RESEARCH & DEVELOPMENT
MotionFrame have analysed many facets of the UK Construction market in the process of developing the MotionFrame product portfolio.
A key market for interrogation has been the commercial sector due to MotionFrame’s extensive hands on knowledge of the end to end practical, business, and commercial aspects of this segment.
We have experience of the good and the bad, the disparity between expectation and delivery and the impacts on the stakeholders throughout the lifecycle of the drywall product. The current climate sees a market that in certain respects falls short of expectations, and in a few cases leaves a legacy of issues that could lead to disastrous outcomes.
MotionFrame’s product set has been developed with process, inter dependencies, quality, sustainability, and safety consideration in equal measure. Our findings and remedies, through the adoption of the MotionFrame product set, for the commercial sector are as follows.
Programme and Sequence
The following observations have been extracted from a traditional high-rise apartment block build sequence that has been adapted to swap out the traditional drywall system for the MotionFrame Walling System.
The MotionFrame Walling System is 50% faster to install with a 43% saving on labour costs and delivers M&E handover reductions from 6 adopting traditional methods, to only 2.
The reduction in handover volumes will significantly reduce the probability of quality related issues and will increase the productivity of the M&E contractor; the services teams will be also be able to take an entire floor and efficiently complete their works in a single visit.
Commercial Build - System Benefits
The MotionFrame Walling System, which incorporates the MotionFrame Stud System, is a total internal walling solution that caters for the demands of bidirectional building movement in a unique and innovative off-site manufactured solution.
MotionFrame have adopted parametric modelling for all system designs. Templated generic model components are adapted per project type through dimensional and performance data inputs which are then combined to create the total build design for BiM integration.
Elevations are designed before build works commence, ensuring that all detailing considerations and subcontractor interdependencies are dealt with during the preconstruction stage.
The panels are fabricated at the manufacturing stage with allowances for M&E services as per the design; these include all service cut outs for light switches, sockets and larger BWIC openings for ducts and pipework.
The solitary build model’s data delivers all published project outputs for manufacturing, installation, and detailed interrogation. Any design updates are therefore cascaded to all stakeholders ensuring synchronicity of information
Manufacturing and Logistics
Quality of the system is guaranteed through the high standards and tolerances achieved in the controlled environment of offsite manufacturing.
System consignments are manufactured and stored ready for call off on a ‘just in time’ basis and then delivered directly to the workface, freeing up valuable site storage space for other trades.
MotionFrame Walling System consignments are delivered to site uniquely identified, palletised by elevation and in build order ready for swift installation.
MotionFrame Walling System panels use higher performance materials than traditional drywall systems and are therefore robust in use and have severe duty finishes, delivering performance throughout the complete lifecycle of the system.
Traditional method quality issues are eradicated as the design and preplanning of the MotionFrame Walling System combined with the stringent offsite manufacturing protocols of an engineered panel and the simple on-site installation process significantly reduces the opportunity for poor quality workmanship.
Compared with traditional systems, the MotionFrame Walling system does not require excessive material contingencies for damage, waste, or loss (25% of total material volume). Therefore the, transportation and site logistics are significantly reduced with fewer deliveries, lower crane or hoist time and the removal of unnecessary relocation and distribution of material product around site.
The System panels are dry fitted and placed into a state of bi-directional compression that results in the formation of a robust elevation. This method, combined with the inline damping properties of the legs, caters for a degree of horizontal and vertical deflection, whilst retaining a rigid and high performing installation.
Site supervision and quality management headcount is reduced due to simplistic and formulaic build processes that significantly remove the margin for error.
Fire compartmentation lines are strictly followed through a simple installation process with uncomplicated stud arrangements at interfaces, removing the requirement for high volumes of detailed drawings that are difficult to follow and equally as difficult to build.
System installation at site creates negligible waste, with less than 2% of the total walling area requiring nominal trimming (which is subject to build tolerance variations) and all studs delivered to site cut to length, the MotionFrame Walling System therefore does not contribute to the excessive site waste management burdens of traditional methods.
The dry fitting of the system panels through compression allows them to be demounted, stored, or repurposed for alternative living environments, as necessary. The embodied carbon rating for the system therefore far exceeds the sustainability performance of traditional walling solutions and materials.
Commercial Build - Quality
In 2016, conservative estimates suggested that poor quality workmanship costs the UK construction sector between £1Bn to £2B (1% - 2%) per annum. In comparison, the American estimate was as high as 5-6%.
The Chartered Quality Institute in collaboration with academia and industry are endeavouring to unravel the true impacts of quality failure in the industry.
Traditional methods of internal walling fit out are persistently failing to deliver on quality and as such the subcontractors are regularly in dispute with their clients over a failure to deliver on contracts in hand or more damagingly falling victim to historic legacy fit outs; which are disruptive and costly for both the Major Contractor and themselves.
It is estimated that up to 7% of a subcontractor’s turnover is spent on legacy related corrective rebuild costs due to substandard workmanship. Quality costs are therefore a major challenge in the sector.
The cumulative effects of these costs for main contractors and the developer’s businesses are widespread and reputationally damaging.
Commercial impacts beyond disruption costs include:
Liquidated and Ascertained Damages (LAD’s)
The design and preplanning of the MotionFrame Walling System combined with the stringent offsite manufacturing protocols of an engineered panel and the simple on-site installation process significantly reduces the opportunity for poor workmanship.
The MotionFrame Walling System incorporates only eight components on a typical build that need to be assembled on site. Only one of these components requiring any on site cutting.
Commercial Build -Environment
The MotionFrame Walling System significantly reduces waste and the associated management costs as already outlined.
Optimised manufacturing off site with recyclable materials
Site ready and dimensioned panels requiring no trimming.
Compression area completion (less than 2% of the wall area) will require a level of trimming
High performance laminates with robust severe duty face boards that are resistant to onsite, preinstallation damage
MotionFrame Stud lengths can be delivered from the manufacturer cut to length
MotionFrame Stud components supplied to the required volumes
Waste management savings are therefore also significantly reduced.
Traditional methods of material contingency allowances (at typically +25% of requirement) lead to:
Additional transport to site
Additional unloading, distribution and redistribution
Potentially 25% Waste
Beyond the excessive and unnecessary environmental impact, all the above have sizeable commercial costs that can be significantly reduced through the adoption of the MotionFrame Walling System