Supported by

Your guide to specifying Modular Buildings

Your guide to specifying

Off-site
manufacture
Maximising value and
minimising risk

Supported by

Your guide to specifying Off-site manufacture

Your guide to specifying

Off-site manufacture
Maximising value and minimising risk

Contents
1

Executive Summary

Introduction

The Traditional Approach

Avoidable Pitfalls

Early Involvement of the Off Site Manufacturer (OSM)

Design & Specification

Key Requirements for a Performance Specification

13

Conclusions

14

Appendix A

Exploit Suppliers Capabilities

15

Appendix B

Useful Sources of Information

17

Appendix C

Preparing a Tender

18

Courtesy BWA

Supported by

Your guide to specifying Off-site manufacture

Contributors
Doug Waters - Lead Author

BAA Ltd

Nigel Fraser

BAA Ltd

Richard Kelly

BAA Ltd

Richard Ogden

Buildoffsite

Brook Nolson

Britspace

Damian McCoglan

Terrapin

David Appleford

Acermetric

Tom Weaver

Yorkon

Peter Warner

Yorkon

David Johnson

Yorkon

Anna Winstanley

Laing ORouke

Stephen Hough

Crown House Technology

John Stehle

Crown House Technology

Paul White

Crown House Technology

Bassum Burgan

SCI

Michael Lealan

NG Bailey

Paul Jackson

NG Bailey

Frank McLeod

Bryden Wood McLeod

Jeremy Smith

Wilson James

Graham Townend

Framing Solutions

Eric Dean

Panaloc

Abbreviations used:
BRE:

Building Research Establishment

CIRIA:

Construction Industry Research and

Information Association

GA:

General Arrangement drawing

IMMPREST:

Trademark derived from: Interactive

Method for Measuring PRE-assembly
and STandardisation

M&E:

Mechanical and Electrical services

OSM:

Off Site Manufacture

RHA:

Road Haulage Association

SCI:

Steel Construction Institute.

Your guide to specifying Off-site manufacture. Maximising value and minimising risk
R Kelly, BAA
Revision 2, 17 August 2009
3

1 Executive Summary
Buildoffsite and BAA recognised a need for guidance to help

It is beneficial to introduce design freezes into the programme as

client and specifier organisations to get best value from off site

these will help to mitigate the effects of any late design changes,

building suppliers. Generally, it has been observed that tender

which may not be as easy to incorporate when using an offsite

packages are sent out with too restrictive design information

solution.

and too late in the design process. This inhibits the off site
suppliers from fully exploiting their skills and expertise to deliver

The offsite specialist should be involved during the design stages,

efficient economic solutions to meet clients and specifiers

working with the designers, to ensure that the design is not

needs.

taken to a stage where it restricts the benefits that can be

brought through the use of offsite manufacture. An integrated

These guidelines aim to address this problem by advising when in the

design team will generate most value.

design process to involve off site manufacturers and to what level of

design projects should be taken before tenders or requests for

The client should be satisfied that the off site supplier has the

information are issued.

appropriate level of competence required. This is difficult to

establish without carrying out an indepth audit by a

The guidelines are the result of two workshops and a series of follow

manufacturing specialist. Accreditation schemes such as the

up meetings which have been held at CIRIA using the Buildoffsite

Buildoffsite Lloyds Register will help

membership. This has provided knowledge and expertise to advise on

the level of information that is required and when involvement can
most effectively be used in the project process.
There are a number of conclusions which can be drawn as a result;
Initially, design should be kept outline, flexible and should not be
too detailed. Ideally the design should be limited to performance
specifications with clear definition of the purpose of the building
and its functionality, supported by basic layouts, plans and
elevations.
It should be understood at the start of the project that offsite
manufacture has implications for the design, manufacture and
assembly programme. Project programmes must reflect these
variances in stage durations from the start as late adoption of
offsite manufacture may adversely affect completion dates whilst
early adoption can pull it forward.

