Delivering Infrastructure with Certainty:
DfMA Case Studies
11/07/2018
Delivering Infrastructure with Certainty
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Where we work
Delivering Infrastructure with Certainty
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Laing O’Rourke – Approach to Delivery
Delivering Infrastructure with Certainty
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Laing O’Rourke – Digital Engineering
Delivering Infrastructure with Certainty
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Laing O’Rourke – DfMA and Offsite Manufacture
Delivering Infrastructure with Certainty
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Laing O’Rourke – Direct Delivery
Delivering Infrastructure with Certainty
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Laing O’Rourke – Unique Business Offering
Delivering Infrastructure with Certainty
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Laing O’Rourke: DfMA Programme benefits
Traditional Construction Process
Concept Feasibility Funding Site
Preparation Construction
Fit-out &
Finishing
Testing &
Commissioning
Design &
Engineering Completion
Concept Feasibility Funding
Design and Engineering
Site Preparation
Manufacture
Assembly
Fit-out and Finishing
Testing and Commissioning Completion
TIME SAVED
DfMA Construction Process
Incremental Innovation: DfMA Shell Abutments
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DfMA Programme benefits
Traditional Construction Process
Concept Feasibility Funding Site
Preparation Construction
Fit-out &
Finishing
Testing &
Commissioning
Design &
Engineering Completion
Concept Feasibility Funding
Design and Engineering
Site Preparation
Manufacture
Assembly
Fit-out and Finishing
Testing and Commissioning Completion
TIME SAVED
DfMA Construction Process
Site Preparation
Manufacture
Incremental Innovation: DfMA Shell Abutments
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Certainty
Manufacture
Site Preparation
Crossrail – Liverpool Street
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DfMA platforms for an underground station
Crossrail – DfMA Platforms for an underground station
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Liverpool Street vs Tottenham Court Road
Tottenham Court Road Station
Traditional Insitu
Liverpool Street Station
Design for Manufacture
and Assembly
Crossrail – DfMA Platforms for an underground station
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Tottenham Court Road : In-situ construction
Crossrail – DfMA Platforms for an underground station
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Liverpool Street Station
Video Precast Installation at Liverpool Street
2min duration
Crossrail – DfMA Platforms for an underground station
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Liverpool Street vs Tottenham Court Road
• Precast elements shipped
to site as just-in-time
deliveries
• Elements were installed as
they were delivered which
enabled logistics on a
central London project with
stringent space limitations
190 reduced articulated lorry
movements in central London
Crossrail – DfMA Platforms for an underground station
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Liverpool Street vs Tottenham Court Road
DfMA installation team = 7 Insitu installation team = 57
2973 Man hours 36882 Man hours
617mm of platform per hour 152mm of platform per hour
0 safety
accident
s
3 safety
accidents
12 outstanding
Snags
2973 Man hours
617mm of platform per hour
0 safety
accidents
0 outstanding
Snags
Liverpool Street Station Tottenham Court Road
Crossrail – DfMA Platforms for an underground station
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Liverpool Street Station
Video Comparison video
1min duration
Crossrail – Liverpool Street
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Innovation and Technology
Wi-Fi Communication
3D printing
Wi-Fi used for both radio & table PC communication systems
3D models made for
team briefings
Communication Visual
interpretation Data
Gathering
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C502 Liverpool Street Innovation & Technology
C502 Liverpool Street
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Communication Visual
interpretation Data
Gathering
• Dilapidation survey
prior to hand over
Innovation & Technology
• Progress reporting, High
level visual inspection and
inaccessible
UAV Technology
Augmented
reality Smart
Helmet
C502 Liverpool Street Innovation & Technology
• Check Mode
• 3D Model Mode
• AR Model Mode
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Communication Visual
interpretation Data
Gathering
C502 Liverpool Street
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Communication Visual
interpretation Data
Gathering
Innovation & Technology
working with Topcon and Soluis to use the Falcon 8 Drone to
capture photogrammetry and Terrestrial LiDAR scans within
the tunnels
UAV Technology
C502 Liverpool Street
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Communication Visual
interpretation Data
Gathering
UtterBerry, an intelligent wireless sensor system using the world’s smallest wireless sensors
These wireless sensors self-calibrate to form a
mesh network and relay data between each other, working as a family of sensors in any particular area. They do not require line of sight between each other https://utterberry.com/
Innovation & Technology
C502 Liverpool Street
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• 360 camera - Reduction in the time spent for inspection
• HD archived film footage record of construction progress –
which can be revisited as required to clarify details.
