END-TO-END SOLUTIONS P


More predictable, more efficient and more sustainable – is it any wonder that use of prefabricated heating solutions is on the rise? Tony Falconar, national sales manager at Baxi Packaged Solutions, looks at the benefits of taking it all off site


The rise of prefabrication


refabrication, also known as off- site fabrication, is well-established in construction as a means of providing a streamlined end-to- end solution that delivers quality, customisation and time saving


benefits with reduced carbon emissions. In the building services world too, use of


prefabricated modular heating solutions is gaining popularity to meet stricter performance targets for heating and hot water for refurbishment projects as well as for new build. By carrying out most of the manufacturing off-site, using specialist machinery in a quality-controlled factory environment, the highest build quality can be achieved through improved control procedures and end-of-line testing. Sustainability is a major driver for businesses, so it’s worth noting that off-site fabrication also has the potential to reduce waste, leading to a lower environmental impact. The focus here is primarily on refurbishment


projects, where use of prefabrication makes everything simpler, faster and more efficient. And the best part is that this technique can be used for the full range of applications, from complete packaged plant rooms to energy centres and single boiler systems.


Digital design


So how does the process work? Each individual prefabricated module is typically designed using BIM tools and 3D computer-aided design (CAD) modelling. As the process requires key stakeholders including manufacturers and M&E designers to be brought together at the outset, all project requirements and any limitations can be addressed in the design at the early stages, along with any future plans.


The early visualisation of the design then enables revisions to be made collectively and collaboratively while supporting best practice design, installation, operation and maintenance. Only once the final design has been approved, does production take place in a quality-controlled factory environment.


Time savings


Prefabrication enables the best use to be made of the available spaces, whether a small basement plant room or a full roof-top packaged plant room. Common challenges to installation such as space and access restrictions can be addressed and overcome through the design and time-consuming snags onsite avoided. Prefabricated packaged plant rooms – either


roof mounted or externally located – are increasingly popular, particularly on projects


where strict limitations apply as to when work can be carried out. The packaged plant room can be purpose-designed in sections or as a single lift, depending on the site requirements, to enable straightforward transportation, accurate positioning and easier installation. Skids are similar to plant rooms but without the walls. Modular skids can replace part of a system in an existing plant room or be designed to meet new requirements and bolted onto the existing installed system. Skid modules lower space requirements through optimised design and a reduced footprint. This can overcome any project limitations to turn otherwise challenging installations into a faster, easier and safer process.


Straightforward project management


A major advantage of using a prefabricated solution is that there is one point of contact for the whole system. As the equipment comes from one supplier, only one delivery slot is required, making arranging site access more straightforward and reducing the possibility of late delivery, which helps keep the project on track. The benefit of this approach is that it ensures simpler project management and logistics, hugely reducing the potential for delay, helping to keep the project on schedule and avoiding any last-minute hitches. It also enables just-in-time delivery, removing the need to store equipment on site and simplifying site management.


Flexible options


Prefabrication offers flexible design options for customisation as well as bespoke solutions. An example of the former is the series


of prefabricated understairs heating and hot water solutions that we at Baxi Packaged Solutions have designed for Travis Perkins’ WholeHouse, utilising our heat pump technology. WholeHouse is a ground-breaking digital platform for small to medium-sized housebuilders, aimed at streamlining the design and delivery of low carbon homes. By working collaboratively with other partners on the design, we have been able to create standardised, optimised heating solutions that simplify installation and can be prefabricated in our factory.


Future-proof solutions


The circular economy has a key role to play in reducing the environmental impact of the built environment. Prefabricated packaged plant rooms can not only improve operational building efficiency when replacing older, less efficient plant, but can then be reused at other sites. A case in point is the packaged plant room designed and built by Baxi Packaged Solutions for WGM Consulting Engineers to serve Queen Elizabeth University Hospital’s Maternity Unit. The plant room successfully meets the immediate need for continuity of service at the hospital facility, providing flexibility to develop the existing estate in line with NHS net zero targets. And importantly, there is the opportunity to use the plant room at other sites at a later time, meaning that the intermediate solution for the Maternity Unit is not wasted.


Multiple benefits


Use of prefabricated heating solutions can streamline heating refurbishment projects and provide benefits at every stage of the project. The upfront design provides assurance of enhanced efficiency and sustainability. Productivity is increased on refurbishment projects as contractors can forge ahead with preparatory work to speed up installation while the heating solution is being fabricated in the factory environment. The number of workers, skills and time required on site is also reduced, helping address the skills shortage. Safety is improved as it removes the need for onsite hot works relating to installation. End users benefit from the reduced disruption and increased efficiency delivered by this process. It also provides the opportunity for building managers to refurbish multiple heating systems across their sites swiftly and safely.


In summary, off-site fabricated solutions can provide quality end-to-end solutions to meet all project requirements. By engaging with architects, clients, contractors, and off- site manufacturers from the outset, building services professionals can ensure that enhanced efficiency and sustainability are addressed in the design.


14 BUILDING SERVICES & ENVIRONMENTAL ENGINEER NOVEMBER 2023


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