Proposal for StikBilt - Prefabrication in Building - ABPL90325_2020_SM2

Proposal VITHAUS x StikBilt

23 October 2020

Proposed for Aslan Ghods Nahri Managing Director of StikBilt Parkville, VIC 3010 Prepared by Nesia Cahyono VITHAUS Latvia, LV 1009 vithaus@gmail.com

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Executive Summary StikBilt is the largest construction company that focuses on building detached house in Australia Being in the industry for more than twenty years, StikBilt is still implementing a traditional construction method in building its standard house. On the other hand, VITHAUS is a relatively new European-based construction company that is specialised in providing instant houses through modular prefabrication. Following its expansion plan to Australia, VITHAUS is proposing a partnership with StikBilt. In this proposal, VITHAUS introduces KOBEHAUS, the StikBilt’s standard house which is prefabricated in the factory. Mutual benefits will be obtained as VITHAUS is sharing its technology, and StikBilt is using its dominance in Australian market to get clients. The effectiveness and efficiency of using modular prefabrication results in higher profit and other benefits. By implementing KOBEHAUS, a partnership between StikBilt and VITHAUS is projecting profit.

KOBEHAUS A combination of KOSHAUS and CUBEHAUS, which is a prefabricated pitched-roof and flat-roof house, respectively. KOBEHAUS is prefabricated with the highest prefabrication degree; module.

KOBEHAUS

3 modules of KOSHAUS

+13%

profit on top of the StikBilt’s initial profit

$35,412.11 total net profit for each standard KOBEHAUS being sold to the market

100%

2 modules of CUBEHAUS

106 days 87%

~ 100% TIME

42 days living space

garage

Hit the breakeven point in less than 24 months.

VITHAUS x StikBilt

~ 40%

StikBilt COST

KOBEHAUS

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Table of Contents Executive Summary............................................................. 2 Table of Contents.................................................................. 3 About Us: since 2002............................................................ 4

Our Specialisations..................................................... 4 Introduction............................................................................. 6 Proposal .............................................................................. 7 1.0 Proposed Technique....................................................... 8 KOBEHAUS...................................................................... 8

Member Schedules...................................................... 14 2.0 Construction.................................................................... 18

2.1 Prefabrication in Factory..................................... 18

Special Connections...................................... 21

Prefabricated Modules.................................. 22

2.2 Site Preparations................................................... 24

2.3 Transportation........................................................ 26 Regulations....................................................... 27

2.4 On-site Assembly................................................. 28

Special Systems.............................................. 30 Stitching............................................................. 31 3.0 Why KOBEHAUS?............................................................ 32

3.1 Benefits of Prefabrication................................... 32

3.2 Benefits of VITHAUS............................................. 33

3.3 Faster Construction.............................................. 34

3.4 Cost Effective.......................................................... 40

Cost Breakdown.............................................. 41

Initial Capital Costs........................................ 42

Financial Feasibility....................................... 43

Benefit-Cost Analysis................................... 44 4.0 Barriers: KOBEHAUS..................................................... 45 5.0 Conclusion........................................................................ 46 6.0 List of Appendices......................................................... 47 7.0 References....................................................................... 55

VITHAUS x StikBilt

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About Us since 2002 Change the way you think about house construction.

VITHAUS is one of the leading prefabrication companies in Europe. Our passion is in providing instant houses for the community. It is always under our concern that the houses are of high quality and environmentally friendly. In the past decade, we have been extending our branches to six areas in Europe: Austria, Latvia, France, Netherlands, Spain and Portugal. Through these cities, we supply instant houses to most of Europe (VITHAUS 2020).

3%

Our Specialisations

total market in Europe Union

design, manufacture, sale Our specialisation is in providing ready-to-live detached houses in a short time. We prefabricate timber modular houses according to our standard projects: KOSHAUS and CUBEHAUS, and assemble them on site.

Our house comes in a full package consists of utilities and furniture. They are designed to perform in four different climates.

KOSHAUS KOSHAUS is a standard house with pitch roof. There are five sizes available: » » » » »

KOSHAUS 26 KOSHAUS 53 KOSHAUS 78 KOSHAUS 106 KOSHAUS 132

CUBEHAUS CUBEHAUS is a standard house with flat roof. There are two sizes available: » »

CUBEHAUS 80 CUBEHAUS 93 Figure 01. VITHAUS’s past projects Source: VITHAUS, 2020

VITHAUS x StikBilt

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2020 The year of pandemic

26% total market in Europe Union

01 05 01

This year, people are restraining themselves from spending money on non-urgent expenses. All industries are affected, no exception for the construction industry. However, we like to see this condition from a different perspective. After the pandemic is over, we believe the economic growth will be followed by a huge leap in residential housing demand.

Our in-house R&D team believes there is a promising opportunity in Australia’s market, especially Victoria. The underlying reasons are the population demographic in the regional area as well as the severity of the pandemic within the state. As the pandemic is still an issue, we are seeing this as a perfect time to settle down in Victoria. We are hoping that by the time the pandemic is over, we are ready to deliver our service to the local community.

Following our expansion idea to Victoria, we are intending to collaborate with a local construction firm to familiarise ourselves with the local environment. As a leading residential builder in Australia that shares the same values of quality and sustainability, we believe StikBilt can be our partner in Australia. We are confident to achieve a success in our collaboration due to our affordable price and our advanced techniques that are suitable for Australia’s climate.

headquarter branches proposed branch in Victoria

VITHAUS x StikBilt

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Introduction

This report serves as a proposal for StikBilt to collaborate with VITHAUS. We will be introducing a new technology in building houses that will be the interest of Australian community. This report will cover six sections as follows:

Proposed technique This section introduces the products that we are proposing

Construction This section describes the prefabrication, transportation and installation processes Benefits This section provides evidence on time and cost reduction in implementing the proposed design Limitations This section covers the limitations of the proposed technique and how it will have impacts on projects

Conclusion This section wraps the report by highlighting the important points

VITHAUS x StikBilt

1 2 3 4

5

1 2 3 4

5

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Proposal

Upon our decision to do expansion to Australia, our internal team has been conducting a further study as part of the process. The findings and suggestions are listed below:

Australia is seen as a suitable area of expansion. One of the reasons is the high indulgence factor in the country. According to Hofstede (2020), Australia scored 71 out of 100. This factor describes Australia as a country with a community that has weak control over their impulses and desires to enjoy life. Therefore, it is expected that housing demand will significantly increase once the pandemic is over.

