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

BARCLAY’S
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
MODULAR – The
Process

PHASE 1 -
PHASE 2 – INTEGRATION PHASE 3 – MEP
MANUFACTURED
OF SUBASSEMBLIES INSTALLATION
MODULAR STEEL FRAME
IN FACTORY

PHASE 4 – MODULE
PHASE 5 – ERECTION &
INTERIOR & EXTERIOR
MATELINE
FINISHES
CONNECTIONS
MODULAR – Union Field
Work

EXCAVATION FOUNDATION UTILITIES

PROJECT
$
VALUE

On-Site
MODULE 20%
FIRST FLOOR STEEL ERECTION ERECTION Factor
y
80%

MODULE
MATELINE CONNECTIONS
Typical floor
layout
Multi skilled modular teams
MODULAR – Foundations
 MODULAR – Structural Scheme
Hat Truss
Mass damper

Building
Setbacks

Building Massing E-W Braced

Typical N-S Braced Frames
Frames
Modules

Dean Street Transfer

Plinth
Basement and
Fo
undation
Structural Scheme:
• Zero concrete above ground
• Progressive collapse compliance
• Zero hot works on site
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

• Façade seal and DFMA

Leadership:

• Collaborative Partnership Contract

• Innovative Developer

• Design for Manufacture & Assembly

• Repeatable Design (with customer choice)

Next Steps:

•UK Supply chain capability

(façade/steel frame/assembly)

• Find a developer