Courtesy BAA

These guidelines provide practical advice which may be applied to a

wide range of projects, from designing and constructing complete
buildings to designing and manufacturing the service modules which
fit within them.
BAA and Buildoffsite wish to thank all those who took part in the
development if these guidelines, providing information, thoughts,
comments and guidance.

Supported by

Your guide to specifying Off-site manufacture

2 Introduction
It is generally accepted that off site manufacture (OSM) can in
many circumstances present a significantly beneficial alternative
to traditional on site construction. To achieve the optimal level
of intervention by the client and their consultants it is necessary
for the OSM to be allowed to contribute their expertise to bring
the full benefit of OSM early in the project.
To investigate the correct level of intervention and the levels of
specification to be provided in tenders a series of workshops have
been held by BuildOffsite and BAA Limited to consult with the off site
industry.
This is the output from those workshops and it is hoped that their
use by clients and consultants will encourage increased submissions
to tenders invited by construction clients and ensure more effective
use and continued growth in the off site market.

Benefits that may be expected from OSM:

!

Shorter overall programme

Predictability & reduced risk

Lower project cost

Better & consistent quality

Less impact on site operations

A safer project

Reduced material waste

Reduced construction traffic on site

3 The Traditional Approach

While the informed client may have an excellent understanding

Relevant site information

of what they want their building to do and how they want it to

Location

be delivered this can miss the opportunity of further success by

Site constraints & restrictions

using offsite manufacture. Too much constraining information

Site access

included in a tender based on pre-conceived construction

Hours of working

solutions will restrict the benefits that the OSM can bring to the

Incoming services

project

Adjacent structures

Whilst there are a number of procurement approaches, typically the

This level of information is generally acceptable for a traditionally

client and their consultants will produce a package of information for

constructed in situ building but could become too detailed to allow

a tender design up to scheme design as a minimum which will

the OSM to bring their product benefits and knowledge to the

include;

project. Once the design has progressed past outline scheme design
any OSM will have to redesign the project to suit the constraints of

Purpose of the building

Temporary, permanent or re-locatable

will have limitations on spans, loadings, numbers of floors and

Required lifespan or number of moves

transportation. This is a wasteful use of the consultants and the

Access by customers or staff only

OSMs resource and hence the clients money, while restricting the

Defined occupancy levels

useful benefits that offsite manufacture can bring to the project.

Footprint, GAs and elevations

Involving the OSM too late in the project results in more

Room relationships and data sheets

preconceived ideas which then require re-assessment.

Critical restraints

Floor loading requirements

Foundation designs

Ceiling/storey heights

Internal environment criteria

Full internal finishes specification

External finishes specification

M & E requirements

Budget & Time

!

Budget expectations

Timing expectations

Design
!

Clear ambitions for final design and visual profile for the
project

their modular system. All methods, whether steel or timber framed,

Local authority planning constraints

Consideration of future proofing

Supported by

Your guide to specifying Off-site manufacture

4 Avoidable Pitfalls
The offsite manufacturers who were consulted in the

The result of these items is a high proportion of tenders returned

preparation of these guidelines have suggested that the

incomplete, or projects which when completed, fall short of client

following points are the most prevalent causes of tenders being

expectations, bringing the OSM industry into disrepute. This may

returned incomplete or project resources not meeting clients

cause both clients and consultants to doubt the benefits which OSM

expectations.

can bring to future projects.

Over design by consultants

Lack of clarity in performance standards

Too much detailed design too early

Being over prescriptive in non-essential areas

OSM supply chain capabilities & cost drivers not understood

early enough

Consultants trying to design for manufacture without the

specialist skills

Budget constraints ignored

Practicality of build ignored, is it suitable for OSM?