Greater Melbourne is the most suitable area to establish the first branch in the southern hemisphere because of two reasons. Firstly, Victoria is still in the lockdown stage (Victoria 2020).

It will be a perfect time for us to get everything ready. Secondly, Melbourne is the capital city of Victoria, and is the second most populous city in Australia (Glenn 2018).

For efficiency, it is suggested that VITHAUS cooperates with local construction companies in order to lower the barriers of entry to the industry.

StikBilt is seen as a suitable local builder to collaborate with. Established in 1999, StikBilt is an experienced builder that is specialised in building houses across Australia. StikBilt has been expanding to three states: Victoria, New South Wales and Western Australia. Very similar to VITHAUS, StikBilt has a standard housing design to build. However, StikBilt is still using traditional construction techniques for all projects, while VITHAUS is using the standard projects to achieve economy of scale in the factory.

VITHAUS and StikBilt undergo a partnership relationship by providing one door housing solution to Australian market. In this collaboration, VITHAUS and StikBilt bring mutual benefits for each other. VITHAUS introduces the effective prefabrication technique to StikBilt, while StikBilt shares its excellent branding exposure in the Australian market to VITHAUS.

Based on these five points, we are proposing a partnership collaboration with StikBilt. We believe that our collaboration will be successful, especially with the unprecedented technique we are offering to Australia. The detail of the technique is elaborated in the next section.

VITHAUS x StikBilt

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1.0

Proposed Technique KOBEHAUS VITHAUS’s main business is manufacturing modular prefabricated buildings. Dissimilar to the normal design-driven modular buildings, most of our products are on-shelf designs.

In Europe, we have two standard projects: KOSHAUS and CUBEHAUS. The former is a pitch house, while the latter is a flat-roof house. Each of them has a few further options depending on the size of the land and the number of bedrooms (VITHAUS 2020). In collaboration with StikBilt, we proudly present KOBEHAUS as a new standard project in Australia. It is a new design that well represents StikBilt’s standard house. By combining our signature KOSHAUS and CUBEHAUS, our highly experienced designer comes up with KOBEHAUS. This section will display the StikBilt’s standard house and how our technique will realise the design as a modular building.

StikBilt’s Standard House » » » » » »

Landing and steps Entry Dining room Kitchen Garage Formal lounge

» » » » » »

1 master bedroom 2 bedrooms 1 ensuite 1 bathroom 1 laundry Decking/terrace

Dwelling Area

160.70 m2

Garage Area

41.23 m2

Terrace

27.68 m2

Landing & Steps

8.70 m2

Site 733.00 m2 Rooms 3 Dimensions (m)

VITHAUS x StikBilt

15.20 x 13.29 x 3.70

Depart from these specifications, we guarantee that KOBEHAUS will come with similar configuration plus a high and uniform quality across all products. We have our reliable supply chains working with us to provide all consumable and non-consumable materials.

LANDING & STEPS 8.7m2

FORMAL LOUNGE 21m2

MASTER BED + ENSUITE 18 + 3.20 m2

BATH 6.3m2

ENTRY 7.21m2

GARAGE 41.23m2

KITCHEN 12.65m2

BED 2 15.40 m2

DINING + FAMILY 19.00m2

BED 3 10.38m2 L’DRY 3.77m2 TERRACE 27.68m2

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Figure 02. Impressions of StikBilt Standard House Source: illustrated in Revit

Building Area

152.57 m2

Useful Area

160.70 m2

Dimensions (m)

15.20x 13.29 x 3.70

Ceiling Height

2.10 - 3.27 m

Rooms 3 Terrace

27.68 m2

Prefabrication

33 days

Price

152,551.38

KOBEHAUS is a combination of KOSHAUS and a modified CUBEHAUS. The modification is undertaken to redesign a dwelling house of CUBEHAUS into a garage. In this combination, KOSHAUS will be used to fully cover the Dwelling area, while the CUBEHAUS will be used to fully cover the Garage area.

The Decking and Landing & Steps area will be constructed on site with pre-cut materials. The Deck and Landing & Steps are designed to be semi open.

KOSHAUS and CUBEHAUS will be produced in similar materials to minimise distinct material movements due to temperature or weather exposure. At every connection, control joints will be introduced, and wherever required, expansion joints will be installed. Details of the joints will be illustrated in the section 2.1 Prefabrication in Factory.

VITHAUS x StikBilt

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Figure 03. KOSHAUS Source: VITHAUS, 2020

1.1 KOSHAUS Pitched roof modular house.

KOSHAUS is a spacious house with net lettable area of 152.57 m2. By default, the house consists of: » » » » » »

Landing & steps Entry Dining room Kitchen Garage Formal lounge

» » » » » » »

152.57 m2

Dimensions (LxWxH)

16.30 x 9.36 x 3.70 m

Ceiling Height

2.10 - 3.27 m

Rooms

4 bedrooms (no master bed)

Terrace 40 m2 Prefab + delivery

KITCHEN 11.15 m2

TERRACE 40 m2

STORAGE 7.94 m2

ENTRY + DINING + FAMILY 43.85 m2

BED 2 25.85 m2 BED 4 11.94 m2

The garage will use CUBEHAUS. Figure 05. Plan of KOSHAUS Source: VITHAUS, 2020

VITHAUS x StikBilt

BATH 9.92 m2

BED 1 25.85 m2

160.70 m2 Ensuite Formal lounge

* price is from VITHAUS’s website

120 - 150 days

Price* $90,000 - $110,000

1 master bed 2 4 bedrooms 1 ensuite 1 bathroom 1 laundry Terrace 1 storage room

To mimic StikBilt’s standard house, some changes will be made on KOSHAUS: 152.57 m2 area Storage room 1 bedroom

Building internal area

BED 3 10.93 m2

L’DRY 6.12 m2

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Figure 04. CUBEHAUS Source: VITHAUS, 2020

Building internal area

65.42 m2

Dimensions (LxWxH)

11.00 x 9.40 x 3.15 m

Ceiling Height

2.50 m

Rooms

2 bedrooms (no master bed)

CUBEHAUS

Terrace 18.30 m2 Prefab + delivery

Flat roof modular house.

