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DfMA and Offsite Manufacturing

We think it’s time to modernise construction. For decades we have refused to accept the limits of traditional construction methods. We have rewritten the rules and re-set the agenda by investing in a pioneering offsite production approach, known as DfMA 70:60:30. Today, this approach is enabling us to construct faster, more safely and more efficiently. It is improving product quality, reducing waste and supporting the creation of a more diverse and digitally-skilled workforce.

Our Offsite Journey

As our sector focuses on how to boost productivity and fuel economic growth, we believe it has never been more necessary to modernise how we deliver the innovative buildings and complex infrastructure society needs and which improve all our lives. We think the answer lies in the widespread adoption of DfMA and offsite manufacturing.

With a call for a step change in productivity and build quality, offsite and modular techniques offer the most realistic solution. The ideas behind this approach have existed for many years, however the entrenched self-interest and short-termism that characterises construction has stifled its wide-spread uptake.

With a mission to become the recognised leader for innovation and excellence in the construction industry, Laing O’Rourke has made significant investments to create real critical mass in the delivery of modern methods of construction (MMC), including pre-assembly and modular solutions.

Design for Manufacture and Assembly 70:60:30 (DfMA 70:60:30)

Through our innovative DfMA 70:60:30 methodology; where 70 per cent of the construction is conducted off site, leading to a 60 per cent improvement in productivity, and a 30 per cent improvement in delivery schedule; we have pioneered a new approach with the potential to step-change the productivity of the construction process.

As a result, more client organisations than ever before – both public and private sector - are recognising the need for innovative building techniques that are safer, cleaner and more efficient and provide greater certainty.

Working collaboratively with our wide range of clients and the architecture, design and delivery supply chain, we are working to increase sector-wide understanding allowing for this value-based agenda to be more widely understood and applied, creating the mechanisms which will enable offsite and modular design thinking to become the future industry standard for construction solutions worldwide.

State of the art manufacturing capabilities

Laing O’Rourke’s manufacturing and modular solutions are transforming traditional construction methodologies into a modern process of component-based assembly. Our global capability provides product sets including precast concrete building components, modular bridges for the highways and rail sector, modular mechanical and electrical plant installations, and completed internal room and services ‘pods’.

The social, environment and economic benefits of DfMA cover:

  • Safer, cleaner delivery with improved health and safety performance on site and a safer, operational asset over its lifetime
  • Higher quality construction with guaranteed quality assurance levels achieved on the end-product
  • Speed – innovative construction projects delivered 30% faster than traditional construction, enabling an earlier return on investment
  • Standardise the invisible, customise the visible - an extensive range of interior and exterior options ensure complete design flexibility
  • Earlier adoption of the latest innovations, fully tested and approved prior to commissioning
  • Greater sustainability through advantages in thermal and environmental performance, lower operational maintenance costs and less waste generation in the construction phase
  • Less waste and greater onsite recycling of materials delivers a ‘greener’ construction outcome
  • Greater efficiency in site logistics with up to 90% fewer vehicle movements reducing disruption to the surrounding communities
  • State-of-the-art manufacturing facilities adopting lean automation processes utilising the latest technologies, providing the necessary scale and capacity to meet all project demands

More than a decade ago we invested in Explore Industrial Park, Nottinghamshire (UK) and it is still the most automated concrete products facility in Europe. Now, more than ever before we have a crucial opportunity to innovate and transform the industry. Using modern methods of construction to reform old standards and outmoded thinking we will be able to deliver buildings and infrastructure more efficiently; and through the creation of a sustainable, modern manufacturing-led construction industry that attracts our future generations, to help rebuild our economy and boost productivity.

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