• Increase clarity of detail between onsite and offsite personnel
• Novel and immersive way of presenting information to
operatives
Safety training matrix - NFC tags placed on hardhats would
allow quick access to information about workers safety
accreditations indicating what the operative has been trained
to use (Plant and equipment) and expiry dates
Directional noise cancelling speakers predominantly
for dulling environmental noise
Communication Visual
interpretation Data
Gathering
Innovation & Technology
Crossrail – DfMA Platforms for an underground station
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Liverpool Street Station
Video Innovation video / helmet and drones
1min duration
Crossrail – Passenger Tunnels
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GRC Tunnel Lining
Crossrail – Passenger Tunnels
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Crossrail – Passenger Tunnels
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Crossrail – GRC Tunnel Lining
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Support Frame
Crossrail – GRC Tunnel Lining
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GRC Panels
1700
Base panels
1700
Double curved
4700
Plain panels
5200
Acoustic panels
Crossrail – GRC Tunnel Lining
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Additive Manufacturing
Crossrail – DfMA Platforms for an underground station
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Liverpool Street Station
Video 3d printing
30sec duration
Crossrail – GRC Tunnel Lining
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Manufacture – Support Frame
Crossrail – GRC Tunnel Lining
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Manufacture – GRC Panels
Crossrail – GRC Tunnel Lining
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Installation
Crossrail – GRC Tunnel Lining
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Site Assembly
Crossrail – Liverpool St Station
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MEP Mega Risers
Crossrail Liverpool St. – MEP Mega Risers
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Manufacture
Crossrail Liverpool St. – MEP Mega Risers
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Transport
Crossrail Liverpool St. – MEP Mega Risers
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Pitching & Lifting
Crossrail – DfMA Platforms for an underground station
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Liverpool Street Station
Video Magariser
1min duration installation
Crossrail Liverpool St. – MEP Mega Risers
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Lifting
Crossrail Liverpool St. – MEP Mega Risers
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Lifting
Crossrail Liverpool St. – MEP Mega Risers
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Assembly
Crossrail Liverpool St. – MEP Mega Risers
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Digital to Reality
Crossrail Liverpool St. – MEP Mega Risers
• Design Coordination
• Communication
• 3D Digital Modelling
• Logistical Planning
• Detailed lifting plans and installation guides
• Pride
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The key to success
Crossrail – Custom House
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DfMA Station Structures and Component Tracking
Crossrail – Custom House
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DfMA Station Structures
Crossrail – Custom House
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Constraints
Victoria
Dock
Road
DLR
Overhead
power
lines
Buried
services
Crossrail – Custom House
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Lifting Solution
C.H.L.O.E Custom House Lifting
Operation Equipment
35Ton SWL
Crossrail – DfMA Platforms for an underground station
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Liverpool Street Station
Video Custom House
1min duration installation
Crossrail – Custom House
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DfMA Components
Crossrail – Custom House
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Coffer Slabs
Crossrail – Custom House
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Victoria Dock Road Wall – Design for impact
Crossrail – Custom House
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Stair Stringers
Crossrail – Custom House
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Component Tracking
Crossrail – Custom House
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1 Year and 1 Day
www.laingorourke.com 59
Thank you All material contained in this presentation are copyright of Laing O’Rourke.
Delivering Infrastructure with Certainty
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