120 days

Price* $70,000 - $90,000

KITCHEN 4.79 m2

BATHROOM 4.55 m2

L’DRY 3.59 m2

ENTRY 3.60 m2

Figure 06. Plan of CUBEHAUS

BED 1 10.00 m2

CUBEHAUS is designed to be a compact house with a liveable area of 65.42 m2.

The spaces in the house including: » » » »

Landing & steps Entry Kitchen Living room

» » » »

2 bedrooms 1 laundry 1 bathroom Terrace

To complete the StikBilt specifications, CUBEHAUS will be modified as follows:

DINING + FAMILY 23.32 m2

TERRACE 18.30 m2

1.2

LANDING & STEPS 9.35 m2

BED 2 10.00 m2

65.42 m2 area Landing & steps Dwelling area

41.23 m2 removed Garage

The modified CUBEHAUS will be shown on the next page. * price is from VITHAUS’s website

Source: VITHAUS, 2020

VITHAUS x StikBilt

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Figure 07. Modified CUBEHAUS Source: illustrated in Photoshop

Building internal area

41.23 m2

Dimensions (LxWxH)

6.55 x 6.53 x 3.1 m

Ceiling Height

2.4 m

Modified CUBEHAUS

Rooms -

Garage

Terrace -

The modified CUBEHAUS will share the same appearance with the original CUBEHAUS. The adjustments are made mainly to the size and the interior of the product. The modified CUBEHAUS will be a simplified version of the original CUBEHAUS due to the shift of function from a dwelling house to a garage. The huge reduction in price is because of few reasons:

Prefabrication 30 days

» » » » »

Price* $20,000 - $30,000

GARAGE 41.23 m2

size reduction mechanical removal electrical reduction fitouts removal floor finish removal

Figure 08. Plan of modified CUBEHAUS * price is estimation only

VITHAUS x StikBilt

Source: illustrated in Revit

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KOBEHAUS KOBEHAUS is available in three classes. From the lowest to the highest efficiency classes are Class B, Class A and Class A+ (VITHAUS, 2020). Class B is the default class for KOBEHAUS. Therefore, unless otherwise stated, the word KOBEHAUS refer to as Class B KOBEHAUS. Depending on the clients’ preference, the level of efficiency can be chosen. There is an increase of approximately 10% for one step up of the efficiency level.

Table 01. Footing options for KOBEHAUS

Material

Class B

Class A (Class A (add-ons or specs changes)

Class A+ (add-ons or specs changes)

Roof

Metal profiled sheet

- 200mm rock wool thermal insulation

- 12mm fiberboard isoplaat - 250mm rock wool thermal insulation - 10mm gypsum fiberboard - 50 mm rock wool insulation - 1mm dust barrier

- 25mm fiberboard isoplaat - 350mm rock wool thermal insulation

External wall

Metal profiled sheet

- 150mm rock wool thermal insulation

- 12mm fiberboard isoplaat - 200mm rock wool thermal insulation - 10mm gypsum fiberboard

- 25mm fiberboard isoplaat - 50mm rock wool thermal insulation - 1mm dust barrier

Floor

Laminate EGGER

- 200mm ecowool thermal insulation

- 250mm ecowool thermal insulation

-

Windows and entrance doors

Wooden frame

- 78mm wooden frames with double seal circuit

- 90mm wooden frames with double seal circuit

- 106mm wooden frames with double seal circuit

Structure of interior walls

- AB grade pine frame - 100/150mm rock wool thermal insulation - timber cladding with white SIKKENS coating

Electrics

- metal corrugation with PVC insulation - FRLS wiring cable - double positioned, ceramic based socket groups

Network engineering

- 50/110mm PVC pipes for sewerage - 20mm diameter polypropylene pipe - heated floor in bathroom

Additional expenses

- delivery to the building site >150km - 25T crane rental for installation - footings on site

- 100mm ventilation duct in bathroom and kitchen - roof fan riser

VITHAUS x StikBilt

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Member Schedules KOBEHAUS will be sold at a basic price of $192,457.12 (refer to section 3.2) with member schedules as shown below. It has to be noted that neither of these options will change the design of the building. The options will only impact the interior impression of KOBEHAUS. The specifications that are included in the price are marked in bold.

Table 02. KOBEHAUS member schedule

Specification Efficiency class

Roof

Facade

VITHAUS x StikBilt

Photo

Price

Class B (200mm floor, 150mm wall, 200mm roof, 78mm windows)

$66,500

Class A (250mm floor, 200mm wall, 300mm roof, 90mm windows, 10mm GSP, 12mm isoplaat)

$73,150

Class A+ (250mm floor, 250mm wall, 400mm roof, 106mm windows, GSP 10mm, 25mm isoplaat)

$80,465

Metal sheet

$12,000

Metal tile

$14,630

Shingles

$19,680

combination of metal profile and pine cladding

$17,600

Full pine cladding

$20,300

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Specification Timber coating

Flooring

Heating

Water heater

Photo

Price

Paint

$7,900

Oil coating

$11,440

Laminate egger

$11,000

Parquet board

$14,100

Coil heated floor

$8,190

Electric heaters

$8,900

Infrared warm floor with temperature regulator

$440 each

50 gal. electric heater

$2,800

VITHAUS x StikBilt

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Specification

Photo

Price

Water heater

50 gal. natural gas heater

$2,970

Air exchange

Channel for heat pump

$3,200

Air to air heat pump

$5,400

Recuperator

$560 each

Bathroom complete set

Standard

$27,700

Premium

$29,750

Garage

with automated roller door

$24,300

Terrace

Open-timber floor

$10,600

VITHAUS x StikBilt

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Specification

Photo

Price

with stairs

$3,000

Canopy with metal roof

$18,000

Additional stairs (1.5m long)

$225/step

Delivery up to 150 km

4 trucks

$0

Over 150 km

$8/km

Installation

Tractor push

$6,000

25-ton crane

$295/hr

Stove fireplace

$2,750

Stove fireplace with marble finish

$4,750

Porch at the entrance

Fireplace

TOTAL PRICE

$200,790

TOTAL PRICE IN PACKAGE (1 KOBEHAUS)

$192,457.12

VITHAUS x StikBilt

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2.1

Construction Prefabrication in Factory

The whole construction process will be conducted in a factory where ergonomics can be achieved with a fully controlled environment. It allows different building components to be manufactured simultaneously, and hence reducing the construction time. The process is as follows (images source: Quality Homes, 2019).

