Article September 2020
To develop the best possible solution for the renovation packages, it is necessary to create great ideas and make the right choices within that process in a structured way. For producing and mounting the wall and façade panel on-site, we categorized the blueprint chapters into topics that have strong correlations.
Choices made in terms of production lines and machinery for on-site mounting are used as input for the factory layout design, shown blue in figure 1:
In our next step we defined functions that describe what the product, production, logistic, mounting team and factory should be capable of. For each function, multiple solutions and ideas were devised and visualized in a Morphological Chart. After that a feasibility check was done to categorize the solutions in:
- possibly feasible (needs to be tested)
- not feasible
The outcome of the feasibility was used to exclude the options before choosing the concepts.
We are currently choosing concepts during a pressure cook session in 3 multidisciplinary teams. The final step after concept development is choosing the best concept. This will be done by evaluating the concepts in terms of requirements, whereby scores are linked to the requirements.
Implementing this structured way of working has taken into account a strong correlation between the different topics.
The result provides grip, direction and clarity for the further and detailed development of the product, production, logistics, on-site mounting and factory.
Contribution: Jacob Lub, Buro de Haan, the Netherlands
Article April 2020
Integrated design philosophy is an embedded reality within the INDU-ZERO project. This approach embodies success in delivering a building that not only improves life-cycle costs but also offers a greater potential to reduced first costs. By setting the goal on half price of current traditional solutions, the use of traditional materials is therefore turned down, as it would exceed the budget.
To keep the components simple and uniform the renovation package consists a façade and a roof. Installations are embedded inside these two components. The existing building only functions as a skeleton for this new coat. The renovation packages include heating, ventilation and energy generation. A photovoltaic (PV) module is assembled on the roof component.
Currently we are collecting the ideas for specific functions to create an overview in which we will choose the best ideas regarding the product requirements. The results will be presented during the webinar on the 27th of August 2020.
Contribution: Arjan de Haan & Marthijn Kooiker, Buro de Haan, the Netherlands
Article February 2020
Development of the renovation packages
The development of the renovation package design focusses on low total cost of ownership and high impact on CO2 reduction. To achieve the goal for half the price of traditional labor renovation, INDU-ZERO is looking at large productivity improvement. Mass production manufacturing is proven in other industries to achieve a boost in productivity and quality and meanwhile lowering the costs. Sectors from retail to manufacturing have transformed their efficiency, embraced the digital age and boosted their productivity.
The goal of the design process is to streamline mass production and make it more collaborative. It is important to incorporate repeatability in the design in order to increase the scale and flow in production. By keeping production possibilities in mind it will reduce overdesign and create a cost-efficient constructible design that maximizes the amount of components that can be produced offsite. This early design by production approach will have a significant impact on the rest of the construction process, improve coordination, remove ambiguity and reduce the number of errors. As the number of elements are reduced and variations are already assembled in the factory, the mounting time on site will speed up. Fully implementing best-practice during the design, engineering and production phase is the mind-set of an Industry 4.0 approach!
Due to large variations in project specifications, design often becomes very specialized which can result in on-site complexities and constructability issues being solved late in the process rather than at the outset. Designing renovation packages means that the design phase is not based on a specific project but will look at a solution for multiple similar building types.
By developing solutions that are placed over the existing building they are less complicated. The dependencies are stripped down to a bare minimum: current location of windows, current load bearing, and measurements of the dwelling. The renovation packages have to be pre-assembled as much as possible in order to cut down the labour time, total costs and nuisance on site.
Integrated design philosophy is an embedded reality within the INDU-ZERO project. This approach embodies success in delivering a building that not only improves life-cycle costs but also offers a greater potential to reduced first costs. By setting the goal on half the price of current traditional solutions, the use of traditional materials is therefore turned down, as it would exceed the budget.
To keep the components simple and uniform the renovation package consists of a roof and a façade. Installations are embedded inside these two components. The existing building only functions as a skeleton for the new coat. The renovation packages include heating, ventilation and energy generation. A photovoltaic (PV) module is assembled on the roof component. In our next newsletter we will tell you more about the design of the façades.
Article September 2019
Customized serial production
Renovation construction is characterized by specific tailor-made work. Serial production is hardly involved.One of the biggest challenges for the INDU-ZERO consortium is to integrate customized serial production in the design for the factory. The design of the products and the production process is focused on making this possible. Industry 4.0 seems to offer the solution to this problem. It enables the production of customized work without having to deploy a lot of staff.
Scanners can scan and convert existing houses into 3D, after which the designer/engineer can customize the products. Robots, printers, laser cutting machines and milling machines can be linked to the 3D CAD information through the computer network.For smart machines it doesn’t matter what geometry they need to manufacture, as long as it stays within their scope. However, the time factor does play a role.
The process from idea to final product will have to change drastically to do this. The aim is to put as much knowledge and data at the front line of the design/engineering process as possible. This is where the CAD geometry is made and where there is a good understanding of the construction problems of the renovation project and the steering of the machines. In addition, failure analyses will be made during the process and product optimizations are carried out.
Once the CAD geometry is finished the entire logistics from production to delivery will be carried out according to plan. Miscommunication is ruled out because everything is determined and laid down in the front trajectory. This way the high error rate in the construction can also be drastically lowered.
Contribution: Tom Evers, D'andrea & Evers Design B.V., the Netherlands
Article March 2019
Brogården in Alingsås, Sweden
Brogården in Alingsås at the westcoast of Sweden is a typical Swedish municipality of owned residential houses. During the years 2007-2014 an extensive renovation of the residential area Brogården was carried out. The project received a lot of attention both in Sweden and abroad. The holistic approach and energy efficiency have won several awards, including the Big energy price 2010 and the Sustainable Energy Europe Awards 2014. It serves as a perfect reference for INDU-ZERO.
The residential houses in Brogården are of the type of most common multi familyhouse in Sweden. During the renovation great emphasis was placed on ensuring that the area is socially, ecologically and economically sustainable. While the buildings became highly energy efficient, they also improved on accessibility for the disabled. The renovated houses now have a new built-standard.
The houses were renovated based on passive house technology with well-insulated prefabricated exterior walls with small thermal bridges, new ventilationsystem (85% heat recovery) and good quality windows and doors (U-value = 0.7 W/m2, K). Energy for heating reduced from 115 kWh/m2,y to 19 kWh/m2,y (a reduction of 83%). In the refurbished apartments each apartment has its own individual measurement of hot water consumption and electricity usage. The idea is that everyone will now be able to control their own energy use. It is these kind of renovations that serve a reference for the INDU-ZERO project.
Contribution: Pär Sevensson, Building Future Institute, Sweden