Engineering constraints overlooked

Client standards (especially M&E) which are not appropriate

Courtesy BWA

5 Early Involvement of the OSM

If it is agreed that a project may benefit from off site

The following items have been raised as being of importance

manufacture then early involvement of potential OSM suppliers

to the off site manufacturers

is vital if the design is not to be allowed to go too far down the

Purpose: the need for a clear definition of the solutions

traditional construction route. Involvement should be as early

purpose is considered paramount in the completion of a

as possible and can start by a review of the strategic brief

specification. Above all other concepts the importance of a

including the items listed below;

simple performance specification that does not include

prescriptive pre-design is key

Strategic Briefing Stage

Assess strategic brief with client

standard elements can be important points of compromise

Identify key drivers for success

that must be negotiated between clients and the potential

Identify constraints and risks

Agree process and decision making for design brief

off site manufacturing suppliers

!

Contextual Requirements: the situation within which and

development and approval

surrounding the solution to be proposed should be correctly

Does the project release the inherent benefits OSM can

articulated if an effective and efficient product is to be

bring?

feasibly presented
!

Costing Considerations: clients need to be made aware of the

Some clients may feel that involvement of the OSM at this stage is

costing implications of off site solutions. Understanding the

not appropriate and will detract from the production of an unbiased

impacts of risk, prelims, programme etc not just considering

strategic brief. If this is the case, then the activities listed below
should be assessed for their influence on the project and to prevent

capital cost except where this is the key driver

!

Simplicity is vital: keep the design simple and flexible, this

excessive amounts of unsuitable design work being carried out before

does not mean boring and box like, to allow the OSM to bring

the offsite manufacture route has been fully investigated.

the benefits of their products to the project. Define level to

Outline, Detailed and Final Proposal Stages

!

Identify opportunities and aspirations for design for

manufacture and assembly, agree strategy

Agree process and timing for cost verification and relate

these to design process

Collect historical cost data from similar projects from

potential off site suppliers

Identify opportunity and benefits in early engagement of

supply chain

Identify skills required and who should provide (consultant

versus potential supplier)

Develop processes for seamless engagement of consultants and

suppliers agree deliverables and processes for cost control

Identify site logistics and buildability issues to inform option

selection and design for manufacture and assembly strategy

Manufacturing Concerns: design freeze and exploiting

Agree phasing strategy

visual flair required

!

Costs: clients are likely to benefit from considering the whole

life cost of a building

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6 Design & Specification

The key to gaining the benefit of OSM is to provide a

Dos

performance specification which has ideally been produced in

consultation with the OSM supply chain through early

Share ambitions with the OSM industry

involvement during brief production and proposal development.

Be open & honest

Work with the industry to raise standards & develop products

There needs to be a shift of emphasis away from design onto

Keep specifications simple

purpose and performance. This allows the OSM to tailor the design to

Employ consultants who understand & embrace OSM

suit their method of off site manufacture, to allow maximum benefit

Look for value for money, use tools like IMMPREST to assess
benefits

from their knowledge of module sizes, configurations, spans and

loadings and transportation restrictions. The OSM market seems to

Be receptive to supplier ideas

be developing into two distinct streams with manufacturers who

Use consultants for peer review

produce standard products and those who produce mass customised

Reward success

products.

Use design reviews and a change control process

Give value to speed, quality, safety, waste and predictability

Use off site companies with modern manufacturing methods

The design requirements will indicate one stream or the other. The
parts of the design which affect the clients brand or signature can
be protected by being specified. Other parts of the performance

Donts

specification, acoustics, thermal, lighting levels etc can be set as

levels of performance which need to be met but which the OSM may

Be over prescriptive too soon

design how they are achieved.

Allow consultants to over design

Try to design for manufacture without understanding

Any pre-design that features in a specification will most likely

immediately disadvantage the OSM community, due to the design
consultants lack of expertise in the field of offsite manufacturing.

capabilities and cost drivers

!

Select the off site supplier on cost alone without

understanding their critical capabilities

Solutions to design challenges have often already been addressed by

OSMs.