STEP 1

STEP 2

STEP 3

Materials are stored in the factory. Weather sensitive materials such as timber and plasterboard are kept in an indoor environment to minimise deteriorations.

Prefabrication process is started by framing the floor on an ergonomic workbench.

The height of workbench is adjustable to facilitate several processes.

The finished floor frame is elevated above the head to ease the installation of underfloor cables and pipes. Floor penetrations are created where required.

STEP 4

STEP 5

STEP 6

The floor with cables and pipes is ready to be installed on a wheeled platform. The entire module will be built up on this platform until it is ready to be transported.

Timber studs are nailed to each other to form timber load bearing walls. The wall is assembled on a workbench, and the process can be conducted parallel with timber framing process.

Timber studs assembly is followed by covering the internal side of the wall with plywood. The external side is not cover for cables, pipes and insulation installations.

VITHAUS x StikBilt

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STEP 7

STEP 8

STEP 9

The drywall is nailed to the pre-installed floor. It is erected with the help of gantry crane in the factory. When wall and floor are assembled simultaneously, the wall can be installed straight after the floor installation process.

Roof trusses are assembled in the factory and then followed by the process of placing them in order on an adjustable platform. These processes can be done in parallel with floor and wall framings. The trusses are held together with temporary battens that run in perpendicular direction.

The platform is elevated above the head for ceiling installation.

Before the ceiling is installed, cables, pipes, ducts and insulation are placed on the ceiling on the workbench. The ceiling is attached below the roof with all services already installed.

STEP 10

STEP 11

STEP 12

The roof with ceiling is erected using gantry crane and put in place. The bottom chord of roof trusses are nailed to top plates of the walls.

After the roof is installed, interior works such as drywall taping and mudding can proceed.

Parallel with the interior works, cables and pipes can be placed within the wall from the outside. Simultaneously, roof finishing process can be conducted.

VITHAUS x StikBilt

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STEP 13

STEP 14

STEP 15

Wall insulation is installed from the outside after the cables and pipes installation.

According to the specifications, flooring layers will be installed.

Window and door are produced on butterfly tables to increase the ergonomic.

STEP 16

STEP 17

STEP 18

The outside wall is covered with plywood and then wrapped in building paper to avoid water leakage.

Lightings are installed to facilitate the works inside. The interior work is continued by sanding the wall and applying timber cladding.

Windows and doors are ready to be put in place. The gaps are sealed with foam sealing system and concealed with architraves.

STEP 19

STEP 20

STEP 21

Joinery and services are installed.

Between two in-contact appliances, compressive material will be placed to reduce bumps.

Wall cladding is installed only on sides without connections with other modules. Then, exterior wall proofing is wrapped around the module.

The modules are ready to be transported.

VITHAUS x StikBilt

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Special Connections

MMHC Hinged Roof Connector This connection allows pitched roof to be folded flat during shipping.

Figure 09. Special roof connection

Source: SIMPSON Strong-Tie, 2020

MMHC hinged roof connector developed by SIMPSON Strong-Tie will be used at the truss connection points to reduce the height of the roof (SIMPSON, 2020). For KOBEHAUS, 4.9 m high module is reduced to 3.5 m.

Nail pattern allows nailing on both sides

Off-the-shelf galvanised product

to increase support

Hinged Overhang Connector This custom made connection allows roof overhang to be folded in during shipping.

Three parts to a straight component

Roof finish to be installed on site

Figure 10. Overhang connector

Source: Bob Vila, 2012

Different with MMHC Hinged Roof Connector, this connection enables three components to be folded and unfolded to a straight line. It has to be custom made to match timber size.

Customised product

Roof finish to be installed on site

VITHAUS x StikBilt

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The KOBEHAUS will be divided into five modules. Three of them are parts of KOSHAUS and the rest two are parts of CUBEHAUS. However, the number and size of modules can be adjusted according to the site location and the route that will be taken.

Prefabricated Modules

V B

II III

I

IV

A

KOSHAUS A

CUBEHAUS Terrace

B

constructed on site Steps & Landing

Figure 11. Annotated plan of StikBilt Standard House Source: StikBilt, 2020

MODULE I Size Rooms

: 12.578 x 4.871 x 4.9 m : Kitchen, Dining room, Bed 3

Module I is the first module to transport because it has terrace that will be constructed on site. Module III has external walls on three sides which result in minimimal use of extra packaging.

Figure 12. Module I Source: illustrated in Revit

VITHAUS x StikBilt

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MODULE II Size Rooms

: 14.754 x 2.273 x 4.9 m : Entry hall, Bathroom

Module II is the second module to be transported and the module with the highest slenderness ratio. This characteristic requires temporary reinforcements to make sure the module is transported in a good condition.

Figure 13. Module II Source: illustrated in Revit

The arrangement of Module I to V takes into account the transport limit in Victoria, as well as material movement due to weather exposure. They are arranged parallel to each other to reduce the possibility of one module interlocks the movement of the other modules.

MODULE III Size Rooms

: 6.546 x 4.793 x 3.1 m : Garage

The garage must be divided into two modules due to the width limit. Module IV has a large opening for garage roller door that needs temporary supports.

Figure 14. Module III Source: illustrated in Revit

MODULE IV Size Rooms

: 6.546 x 1.736 x 3.1 m : Garage

Module V covers the rest area of the garage. It requires temporary reinforcements for transport.

Figure 15. Module IV Source: illustrated in Revit

MODULE V Size : 15.204 x 4.467 x 4.9 m Rooms : Formal lounge, master bed + ensuite, bedroom 2 Module III has the largest volume. Similar to Module I, Module III has walls on three sides. It does not require special treatment due to its ideal size.

Figure 16. Module V Source: illustrated in Revit

VITHAUS x StikBilt

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2.2

Construction Site Preparations

KOBEHAUS is compatible with any types of footings. Few types of footings that are commonly used in combination with our prefabricated products are pier and beam footing, slab footing and basement footing (R. 2020). The selection of footings should consider the type of soil and, the typical weather conditions, and the likelihood of termite at the site. In order to be a one-door solution to our clients, we will provide consultancy and construction services to our client upon request. These services will be directly under StikBilt’s supervision, whom we believe must have a better understanding about Australia’s soil conditions.

