BE: What are A.G. Coombs’ capabilities in prefabrication?

Daniel Waack: I like to say that if you can imagine it, we can prefabricate it. Likewise if you identify a problem, prefab can be a solution. Some of our best prefabrication outcomes have come from our team identifying a particular challenge on site, leading to an offsite manufactured answer that can be leveraged in other projects moving forward.

Continuous improvement is one of A.G. Coombs’ core values, and prefabrication is one area where this is realised on a day-to-day basis.

We are constantly looking to refine and standardise our prefabricated components to be easier to integrate into building construction, be more cost effective, and more straightforward to manufacture. Standardisation is leading to more and more prefabrication being incorporated into building services design. 

BE: How is the evolution of prefabrication changing construction?

Daniel Waack: Traditional construction has always been about building from raw materials and individual components on site, that began to change with the use of pre-cast concrete panels and prefabricated steel structural items. Similarly, mechanical services were always “stick-built” too, but in recent years the adoption of prefabricated, modular building techniques began to change that, and now as clients come on board with the concept we are moving to a “kit of parts” approach that standardises common sub-assemblies to achieve efficiencies and economies of scale.

What we are now seeing is prefabrication being driven by the services contractor, with the barriers that once existed gradually breaking down as clients and constructors experience the benefits.

Consequently, our capability at A.G. Coombs has progressed from what is now relatively ‘straightforward’ pipe module manufacture to modular assembly on a significantly larger and more sophisticated scale. We now have a strong focus on the assembly component in DfMA (design for manufacture and assembly). 

BE: How is the integration of prefabrication strategies from Early Contractor Involvement (ECI) impacting design?

Daniel Waack: Front end designers and ECI processes are now beginning to incorporate and leverage offsite opportunities at the early stages of design rather than later shoehorning prefabrication solutions in. This is bringing demonstrable benefits to construction projects.

For example, we were able to incorporate our prefabricated riser frame concepts into the early designs of the recently completed Victorian Heart Hospital. This brought a number of benefits to the project including reducing onsite labour hours, working from height risks, program risk and ultimately assisted in delivering an exceptionally high quality build.

Prefabrication now forms part of our standard project methodology, rather than an after-thought post project commencement, with budgets and prefabrication proposals forming part of the initial pricing. This means that the budget can be appropriately allocated at the start of a project, and a clear plan is formed when the project mobilises. This is being made simpler by the standardisation of repeatable items and the ability to therefore confidently price these into each project. 

BE: What benefits does offsite prefabrication bring to a project?

Daniel Waack: Prefabrication reduces the number of onsite labour hours and allows parallel construction (i.e. on site and offsite), which in turn increases the speed of project completion and can significantly reduce program risk. It also reduces the safety risks associated with working on site, and at heights, and improves build quality as prefabrication is occurring in a controlled environment. This can then lead to a reduction in the amount of rework required on site.