BOILERS & HOT WATER The rise of off-site fabrication O


Off-site fabrication is playing an increasing role in building services solutions to achieve improved quality and performance while reducing onsite time and labour. Tom Murray, head of specification at Baxi Commercial Solutions, discusses how this approach can benefit boiler installation projects


ff-site fabrication, also known as prefabrication, is a well-established practice in the construction sector, popular for the many


benefits that it can deliver, from improved quality and accuracy to increased speed and efficiency. In the building services world too, it’s becoming increasingly common as manufacturers invest in providing more prefab solutions. When it comes to heating and hot water provision, the opportunity for off-site fabrication exists for the full range of applications, from the largest containerised plant rooms down to single boiler systems within existing buildings.


The bespoke boiler rig is a case in point. Replacing inefficient or ageing heating boiler plant with modern, low NOx condensing boilers is an important early step towards generating heating and hot water more efficiently. But in certain buildings, what should be a relatively straightforward project may have numerous challenges – from tight timeframes to restricted access into the plant room.


So how can a solution like the offsite boiler rig overcome these issues?


Bespoke design


The key benefit of a prefabricated boiler rig system is that it can be designed bespoke to specific project requirements. The process brings much of the physical design work forward in the project timeline. This means that any issues around fit and access can be identified and resolved before the start of work on site. In this way, it makes everything simpler. Take space, a common issue on refurbishment


projects. The bespoke rig system can be specially designed to make best use of available space with any physical site restrictions able to be addressed through a choice of header extensions and connections. This results in a well organised plant room that is easier to maintain. Is access restricted? A further option is to design the rig to split into smaller modules for simple re-connection into a single frame in the plant room.


System integration can also be achieved


through the bespoke rig. For example, on older systems, hydraulic separation can be achieved via the rig and a plate heat exchanger.


High-quality solution


Once the design has been approved, the build takes place under factory conditions in a quality-controlled environment with end- of-line testing. The enhanced planning and collaboration required delivers productivity gains on and off-site, reducing the need for high-level on-site skills. This can increase site productivity, as well as improve the quality of installation, reducing the possibility of snags and any related maintenance issues.


Fast, efficient installation


The unit is delivered either as a single pre- assembled wheeled unit or in easily connected modules with insulated pipework set. The ability to match even the position and size of the system connections means that the rig is ready for rapid, easy connection to the system. As such, installation can be carried out quickly and efficiently. This makes it the perfect solution for projects with tight or fixed schedules. Equally, where there is a requirement to complete multiple projects within a tight timeframe, a prefabricated rig will provide a rapid, high-quality solution to high-efficiency heating. One example might be school refurbishments projects, where most work is scheduled to take place within the summer shutdown period.


Reduced onsite labour and skills


A further advantage of an off-site heating solution like the bespoke rig is that it reduces the intensity of skills required on-site and removes the ‘hot works’ associated with boiler assembly. This makes it easier for contractors to plan ahead and put these skills to use on other projects and so increase site productivity. It also means that there are fewer hot works on site, creating a safer environment for the team with less possibility of injuries.


Project certainty


Detailed forward planning and collaboration at the outset means that the cost, size and specification are all fixed and in place before the bespoke rig is built. Programme certainty is therefore improved along with assurance that the specification will be met. At the same time, the reduced downtime and disruption means that the day-to-day operation of the building can continue as normal.


Reduced carbon footprint


Sustainability is a major driver for the building services industry and building operators alike, so it’s worth noting that offsite fabricated solutions have the potential to reduce waste, leading to a lower environmental impact. Offsite also means greater predictability, making logistics planning more straightforward and enabling just-in-time delivery which helps make better use of site space. As the rig unit comes from one supplier, only one delivery slot needs to be scheduled, lessening any impact on the local environment and reducing waste.


Driving efficiency


Off-site fabrication provides an efficient means of overcoming frequent project challenges related to heating and hot water provision. The bespoke rig system is just one example of an offsite solution that brings clear benefits to all stakeholders at every stage of the project, from specification to installation to future maintenance. However, it’s important to note that early engagement between customers, consultants, contractors and manufacturers is vital. The process requires a holistic and strategic approach, which, once adopted, ultimately helps drive efficiency and best practice and


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The concept – key stakeholders discuss the project requirements, identify any limitations and consider any plans, such as future integration of heat pumps, that may need to be addressed in the design.


Design – Each prefabricated module is typically designed by the manufacturer using BIM tools and 3D computer-aided design (CAD) modelling. The iterative process enables revisions to be made collectively while supporting best practice design, installation, operation and maintenance and avoiding onsite snags.


Production – once the design has been approved, production can begin offsite under quality-controlled factory conditions. Specialist machinery, improved control procedures and comprehensive end-of-line testing ensure that the highest build quality can be achieved while avoiding waste.


Installation – the unit is delivered to the plant room either as a single wheeled unit or in easily connected modules with insulated pipework set for safe, fast and efficient installation.


can be instrumental in helping customers plot their route to Net Zero. As manufacturers and offsite specialists, we look forward to working with specifiers and contractors to design and manufacture efficient solutions to high performance heat that will support their customers in meeting their sustainability goals.


An advantage of an


off-site heating solution is that it reduces the intensity of skills required on-site and removes the ‘hot works’ associated with boiler assembly.


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