Table 03. Footing options for KOBEHAUS

Pier and beam Characteristics

» »

» »

Advantages

» » » » » » »

Disadvantages

» » »

VITHAUS x StikBilt

Slab

concrete stump or timber/ brick/block pier and beam typically used when traditional site-built footing is expected built using poured concrete footers mid range price

»

Seismic resistance Flood resistance depends on the materials Can withstand high wind Suitable for soil with high expansion and contraction Suitable for uneven ground air insulation under the home accessible under floor area

»

Not suitable for hurricane and tornado sagging, creaking mold

»

» »

»

Basement

concrete sit on top of the ground with anchors embedded to the ground Insulated at the perimeter The most cost and time effective

»

Seismic resistance flood resistance

»

» »

»

Not suitable on sloping ground

»

»

concrete wall running along the perimeter of footing can be conditioned or unconditioned the deepest footings

extra living or spaces to your home Seismic resistance

Higher cost due to the construction time and materials longer installation time

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Most often, a combination of pier and beam and slab footings are used to support KOBEHAUS. The pier and beam footings are used under the KOSHAUS for the elevated ground floor. Slab footing is used under the CUBEHAUS for the on-ground garage floor.

The construction of slab is started only after Module III is completely assembled.

The pier and beam footings arrangement has been matched with the modules so that some piers will be shared between two modules.

Figure 17. Footings 3D view Source: illustrated in Revit

Pier and Beam & Slab Footings Plan

Figure 18. Footings Plan Source: illustrated in Revit

VITHAUS x StikBilt

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2.3

Construction Transportation

The module has been designed so that it can be transported within Victoria. It must be ensured that all preinstalled furniture and services are tied to the wall and compressive materials have been added between two components. This is to reduce damage during transport. The transporting process is displayed below (images source: Modular Transport Canada, 2016).

STEP 1

STEP 2

STEP 3

The module that is going to be transported is put on a trailer deck. Moving the module to the deck can be done by elevating the module’s platform or using crane.

A set of back lightings and caution warning are attached to the back of the module.

A tractor is attached to the trailer, and then ready to go.

STEP 4

STEP 5

STEP 6

In general scenario, no escort is required to transport Module I to V. However, when it is required, it has to be prepared.

National Heavy Vehicle Regular (NHVR) also provides the service.

The tractor and trailer are off the factory with pilot(s) when required.

The escort must be directly in front of the trailer at all times.

VITHAUS x StikBilt

D

ON RIGID TRUCKS - GENERAL ACCESS

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6.0t

9.0t

Regulations Victoria has regulations on the size of vehicles that are allowed to use Victorian roads. The regulations 6.0t 16.5t restrict the weight as well as the dimensions. However, as KOBEHAUS is built with lightweight materials, the maximum dimension sets the limit for us. Referring to Victoria’s regulations issued by VicRoads, the maximum dimension of a vehicle with general access is 19.0 x 5 x 4.5 m. Pilots and/or escorts might be required beyond certain dimensions as regulated by VicRoads (see Appendix 5). The requirements for 6.0 20.0t general scenario of KOBEHAUS’s five modules are listed below.

Table 04. Pilots and escorts on Victoriaan roads

Module

Size (m)

Pilots

Escorts

I

13.0 x 5.0 x 3.5

2

-

II

15.0 x 2.5 x 3.5

-

-

III

6.8 x 5.0 x 3.1

2

-

V

15.5 x 5.0 x 3.5

1

-

* Comment 10.0t 16.5t

10.0t*

20.0t

2 3 4 4 5

ON SEMITRAILER COMBINATIONS -- GENERAL ACCESS together with Mod. III IV 6.8 x 2.0 x 3.1 -

The selected trailer is 4 axle semi trailers with flatbed. Prior to transporting the modules, authority permit must be received. The permit will states if time restrictions, traffic control or power line works are necessary to travel through busy areas.

6.0t

3 9.0t

9.0t

4 6.0t

9.0t

16.5t

5

Other road factors that may become issues in the transport process are (Westbuilt, 2018):

6.0t Hilly road

Bridge

9.0t

20t

Narrow road

Underpass / tunnel

5 6.0t

16.5t 1.2 m

1.4 m

The best solution to these problems is to adjust the module dimensions.

6.0t

16.5t

1.0 m

1.6 m

Figure 19. 4 axle semi-trailer truck

16.5t

20.0t

Source: National Heavy Vehicle Regulator, 2019

6

ON RIGID TRUCK AND TRAILER COMBINATIONS (Gener VITHAUS x StikBilt

page 28

2.4

Construction On-site Assembly

The modules are designed for assembly using tractor push technique. However, when tight site with diffucult access is encountered, the modules can be adjusted to suit crane lift technique for assembly. The structural elements in each module need to incorporate steel in certain areas to provide strong lifting points for the crane.

Table 05. Assembly techniques

Tractor Push

Crane Lift

Characteristics

Low-loader trailer with a folding gooseneck is used to transport the module. The on-site installation is facilitated with a 4WD tractors and drawbar

The module is craned straight from the trailer

Advantages

» Cost effective » Easy » Suitable for off-road sites

» Seismic resistance » Flood resistance

Limitations

» Uneven or sloping sites » Tight site

» More expensive » Additional footing is needed for the crane

FOOTINGS INSTALLATION

MODULE I ASSEMBLY

MODULE II & TERRACE

The type of footings is selected based on the type of soil on site.

This process must be finished by the completion of Module I prefabrication.

Module I is transported to site and placed on the footings that have been prepared before.

The construction of terrace behind the building is commenced. Module II is placed next to Module I.

Figure 23. Footings installation

Figure 24. Module I assembly

Figure 25. Module II & terrace

Source: illustrated in Revit

Source: illustrated in Revit

Source: illustrated in Revit

VITHAUS x StikBilt

page 29

Tractor Push Tractor push technique moves the module from the trailer to the designated place by controlling the height of the trailer and the footings. It can be seen from Figure 21, the trailer is elevated.

Then, after reaching the final position, the trailer is lowered, leaving the module on the footings. The trailer is then taken out using the drawbar (Figure 22).

1.6 m

Figure 20. Access to assembly Source: illustrated in Revit

Figure 21. Elevated trailer

Figure 22. Trailer is dragged out

Source: Klopp, 2016

Source: Klopp, 2016

MODULE III ASSEMBLY

MODULE IV ASSEMBLY

MODULE V ASSEMBLY

Module III is assembled next to Module I and II. The steps and landing at the entrance is constructed.

Module IV that is transported together with Module III is put on place. Roller door is installed.

Module V is placed next to Module II.

