What is our kit-of-parts approach and why was it needed?

Originally, traditional construction methods were going to be used for the construction of the decanter building for this project – which would house decanter centrifuges used for solid-liquid separation for chemical processing. This meant numerous individual parts were required, with workers from different trades needed to install them, leading to a lengthy construction timeframe.

We explored another option for this using our kit-of-parts approach, a combination of advanced manufacturing, digital design and programme-level thinking to reshape the building process. We analysed and modelled several Modern Methods of Construction (MMC) variations, uncovering an opportunity to leverage 3D primary structural systems, 2D primary structural systems and non-structural sub-assemblies.

This meant site sub-assembly components such as floors, walls and roofs could be manufactured off-site, then delivered and installed immediately once the building was ready to be constructed – with the potential to drastically streamline the project delivery.

What benefits did our kit-of-parts approach bring?

Our research uncovered that a kit-of-parts approach could lead to multiple benefits for this project, ranging from reductions in project delivery to enhanced sustainability. Below we explore the opportunities that not only showed improved outcomes for this project but have the potential to transform other similar chemical industry projects.

1. Saving time by building off-site

Site access issues posed significant challenges for the decanter building’s construction. Our modular, kit-of-parts approach provided another option for walls, floors, roofs and services to be manufactured off-site and then assembled quickly on-site. This would keep the programme moving and avoid delays caused by overlapping works, with the potential for plants to be operational faster.

2. Simplifying construction with the right mix

Our study demonstrated how combining volumetric and panelised construction methods could optimise different building elements while streamlining installation. Volumetric modules were ideal for precision-critical areas like the electrical switchroom, whereas panelised systems accelerated installation and reduced transport complexity. 

Additionally, mechanical and electrical systems were reimagined as modular clusters, reducing the number of components and simplifying on-site work. For instance, 18 types of electrical equipment were consolidated into 11 modular cabinets, significantly improving projected delivery timeframes.

3. Improving onsite safety with pre-assembled components

In the chemical industry, where safety and precision are critical, a kit-of-parts approach was shown to support improved on-site safety by reducing the number of trades and activities required during construction. Pre-assembled panels and modular mechanical and electrical units could all be built off-site and delivered ready for installation, which limited congestion, minimised equipment movement and reduced exposure to hazards.

4. Cutting waste with just-in-time delivery

With limited space on site, logistics were a key consideration of the design. Our kit-of-parts approach provided increased surety that materials could arrive exactly when needed, avoiding storage issues and minimising environmental damage. Alongside this, narrower modules and flat-packed panels were explored, which could reduce transport costs, enhance sustainability and improve schedule certainty.