Courtesy NG Bailey

Specification Contents

Purpose and functionality are the key to effective solutions, for

Any specification should inform as to the purpose and the use that a

example, forecourt check-in facilities at an airport may well be sized

solution will satisfy rather than providing a detailed design that tells

to suit check-in desks and queuing arrangements. This information

the manufacturer how the solution should be fabricated.

would be key, allowing the manufacturers to understand how layouts

could be made to work within standard module sizes.

Specifications should be made as simple as possible, outlining the

solutions purpose and how it will be utilised, not how it should be

How the solution has to be integrated with existing facilities is

designed and manufactured. This requires either earlier involvement

important to allow tolerances to be included in the design and again

by the manufacturer in the design stage or design consultants who

allowing the manufacturers to understand what can be standard

understand the OSMs processes.

modules and what needs to be bespoke.

An aspiration is for the specification to be a single A4 sheet which

Programme

identifies internal & external finishes, environmental concerns and

Programming should be realistic. Detailed design needs to be

project specifics, not a full design that informs the modular builder

advanced early and then frozen. Preparation for offsite generally

how to do their job. Manufacturers do not require details on how

takes longer due to the level of design information required prior to

solutions are to be constructed.

production, start on site is later but work on site is of shorter

duration. Tender periods need to be a minimum of four weeks to
allow the OSM to properly work up their offer. Two stage
development of an offer should be considered.

M & E examples:
Project

Category

Traditional
(weeks)

Off-site
(weeks)

Difference
(weeks)

Benefit

Office

Off-site and
pre-construction

+6

-300%

On-site

-5

+71%

Overall project

10

+1

-11%

Off-site and
pre-construction

17

22

+5

-29%

On-site

140

106

-34

+24%

Overall project

157

128

29

+19%

Hospital

Source: buildoffsite business case studies 001 & 002

10

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Your guide to specifying Off-site manufacture

Compliance
In the case of statutory compliance it is suggested that only

Courtesy Buchan

exceptions, where variations from the standards/regulations are

required, should be included. Otherwise compliance is to be as per
current standards/regulations and is taken as read.
Contractual Arrangements
Contractual and commercial arrangements of the tender must be
clear including options for purchase, lease purchase or hire plus
maintenance requirements where appropriate. Some suppliers may
ask for stage payments ahead of a traditional build programme.
Future Flexibility
Relocation requirements should be realistic and specific. Extra cost is
added to a solution by specifying a requirement for relocation, which
may never actually be required. Consideration should also be given as
to whether requirements for future adaptability, extension and
modification are really necessary.
It is more cost effective to build in future flexibility during
manufacture than as a post construction modification but these will
add cost to the final solution which may be completely unnecessary.

For example, at BREs Innovation Park a show house has additional

support structure built in to allow for the installation of a mobility
hoist from bedroom to bathroom should it be required at a later date.
Inclusion of this support work during manufacturing would be a
fraction of the cost and disruption of a post completion installation.
Logistics
The importance of logistical considerations is not to be
underestimated. Information about site restrictions and integration
with existing facilities is essential and should be fed into the
specification as early as possible. The complexity of the logistics

Consultants
The consultants role should be to interpret the specific requirements
of the client and produce a performance specification. Current
practice is for a clients consultant to complete a comprehensive
specification including a bespoke design for every solution. For
example structural engineers should only request specific loadings
and provide information on ground conditions. Most OSMs have in
house design capability which is 3rd party verified.

demands professional expertise which should be the responsibility of

the supplier/manufacturer.

11

Additional duplicating of consultancy is considered to be inefficient,

Handover information

leading to redesign on the part of the OSM and not allowing them to

OSMs have accurate 2D drawings and 3D models of their products.

use their standard designs and manufacturing expertise.

This combined with a well controlled manufacturing process enables

delivery of very representative as built information, which clients

Design Freeze

are encouraged to ask for.