Figure 26. Module III assembly

Figure 27. Module IV assembly

Figure 28. Module V assembly

Source: illustrated in Revit

Source: illustrated in Revit

Source: illustrated in Revit

VITHAUS x StikBilt

page 30

Special Systems

MODULE I

MODULE II

Hand Winch The winch is used to minimise gap and tighten two adjacent modules.

Source: Gorilla

Figure 29. Placing two modules side by side Source: Land to House, 2016

Hand winch is to be installed after the first module is at its final position. The hook is connected to the other module, and before the second module is placed, the winch is turned to drag the second module closer to the first module.

Can be operated by one worker

Off-the-shelf loadcertified product

The modules must end at the same point

MODULE V ASSEMBLY

STITCHING & EXTERNAL CLADDING

Module V is placed next to Module II.

Smoothening the connections between modules and installing external cladding at the back part of the house.

The cladding at the back of the house is not yet installed because this sides in where the modules meet.

Figure 30. Stitching & External Cladding Source: illustrated in Revit

VITHAUS x StikBilt

page 31

Stitching

Treated connection

The modules have been designed so that their connections are seamless.

Most of them happen at the corner of the walls.

At these connections, minimal treatment is needed because control joint will be introduced at every corner, especially when there is material changes. The points where two modules meet are shown below.

Control joint

Figure 31. Connection points Source: illustrated in Revit

At the treated connection, compressible material is installed and hand winch will be used to make sure flat and tight connections. Foam sealant is applied along the meeting point from the top to below. It helps to fill the gap and glue both modules together.

STEP 1

STEP 2

STEP 3

STEP 4

Compressible material is installed between modules. Modules are dragged closer using hand winch.

Foam sealant is applied in between to seal the gap and to tighten both modules.

Building paper covers the external wall to ensure water tightness in the building.

Timber wall cladding is installed with battens.

VITHAUS x StikBilt

page 32

3.0

Why KOBEHAUS? Benefits of Prefabrication

KOBEHAUS is using modular prefabrication techniques. The general benefits of modular system are:

30 %

Weight

Materials

30% weight reduction compared to concrete frame (Lawson and Ogden, 2010)

Pre-cut materials in the factory save material usage by 15% (Lawson and Ogden, 2010)

15 %

Quality and Safety

Simpler footing due to the less weight, especially on poor soil (Lawson and Ogden, 2010)

20 %

Higher quality and safety in the factory (Rinas and Girmscheid, 2010)

Costs

Time

Upto 20% saving on the capital costs (Lawson and Ogden, 2010)

50% time reduction compared to traditional construction (Lawson and Ogden, 2010)

50 %

Waste Emissions

70%

Cut the volume of landfill waste by 70% due to the factory manufacturing process (Lawson and Ogden, 2010)

BUILDING MATERIALS RECYCLABILITY AND CONSTRUCTION WASTE RECYCLABILITY (Pons & Wadel, 2011) 50%

45%

40%

35%

Recyclable construction waste

30%

43%

43% of the waste from modular prefabrication is recyclable (Lawson and Ogden, 2010)

25% 20% 10%

10% 5% 1%

Non-prefabricated

VITHAUS x StikBilt

2% Concrete

3% Timber

Steel

Recyclable building materials

page 33

Why KOBEHAUS? Benefits of VITHAUS Being in industry for eighteen years, VITHAUS has been bringing great benefits to clients such as:

Comfort

High quality and low cost

Time effective

VITHAUS manages all the supply, production and assembly processes so that the house is ready-for-use, including the finishing and all necessary equipment

The increase in quality of work and the reduction of cost are enabled by fully prefabricating the modules in the factory.

The design is predetermined and there is no additional time required to conduct tender for builder and subcontractors.

Moreover, parallel activities are possible in the factory.

Easy to assemble

Low environmental impact

Opportunity to expand

The modules are lightweight and transportable. Standard truck and trailer are sufficient to transport them.

By default, the modules can be assembled on site without crane.

Saving on natural resources and reduction in carbon emission happen at all stages.

Timber requires less energy during production. It also absorbs and stores CO2 over its lifetime. Transporting the building in modules reduces the number of vehicles.

The characteristics of the modules makes it practical to be adjusted in the future. A small VITHAUS house can be developed into a larger house or turned into a cozy guest house at anytime.

VITHAUS x StikBilt

page 34

3.1

Why KOBEHAUS? Faster Construction

Due to the prefabrication technique, KOBEHAUS is able to cut the total time by 60% in ideal condition. This time includes the time to prepare the site as well as the time to deliver materials to the site. The reduction in time is calculated through Microsoft Project (Figure 34 and Figure 35 on the next page), and has considered the potential risks through a triangular risk distribution model (Figure 32 and Figure 33 below). Fifty per cent time reduction is realisitic as supported by several studies such as a study by Lawson and Ogden (2010) that says prefabrication can save 50% time according to the degree of prefabrication.

106 days

97.3 days

131.6 days

42 days

37.8 days

50.4 days

Triangular distribution model represents the probability of a scenario by highlighting three important points: the most likely, minimum and maximum conditions. The most likely time for StikBilt and KOBEHAUS are 106 and 42 days, respectively. Figure 32 and Figure 33 show that StikBilt has a bigger standard deviation and a more skewed triangle than KOBEHAUS. In this instance, StikBilt has a bigger possibility to be delayed than KOBEHAUS. The reason is because StikBilt has more unexpected factors on site, including the weather, workers’ availability and productivity, reworks, and health and safety.

Figure 32. StikBilt triangular distribution (above)

Figure 33. KOBEHAUS triangular distribution (below)

Source: illustrated in @Risk

Source: illustrated in @Risk

VITHAUS x StikBilt

page 35

STIKBILT

Start: Wed 10/7/20ID: 0

Finish: Wed 3/3/21 Dur: 106 days Comp: 0%

The network diagrams show that traditional construction technique results in more activities in the critical path. In contrast, modular prefabrication allows parallel manufacturing process, hence, less sequential process with more floating activities can be achieved.

KOBEHAUS records a total time of 43 days in comparison to the traditional method at 106 days.

