Leveraging “Design For Manufacturing” for More Sustainable Buildings

By Patrick
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This blog is adapted from an AIA presentation on Technology and Practice presented in partnership with the UNC Charlotte College of Architecture in October 2016.

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for More #Sustainable Buildings

construction

Design for Manufacturing is a process whereby designers consider the impact of manufacturing processes in the way they design buildings.

Large components—whether large concrete panels or whole modular rooms for an apartment building—might be completed within a factory environment and delivered to a jobsite where they are connected to MEP systems.

To be successful in this approach, designers must work with building component manufacturers to understand their capabilities and design a construction approach that accounts for the logistics of getting modules to the jobsite and installed.

By considering how to optimize factory processes and then most efficiently assembling the modular elements in the field, designers can leverage strategies that greatly eliminate construction waste.

With reduced waste, building owners can adjust their budgets and apply significant savings from improved processes to better materials and overall more sustainable buildings.

The Two Paths to Reducing Construction Costs

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Reducing Construction Costs

Construction projects typically see amounts of waste near 30% due to redundant rework and inefficiency. Without this waste, building owners could achieve significant project savings and reinvest in higher quality materials that are less harmful to the environment.

There are two potential approaches to reducing costs in construction:

  • AEC professionals can continually look for cheaper materials and labor to control construction costs. For example, vinyl is a very popular building material, largely because it is inexpensive compared to wood and other solutions. Yet PVC is made from chlorine salt using lots of electricity in a very environmentally unfriendly process.
  • Alternatively, AEC professionals can change their processes. By adopting a Design for Manufacturing approach, fabricators can automate many of the repetitive tasks that have to be done to produce a building. Fewer, albeit more highly skilled, workers can manage building component production in a safe, factory environment.

The latter approach may require a greater upfront investment, but the return on that investment can be recouped through the dramatic reductions in waste. Those savings can, in turn, be applied to investment in more sustainable building solutions.

Reinvesting Savings in Sustainability

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Green projects are projected to grow significantly in the years ahead. At present, buildings consume 70% of all electricity in the United States, reports the U.S. Green Building Council. There are numerous ways to reduce this electric consumption, but most AEC professionals consider building products rather than building processes as a solution.

Designers’ strategies for achieving sustainable design might range from making tighter envelopes that require less heating and cooling, adding solar panels, using smart lighting controls, to numerous other initiatives.

In the UK and some other countries, laws limit buildings’ greenhouse gas emissions. In some parts of the U.S.—namely, California—there are some emissions limitations set by law, but most green building is done in the name of incentives such as LEED or the 2030 Challenge for Sustainability, among other programs.

But for owners and AEC professionals that truly care about green buildings, it is important to also consider a clean AEC process.

A Design for Manufacturing approach to AEC could potentially lead to cleaner processes than traditional onsite construction.

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for More #Sustainable Buildings

Related Resources

Design for Fabrication Industry Solution Experience

A Treasure Trove of AEC Insights and Discoveries

By Akio
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To create truly innovative structures, today’s AEC professionals must look first at their creation process. Pushing the boundaries requires new technologies, new strategies and a new mindset.

The truly innovative AEC professionals are looking beyond what’s been done, to what’s being done across other industries.

Here you’ll gain insight from experts on the cutting edge of the industrialization of design and construction. Discover how to apply the efficiency of industrialized manufacturing strategies to any project, and the significant advantages this approach can yield.

If we look beyond traditional AEC methods, we can transform the efficiency with which projects are delivered and operated.

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of #AEC Insights & Discoveries”

In these articles, you will gain valuable insight, including:

  1. The benefits of adopting an industrial, manufacturing-based approach toward building design and construction and the new mentality needed to achieve this industrial approach to AEC.
  2. How early collaboration and a focus on installation during design can reduce requests for information and change orders—and increase operational performance throughout a building’s lifecycle.
  3. Tips for implementing manufacturing processes and improving AEC coordination, and the 5 manufacturing strategies that can help construction projects transfer greater value to their customers.
  4. Insight into using virtual design to fabricate buildings with the same efficiency that the aerospace industry uses digital models to assemble airplanes.
  5. How to industrialize work processes to create work packages that can be built and assembled by non-skilled workers.

Access the content now.

explore-4-chapters

Simulation Helps Save the World’s Architectural Heritage

By Akio
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by Kristina Hines

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#Architectural Heritage | @Uni_hassan1 @3DS_SIMULIA

UNIVERSITY HASSAN FIRST

The urge to become an engineer hits many people early on in life. Dr. Hicham Fihri-Fassi first felt the call as a young high school student. “I’ve always liked to innovate, and engineering enabled me to do just that,” he says.

Dr. Fassi has since taken those teenage ambitions and made an impressive career of them—today he serves as professor of mechanical engineering at Morocco’s University Hassan First, and is a member of the Faculty of Sciences and Technologies in Settat (FSTS).

Dr. Fassi with some of his engineering students.

Dr. Fassi with some of his engineering students.

True to his drive for innovation, he’s also responsible for establishing a new research and innovation center at the university, pulling together interested experts from various industrial companies to promote the use of mechanical simulation and other engineering tools, informing and educating his students in the process.

clicktotweetClick to Tweet: The team at @Uni_hassan1 Morocco
uses simulation to restore heritage buildings

Dr. Fassi is also very focused on the wealth of architectural and archaeological sites in the surrounding area, and has become a strong advocate of preserving them. One of the tools he uses for this work is Abaqus FEA software from SIMULIA, the Dassault Systèmes brand for realistic simulation.


Read the full case study on how University Hassan First restored ancient structures using simulation.


Dr. Fassi and fellow researchers at University Hassan First were faced with compatibility problems when replacing centuries old masonry with modern construction block and mortar while restoring heritage buildings.

Fortunately, realistic simulation helped the university identify internal compressive stresses between dissimilar materials.

The masonry on the left was repointed with compatible mortar, the one on the right with mortar of greater rigidity. Note the stress lines extending into the structure—these will eventually crack or even crush the legacy material, leading to structural failure of an important artifact.

The masonry on the left was repointed with compatible mortar, the one on the right with mortar of greater rigidity. Note the stress lines extending into the structure—these will eventually crack or even crush the legacy material, leading to structural failure of an important artifact.

Restoration workers were able to fine-tune repair materials in advance, match the physical properties of legacy materials and avoid potential damage to important architectural structures.

clicktotweetClick to Tweet: You only have 1 shot to replace ancient
masonry w/modern materials for preservation.

CASE STUDY: Discover how researchers at University Hassan First in Morocco study and preserve the interface between mortared blocks in ancient buildings.

Related Resources

Collaborative, Industrialized Construction – Industry Solution Experiences from Dassault Systèmes

SIMULIA for realistic AEC simulation

Originally published on 3ds.com/simulate



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