A complete design freeze such as that used in the manufacture of

automobiles on receipt of a customer order would be necessary for

Keep it simple and:

off site manufacture to be fully effective. However, it would be

unrealistic to believe that a final design could be decided at a very

Allow flexibility to accommodate module design & structure

early stage and remain unchanged throughout the construction

Keep specifications concise & clear with scope for

development by supplier within agreed parameters

process. Instead a suggested phased freeze might be a more

achievable target.
Clients also need to be made more aware, at the time, the impact of

Further to this, clients should be made aware of what are the largest
cost drivers in modular manufacture so that decision making is more
informed. Clients should state what is set in stone and must be
adhered to, for example clients colour schemes and branding.
Clients should be careful to select off site manufacturers who
operate modern manufacturing methods. Although progressive
design fixity is still going to be important, they will be the ones with
most agility to respond to detail change, lead time changes and
quantity design

Courtesy BWA

12

Use the capability of the supply chain

Understand that every supplier is different

Be prescriptive only where you must; finishes, claddings,

changes to a design, so that time and cost overrun on a project could

be easily attributable and not come as a surprise to the client.

Involve OSM early in the design process

acoustics, bomb blast resistance etc

!

Avoid wasteful design activity

Supported by

Your guide to specifying Off-site manufacture

7 Key Requirements for a Performance Specification

The following list of key requirements should be considered for

In addition the tender will need to confirm the type of contract, the

inclusion in any performance specification issued for projects to

appointment of principals (planning supervisor, clients agent,

adopt off site manufacture:

architect, and engineer etc) and details of cost and programme

targets. Commercial arrangements for the tender should also be clear

Requirements (usage, quantity, quality, true design life)

Criteria associated with the site, including location

Limiting dimensions and volumes

Critical functional relationships

Service Requirements: electricity, gas, water, sewerage, fire

A guide to cost and programme

Strengths and forces: imposed loads, exceptional loading

Cladding preference and thermal performance

Fire performance

Acoustic performance, internal & external

Logistic requirements: flat-pack/space frame, transportation,

stating options on purchase, lease purchase or hire.

restrictions, speed of erection, erection requirements

!

Specific interfaces

Security requirements

Finishes required

Sustainability energy targets and materials use

Maintainability and hand over information

Re-locatability

Courtesy Southern Housing Group

Courtesy Caledonian

13

8 Conclusions
The following simple conclusions can be drawn;

Issue performance specifications, dont be too prescriptive

too early in the process

Involve the offsite manufacturer in the design process during

Understand the effect of offsite manufacture on the design,

manufacture and assembly programme stages and make

Understand the cost drivers

sensible allowances

Provide clear definition of the purpose of the building and its

Allow professionals to manage the logistics

functionality

Programme in phased design freezes and understand the

Understand and fully cost the benefits and risks of offsite

manufacture

Keep design simple & flexible, but not boring, to maximise

benefits from the OSM

Dont take the design too far or make it too detailed and
dont try to design for manufacture

Assess the critical capabilities of the off site suppliers that

are intended to be used (NB the Buildoffsite Lloyds Register
accreditation scheme has been established to assist clients
select the best off site suppliers)

Courtesy BWA

14

outline, detailed and final proposal stages

implications of late design changes

!

Dont allow design work to be duplicated (consultant/OSM)

Supported by

Your guide to specifying Off-site manufacture

Appendix A Exploit Suppliers Capabilities

It was suggested by the OSM suppliers involved in the

Dimensional Planning

workshops that an awareness of the current products available

The dimensions of the finished project are critical to the success of

on the market and the associated details would be of great value

the use of modular construction and OSM.

to design consultants and to a slightly lesser degree, clients and

their project managers.

The design should give due consideration to:

Other useful sources to provide further guidance are manufacturers

The planning grid for internal fit out

design guides, e.g. Yorkon and design guides provided by the industry

Transportation requirements, including access

sectors: steel, timber, concrete.

Building form, as influenced by its functionality

Foundation tolerances

The following information is generic with the exception of the table

Production controls

of sizes which will ultimately vary with manufacturer.