Some factors that contribute in the reduction of time are (Larsson and Simonsson, 2012; Construction World, 2019):

Footings installation Start: Wed 10/7/20 ID: 1 Finish: Mon 10/12/20Dur: 4 days Res:

Floor

Start: Wed 10/7/20ID: 2

Finish: Mon 11/9/20Dur: 24 days

Comp: 0% Wall

Start: Tue 11/10/20ID: 8

Finish: Mon 2/8/21 Dur: 65 days Comp: 0% Roof

Start: Mon 12/7/20ID: 20

Finish: Mon 1/18/21Dur: 31 days

Comp: 0%

Window & Door

Start: Tue 1/19/21 ID: 26

Finish: Thu 1/21/21 Dur: 3 days Comp: 0%

Electrical & Plumbing

Start: Mon 10/26/20 ID: 29

Finish: Mon 1/4/21 Dur: 51 days Comp: 0% Fitout

Start: Fri 2/12/21 ID: 32

Finish: Tue 3/2/21 Dur: 13 days Comp: 0%

Finishing & Cleaning Start: Wed 3/3/21 ID: 36 Finish: Wed 3/3/21 Dur: 1 day Res:

Figure 34. StikBilt network diagram Source: illustrated in Microsoft Project KOBEHAUS

Start: 10/7/20

Finish: 12/3/20 Comp: 0%

ID: 0

Dur: 42 days

Page 1

conditioned space, no weather issue

Footings installation Start: Wed 10/7/20 ID: 1 Finish: Thu 10/15/20 Dur: 7 days Res:

Module I

Start: 10/7/20

Finish: 11/18/20 Comp: 0%

A (Terrace)

Start: 10/7/20

Finish: 11/24/20 Comp: 0%

Module II

Start: 10/7/20

Finish: 11/20/20 Comp: 0%

Module III

Start: 10/7/20

Finish: 11/23/20 Comp: 0%

Module IV

Start: 10/7/20

Finish: 11/23/20 Comp: 0%

ID: 2

Dur: 30.5 days

ergonomic leads to higher productivity

ID: 35

Dur: 34.5 days

ID: 39

Dur: 32.5 days

less subcontractordependent

ID: 75

Dur: 33.5 days

ID: 107

less unexpected factors

Dur: 33.5 days

B (Steps & Landing) Start: 11/20/20

Finish: 11/23/20 Comp: 0%

Module V

Start: 10/7/20

Finish: 11/24/20 Comp: 0%

ID: 139

Dur: 1.5 days

ID: 142

Dur: 34.5 days

Finishing & Cleaning Start: Wed 11/25/20ID: 176 Finish: Thu 12/3/20 Dur: 7 days

Figure 35. KOBEHAUS network diagram Source: illustrated in Microsoft Project

simultaneous lines in the factory

better upfront planning can be achieved

Res: Page 1

VITHAUS x StikBilt

StikBilt - Time Schedule ID 0 1 2

Task Name

Duration

STIKBILT

106 days

Floor

4

Material cutting 2 days

5

Beam & joists

7 days

6

Flooring panel

7 days

7

Floor layering for tiling

7 days

Wall

9

Material delivery1 day Material cutting 3 days

11

Wall frame installation

12

Wall insulation 4 days installation

13

Plasterboarding 7 days

14

Building paper 2 days installation

15

Exterior wall

5 days

16

Wall sanding

4 days

17

Exterior wall proofing

3 days

18

Sealing

3 days

Wall painting

7 days

Roof

Material delivery1 day Material cutting 3 days

23

Roof frame installation

24

Roof insulation 3 days installation

25

Ceiling installation 7 days Window & Door

28

November 2020 2 7

12

17

22

27

3 days

Material delivery1 day

28

Window & door 2 days installation

29

Electrical & Plumbing 51 days

30

Under floor 3 days services installation Electrical&Plumbing 7 days rough ins Fitout

13 days

33

Mechanical Electrical installation

34

Joinery&cabinetry 5 days installation

35

Bathroom tub installation

36

23

10 days

27

32

18

31 days

22

31

13

15 days

21

26

8

65 days

10

20

October 2020 3

24 days

Material delivery1 day

19

28

Footings installation4 days

3

8

23

5 days

3 days

Finishing & Cleaning1 day

Project: STIKBILT Date: Tue 10/20/20

Task

Project Summary

Manual Task

Sta

Split

Inactive Task

Duration-only

Fini

Milestone

Inactive Milestone

Manual Summary Rollup

Exte

Summary

Inactive Summary

Manual Summary

Exte

Pag

page 37 December 2020 2 7

art-only

12

17

22

27

January 2021 1 6

11

16

21

26

Deadline

Manual Progress

ish-only

Critical

Slack

ernal Tasks

Critical Split

ernal Milestone

Progress

ge 1

February 2021 31 5

10

15

20

25

March 2021 2

7

KOBEHAUS - Time Schedule ID 0 1 2 3 4 8 19 22 25 28 32 33 34 35 36 37 38 39 40 72 73 74 75 76 104 105 106 107 108 136 137 138 139 140 141 142 143 173 174 175 176

Task Name

Duration

KOBEHAUS

42 days

Footings installation Module I Prefabrication Floor Wall Roof

7 days 30.5 days 29 days 8 days 21 days 13 days

Window & Door Electrical & Plumbing Fitout Cleaning & Finishing Delivery On site assembly A (Terrace) Pre-cut materials Material delivery Construction Module II Prefabrication Delivery On site assembly

18 days 11 days 4 days 1 day 0.5 days 1 day 34.5 days 2 days 1 day 4 days 32.5 days 29 days 0.5 days 1 day

Seaming Module III Prefabrication Delivery On site assembly Seaming Module IV Prefabrication Delivery On site assembly Seaming B (Steps & Landing) Concrete delivery Construction Module V

1 day 33.5 days 21 days 0.5 days 1 day 1 day 33.5 days 19 days 0.5 days 1 day 1 day 1.5 days 0.5 days 1 day 34.5 days

Prefabrication Delivery On site assembly Seaming Finishing & Cleaning

29 days 0.5 days 1 day 1 day 7 days

Project: KOBEHAUS Date: Tue 10/20/20

October 2020 2 4

6

8

10

12

14

16

18

20

22

24

Task

Inactive Task

Manual Summary Rollup

Split

Inactive Milestone

Manual Summary

Milestone

Inactive Summary

Start-only

Summary

Manual Task

Finish-only

Project Summary

Duration-only

External Tasks

Pag

4

ge 1

page 39

26

28

30

November 2020 1 3 5

7

9

11

13

15

External Milestone

Manual Progress

Deadline

Slack

Critical Critical Split Progress

17

19

21

23

25

27

29

December 2020 1 3

5

page 40

3.2

Why KOBEHAUS? Cost Effective

Despite the arguments that prefabrication does not always reduce cost, this section provides cost breakdown that describes how KOBEHAUS will save a total of 13% cost reduction. The time reduction which has been discussed in the previous section is one of the contributors to the cost efficiency. A total of 106 days on site is reduced to 42 days by applying modular prefabrication technique. According to a research by Lawson and Ogden (2016), few factors that affect the saving are:

2-3% 5-7%

3-6%

1-2%

Shorter hiring time

COST SAVING

Professional fees reduction Snagging reduction Site preliminaries

80-89%

11-20% Total cost saving from a typical traditional construction

Cost of modular building

Based on this finding, the 13% cost reduction of KOBEHAUS is proven realistic. Moreover, in the research, Lawson and Ogden (2016) specifies that the proportion of cost in traditional construction will be different to the proportion of cost in modular prefabrication.

