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Lessons from New Zealand:
what’s going on over the ditch
Pamela Bell
PrefabNZ CEO
Melbourne
August 2014 Thomas Edison ‘Single Pour System (1906-1919)
Matti Suuronen ‘Futuro’ (1968-1978)
Introducing Prefab: Andre Hodgskin, Architex ‘I-Pad’ (2005)
Design in LARGE
CHUNKS
Greater profitability at SCALE
Certify with CERTAINTY
Build FASTER
•  prefab / prefabrication =
construction off site
(offsite or OSM)
+ assembly at site
•  prefab complements
traditional methods
S, M, L, XL…
Prefab types
Component -
Panel (2D) -
Volume (3D) -
Hybrid -
Complete Building NZ’s prefab pioneers
Pre-1800s Maori Raupo Whare
1830s timber frame from UK + Australia
1900-1930s = 1,600 timber kitset houses for Railway workers
1930s-1940s = State Housing panel programme with returned servicemen
1960s = 850+ timber frame houses create Twizel for Hydro-scheme workers
1970s = Industrialised Building Systems planned 1,200 houses each year
1960s-2000s = 40,000+ Lockwood solid wood component system houses
1. Components
NMIT (ISJ Architects)
NMIT (ISJ Architects)
Prenail roof trusses and wall frames – 95% new build residential (PlaceMakers)
Custom component systems, bachkit + I-pad (Architex), k-bach (SPA)
2. Panels
Britomart (Stanley)
Tiltpanel House (ISJ)
Compressed timber panel systems, eg. Metrapanel, Triboard
Composite panel systems, eg. SIPs, CLT, MagOx and Custom Panels
3. Volumetric
Elam Hall (Stanley)
468 bedsit modules
Make 5-7 modules per
day
Install 6 modules per
day
0.5% wastage
100% completed
bedroom pods
Volumetric / modular systems, eg. bedsit modules by Stanley Construction
Elam Hall (Stanley Group)
Restart Mall (BuchanGroup)
2. Hybrid (module+panel)
Victoria University of Wellington First Light team + industry
2011 Solar Decathlon 3rd, NZIA International Award 2013
First Light House (FL Studio)
Whakahoro Eco Lodge (FL Studio)
Hybrid module+panel system, Vision West Housing (Studio 19 Unitec + SGA)
5. Complete Building
Park Terrace (Architex / KHH)
Complete buildings, eg. Cottages NZ + port-a-bach (Atelier Workshop)
Reframing prefab / offsite
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increased quality control
shorter time-frames
cost-effective
efficient resource use
architect design
health and safety benefits
Vision West (SGA)
NG Bailey, 2013
Saving time = Saving $$
Page,2012
Intangibles
•  Improved H&S due to better
control of site activities
•  Better quality – 50% of
respondents say high impact
•  Good for restricted sites –
scaffold, staging areas,
material storage etc.
•  Better certainty of project time
– 66% respondents say
decreased time
•  Less environmental impact – an
average saving on material
waste of 6%
Massey University CoCA (Arrow International)
The ‘s’ word
•  material and energy resource benefits:
–  90% waste can be reduced
–  50% saving in construction energy use
–  easier capture and reuse of materials
–  reduced defects
•  social sustainable benefits:
-  less noise, pollution, scaffolding and
traffic at site
-  reduce habitat disturbance at site
-  safe, healthy, controlled indoor
environment
-  protect materials from wet weather
-  designs for flexibility and disassembly
What’s tricky about prefab / offsite?
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misperceptions
individual site context
transport box restrictions
limited market size
start-up costs
Global prefab / offsite?
USA: prefab is about 85% of non-res buildings
NZ: prefab is about 52% of non-res buildings (main frame, floors, walls, roof)
+ 17% of residential buildings (measured by component by cost)
USA = Dwell magazine, MoMA (NY) Home Delivery, Dwell on Design (LA)
New York: The Stack residential + Jackson Green (NJ)
Atlantic Yards, 32 storeys, 1,500 unit mixed use complex
Tallest modular building in the world
Wikihouse Open Source Architecture + MIT ‘Digitally Fabricated Housing’(2004)
UK: Murray Grove
3 days per floor (4pp)
Saved 22 wks, 30% on precast
Units sold in 1 day off plans
UK: brick n-tile prefab
Sweden: prefab custom panels are the traditional construction technique
China: 2012, Broad builds T30 30-storey hotel in 360 hours (15 days)
2011, T15 15 storeys in 48 hours – future is 202 storey vertical city….
China: Interprefab, May 2013
Germany: Bauzentrum Poing – 54 display houses, incl Hufhaus
Japan: Sekisui House + Daiwa, Sekisui Heim + Misawa – 15% market, 8%+ cost
Sekisui House builds 50,000 houses pa (twice the total building consents in NZ)
incl 5,000 Zero Energy (half of all detached houses)
Fun times @ PrefabNZ since 2010…
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Portal website
Newsletter
Events and Conference
Technical Seminar Series
Media / Magazines
Kiwi Prefab Exhibition and Book
Publications – Roadmap, Value Case
HIVE Christchurch
Stakeholder groups – Government (MBIE),
Construction Industry Council (CIC),
Productivity Partnership, etc.
Events: 24 regional events
+ 2 major 3-day conferences
Partners + Stakeholders: everything is a collaboration
Board + Members – the magic is in mixing it up – it’s a simple equation of great
minds and an open collaborative approach to working together
VUW + Puke Ariki, New Plymouth summer 2012-13 - 54,000 visitors in 4 months
NZ’s first book on prefab - www.aaltobooks.co.nz
Roadmap
Value Case for Prefab
•  Save 15% construction cost
(NZD30-40k)
•  Save NZD 2.5M by reducing
tenders to 2 quotes
•  60% reduction in time
•  Increase industry productivity by
2.5% (= 0.25% GDP increase)
Page,2014
Ministerial Briefing, Housing for the Future, Retirement Villages Conference
HIVE Christchurch
•  HIVE Home Innovation Village
•  One-stop-shop housing showcase
•  Christchurch City Council leased site
•  Open April 2012 – September 2014
•  Over 20,000 visitors to date
•  www.homeinnovation.co.nz
9 dwellings at site over two years – award winning housing designs
HIVE Auckland
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High-quality, functional and costeffective permanent medium-density
housing with temporary showcase
•  Precedent hybrid prefabrication
technologies and medium-density
typologies – panels + volumes
•  Stakeholders incl. Auckland Council,
Auckland Council Property Ltd,
BRANZ, MBIE, Productivity Partnership,
Beacon Pathway, AECOM, AUT, CMA
+U, NZGBC Homestar, Lifemark,
Jasmax, Wraight + Associates etc.
Productivity Partnership, 2013, updated 2014
Summary
$
1.  key message is that prefab saves time,
saving time = fastest way to save money
2. informing / educating about prefab
means proving the economic value case
= quantifying qualitative benefits
3. 5 years of communication in NZ, focusing
on quality design + construction, and
demonstration through show-and-tell
= making inroads with key stakeholders
2015 Prefab Co-Lab
22 - 24 April 2015, Wellington, New Zealand
[email protected]
www.prefabnz.com

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