this way can help to push the well-publicised benefits of offsite even further. Whether this a reduced construction programme time through to improved efficiency and productivity levels on-site. How can you best incorporate DfMA principles on your next offsite project? At its heart is correct first-time products, accurate manufacturing and assembly tolerances, as well as a structure that is designed to be easily assembled. Digital technology is surely the perfect partner, with the benefits and capabilities of 3D modelling, cloud-based collaborative environments and streamlined data flows from office to field and vice versa, all aligning with the demands and requirements of offsite construction.

DfMA in action

Winner of ‘Infrastructure Project’ in the 2024 UK Tekla Awards, the Gatwick Airport Station upgrade was undertaken to improve the facilities within the station. Specifically addressing issues with overcrowding and improving the passenger experience, it also ensures additional capacity for future growth. It was a critical requirement for the project to try and deliver these works while maintaining near normal operations for the passengers using the station. One of the key components was the expansion of the existing station concourse, which had to be built over the top of four existing live tracks and platforms. This required the maximising of all DfMA opportunities and extensive advance co-ordination with MEPH and Finishes, while also ensuring full integration with existing structures and services.

Kilnbridge Construction Services were tasked with delivering three structures within the scope of works, collaborating with Costain, Systra, Emico and others to deliver the project successfully. The main overarching challenge on the project was the severe spatial constraints, with virtually every component having to arrive on the project ready for direct installation and the Kilnbridge team having to maximise the amount of work completed on all components offsite. This was achieved in several ways, including:

• Extensive co-ordination and allowance for cladding and MEPH support structures and penetrations, to ensure they were fully integrated at design stage

• Development and integration of connections and interfaces with all balustrades and glazing by third parties

• NC and PDF files for each component were exported directly from Tekla Structures for profiling, cutting and drilling using full CNC operating systems

• Ensuring exact build sequence management
• IFCs for the individual assemblies were used to assess transportation constraints, including swept path analysis and crane lifting operations to ensure weights were compatible with size restrictions.

Learn more about the value of Trimble’s digital offering for offsite construction at 2024 Offsite Expo, Stand F16 For more information visit: www.tekla.com/uk

Image: The Gatwick Airport Station upgrade was best ‘Infrastructure Project’ at the 2024 UK Tekla Awards

Source: Offsite Magazine – Issue 44

Offsite Expo 2024

Heading to this years’ Offsite Expo? If so, ensure you head across to stand B14 and pick up your free copy of Offsite Magazine!

Registration is free, visit www.offsite-expo.co.uk for more.