Alignment with external dimensions of cladding

Repeatability in modular manufacture

Types of Modules
Modules can be manufactured and delivered in a number of different
formats to suit the needs of the client and the project constraints.
The options typically include:
!

Four-sided modules

Partially open-sided and open ended modules

Open-sided (corner supported) modules

Mixed modules and planar floor cassettes

Modules supported by a primary structural frame

Other module types

!

Stair or lift modules

Non-load bearing pods

Open floor modules

15

Modular dimensions
Application

Internal
wall height (mm)

Internal module
width (mm)

Internal module
length

Ceiling floor
zone (typical)

Study bedrooms

2400

25002700

5.4 to 6 m

300 mm

Apartments

2400

3600

6 to 9 m

450 mm

Hotels

24002700

33003600

5.4 to 7.5 m

450 mm

Schools

27003000

30003600
open-sided

9 to 12 m

600 mm

Offices

27003000

3600

6 to 12 m

600750 mm

Health sector

27003000

30003600
open-sided

9 to 12 m

600750 mm
Source: RHA

Transportation and Logistics

Not only do projects need to consider designing to suit where

Movement of modules of different widths requires different police

notices, escorts and additional crew as listed below for the UK:

possible generic module sizes but also for the restrictions on

transportation and site logistics.

Modules exceeding 2.95 m width require two days police

notice

Modules exceeding 3.5 m width require a drivers mate and

two days police notice

Modules exceeding 4.3 m width require police escort

Maximum practical height of the load is 4.95 m although

there are no legal height restrictions on UK roads.

Standard container vehicles are typically 6.2 m or 12.2 m

long; they can delivery one large or two small modules
Source: RHA

NB Air suspension equipped vehicles may rise when in motion

causing the load height to increase

16

Supported by

Your guide to specifying Off-site manufacture

Appendix B Useful Sources of Information

Buildoffsite
[Link]
Buildoffsite

Glossary of Terms
[Link]
Loughborough University

IMMPREST Toolkit
[Link]
SCI

Case Studies on Modular Steel Framing

The Steel Construction Institute, ISBN 978 1 85942 095 9
Gibb, A G F

Off Site Fabrication

Whittles Publishing, ISBN 978 1 87032 577 6
Lawson, R M and Grubb, P J

Modular Construction Using Light Steel Framing: An Architect's Guide

The Steel Construction Institute, ISBN 978 1 85942 096 6
Department for Education and Skills (now Department for Children,
Schools and Families)

Toilets in Schools
DFES 00365 2007, ISBN 978 1 84478 925 2
Offsite Magazine
Published annually by Building Magazine in association with
Mtech

17

Appendix C Preparing a tender

Flow Chart to help create a concise tender for issue to Offsite
Manufacturer

Have the criteria to

decide modular against
traditional been
assessed?

No

Complete
assessment

Yes
Have the key drivers
for OSM been
identified?

What are the risks and

constraints?

What will the building

be used for?

What absolutes are

required?

What are the

variations from normal
standards?

Logistics
M&E
Sustainability
Value
Speed
Quality
Labour
Site access

Ceiling height
Finishes
Re-locatability
Interfaces
Maintainability
Loadings
Fire rating
Acoustics

Concise tender for issue

to potential OSMs

18

Your guide to specifying modular buildings: maximising value and minimising risk
Buildoffsite and BAA recognised a need for guidance to help client and specifier organisations to get
best value from modular building suppliers. Generally, it has been observed that tender packages
are sent out with too restrictive design information and too late in the design process. This inhibits
the modular suppliers from fully exploiting their skills and expertise to deliver efficient economic
solutions to meet clients and specifiers needs.
These guidelines aim to address this problem by advising when in the design process to involve
modular manufacturers and to what level of design projects should be taken before tenders or
requests for information are issued.
The guidelines are the result of two workshops and a series of follow up meetings that have been
held at CIRIA using the Buildoffsite membership. This has provided knowledge and expertise to
advise on the level of information that is required and when involvement can most effectively be
used in the project process.

[Link]