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B2 -Atlantic Yards Brooklyn New York

Rob Francis Director, Innovation & Improvement

Assembly not Construction Lean Construction in practice

Collaborative Partnership

50/50 J.V.

Unique Structural design

Banker Steel

McGrath Facade

Atlantic Yard Master Plan


8 buildings in 8 years 4000 apartments

BARCLAYS ARENA

B2 footprint

First phases integration to Barclays Centre

B2

First Modular Residential Building: B2


Residential building at Atlantic Yards Modular construction 348,000-square foot (210/sq.ft) 32-story building Approximately 363 rental apartments (201k ea) Contract Value: $117 million (73.125m) Preconstruction: Start Date December 2012 Modular Pre - Production: Start Date July 2013 Modular program: 32 weeks Completion Date: Summer 2014 LEED Certification: Goal of LEED Silver Conventional building, using conventional materials

assembled in an innovative way


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MODULAR The Process

PHASE 1 MANUFACTURED MODULAR STEEL FRAME

PHASE 2 INTEGRATION OF SUBASSEMBLIES

PHASE 3 MEP INSTALLATION IN FACTORY

PHASE 4 MODULE INTERIOR & EXTERIOR FINISHES

PHASE 5 ERECTION & MATELINE CONNECTIONS

MODULAR Union Field Work

EXCAVATION

FOUNDATION

UTILITIES

PROJECT $ VALUE

FIRST FLOOR

STEEL ERECTION

MODULE ERECTION

On-Site 20%

Factor y 80%

MODULE MATELINE CONNECTIONS

Typical floor layout

Multi skilled modular teams

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MODULAR Foundations

MODULAR Structural Scheme


Hat Truss Mass damper Building Setbacks

E-W Braced Frames Building Massing Typical Modules N-S Braced Frames

Dean Street Transfer

Plinth Basement and Foundation

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Structural Scheme:
Zero concrete above ground Progressive collapse compliance Zero hot works on site

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Interior Design

Bathroom Interiors

On Site installation

On Site Installation

What did we do in 9 months?


Fit out of the factory infrastructure Implemented new Company procedures (ie purchasing, finance, accounts, HR) Designed a new organization structure with new job roles and job descriptions Designed a manufacturing layout (in a very restricted building) New modular processes (de-skill) 3D CAD Bills of Material process Multi-skilled new modular trade union agreement Quality Assurance certification

Innovation
Multi skilled trade union Collaborative partnership On site assembly B2, Brooklyn Manufacturing processes in module teams standardized kits Factory layout by B2 floor level controlled sequence Assembly fixtures Poke Yoke/SMED Mateline design Structural methodology, no concrete Method of de-latch process Faade seal and DFMA

Leadership: Collaborative Partnership Contract


Innovative Developer Design for Manufacture & Assembly Repeatable Design (with customer choice)

Next Steps: UK Supply chain capability


Find a developer (faade/steel frame/assembly)