B2 -Atlantic Yards

Brooklyn – New York

Rob FrancisDirector, Innovation & Improvement

Assembly not Construction – Lean Construction in practice

B2 -Atlantic Yards

50/50 J.V.

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BARCLAY’S ARENA

MODULAR Atlantic Yard Master Plan

B2 footprint

MODULAR – Full Development

B2

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• Residential building at Atlantic Yards

• Modular construction

• 348,000-square foot

• 32-story building

• Approximately 363 rental apartments

•Contract Value: $116 million

•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

First Modular Residential Building: B2

Conventional building, using conventional materials, assembled in an innovative way

PHASE 1 -MANUFACTURED

MODULAR STEEL FRAME

PHASE 3 – MEP INSTALLATION IN

FACTORY

PHASE 2 – INTEGRATION OF SUBASSEMBLIES

PHASE 5 – ERECTION & MATELINE CONNECTIONS

PHASE 4 – MODULE INTERIOR & EXTERIOR

FINISHES

MODULAR – The Process

PROJECT $ VALUE

On-Site 20%

EXCAVATION FOUNDATION UTILITIES

FIRST FLOOR STEEL ERECTIONMODULE

ERECTION

MODULE MATELINE CONNECTIONS

Factory 80%

MODULAR – Union Field Work

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MODULAR – B2 Floor Plan

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MODULAR – B2 Floor Plan

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MODULAR – Foundations

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Basement and Foundation

Plinth

Building MassingTypical Modules

Dean Street Transfer

N-S Braced Frames

E-W Braced Frames

Building Setbacks

Hat Truss

MODULAR – Structural Scheme

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MODULAR – Structural Scheme

PROTOTYPE - Interior Design

PROTOTYPE - Interiors

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

• Factory layout by B2 floor level

• Assembly fixtures

• Mateline design

• Structural methodology

• Method of de-latch process

• Façade seal and DFMA

Leadership:

• Collaborative Partnership Contract

• Innovative Developer

• Design for Manufacture & Assembly

• Repeatable Design