11-15%

5-7%

Site Preparations & Preliminaries in traditional construction

Site Preparations & Preliminaries in modular prefabrication

In this research, site preparations and preliminaries include professional fee, site shed and facilities, storage and accommodation, as well as plant and equipment. The reduction from 11-15% to 5-7% implies that modular prefabrication results in the saving on site preparations and preliminaries. On the next page, the cost breakdown of StikBilt and KOBEHAUS is provided. The former has 10.79% site preparations and preliminaries while the latter has 4.82%. A 5.97% saving in site preparations and preliminaries is made by shifting from StikBilt to KOBEHAUS. Indeed, these figures do not lay within the range mentioned by Lawson and Ogden (2016). However, the difference is at the decimal points which is considered negligible.

VITHAUS x StikBilt

page 41

Cost Breakdown Table 06. Cost Breakdown

StikBilt

KOBEHAUS

Site Preparations & Preliminaries Professional Fees 720.00 480.00

Preliminaries 13,252.14 4,417.38

Excavation 4,913.93 2,456.97

Notes

Reduced number of site personnel and external consultants but increased designing fee due to the possibility of changes in modules Reduced cost to tender, reduced time to hire plant, equipment, site shed and facilities, and storage Reduced footings depth and specifications

Construction Concrete in-situ 8,419.52 2,806.51 Concrete formwork 1,238.47 Concrete reinforcement 2,983.79 994.60

Masonry - Brickwork 10,924.65 10,924.65 Carpentry 16,539.33 16,539.33 Structural steel 1,119.51 1,119.51 Insulation 2,442.51 2,442.51 Joinery 15,792.50 15,792.50 Glazing 1,210.15 1,210.15 Hardware 1,107.19 1,107.19 Roofing 9,314.67 9,314.67 Roof plumbing 3,052.70 3,052.70 Windows 8,235.78 8,235.78 Doors 5,379.50 5,379.50 Plastering 12,205.43 12,205.43 Tiling 2,670.18 2,670.18

Paving / Floor coverings 3,702.64 3,702.64 Painting 10,411.77 10,411.77 Plumbing 15,252.52 15,252.52 Drainage 2,341.59 2,341.59 Electrical services 4,038.60 4,038.60 Sundry appliances 1,786.40 1,786.40 Additional charges - -

Reduced in-situ concrete volume No formwork is required Proportional to concrete in-situ Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same

TOTAL 159055.47 138,683.07 GST (10%) 15,905.55 13,868.31 TOTAL COST + GST 174,961.02 152,551.38

KOSHAUS saves 13%

Site Prep. & Prelim / Total Cost

10.79%

4.82% VITHAUS x StikBilt

page 42

Initial Capital Costs

$141,140,950 To deliver KOBEHAUS, there are initial costs required. These costs include building a prefabrication factory within Victoria. An estimation of these costs are described below.

Land Acquisition

Working Platforms

$130,000,000

$35,000

This cost is to purchase an approximately 26-hectare vacant land in Truganina, Victoria.

The price is estimated based on the listing on Domain (2020).

This cost it to construct all custom-made timber working platforms in the factory. The cost is only an estimate of lump sum amount.

Portal Frames

Steel Equipment

$10,600,000

$50,000

This cost is to construct a portal frame over a total of 10-hectare factory building. The price is estimated based on the rate of building an industrial building using portal frame (Central Steel Build, 2020).

This cost is to provide all custom-made steel equipment in the factory, including the elevated platforms and racking. The cost is only an estimate of lump sum amount.

Gantry Cranes

Trucks

$40,150

$415,800

This cost is to purchase 5x 250kg gantry cranes at $2,500 each and 2x 2000kg gantry cranes at $12,000 each plus GST. The price is derived from a machinery market place in Australia, Machines4u (Machine4u, 2020).

This cost is to purchase 2x 4-axle semi trailers with flatbed at $189,000 each plus GST. The price is derived from a truck market place in Australia, trucksales (trucksales, 2020).

VITHAUS x StikBilt

page 43

Financial Feasibility A total of $141,140,950 is a capital cost that will be spent once at the beginning of the investment. Indeed, it is a significant amount of money. However, 92% of the cost is invested on the land which rather appreciates than depreciates. Based on the previous calculation, KOBEHAUS is able to further reduce the production cost by 13% (refer to the Cost Breakdown). Assuming that StikBilt is normally received 10% profit, selling one KOBEHAUS will generate 23% profit.

10% Assumption on StikBilt’s initial gross profit

+

13% Additional saving by implementing KOBEHAUS

=

23% Total gross profit by implementing KOBEHAUS

Assuming that the selling price is kept the same, with 10% initial gross profit, Selling price Gross Revenue

110% x 174,961.02 23% x $192,457.12

$192,457.12 $44,265.14

80% x $44,265.14

$35,412.11

With 20% running cost, Nett profit

Breakeven point calculation Initial capital cost excl. land

$141,140,950 - $130,000,000

$11,140,950

Breakeven point

$11,140,950 / $35,412.11

314.6 units

Hence, the breakeven point will be achieved at the 315th unit is sold. Referring to the weekly demand index in Victoria (Real Estate Australia, 2020), there is a total of 168.05 demands to buy houses in a week by 10 October 2020. In the last four weeks, there was a total of 557.96 demands of housing. It is not to mention the trend of the graph that is increasing steeply. Kusher also predicts that this number will keep rising following the easing of restrictions in Victoria. Based on this data, we are confident that 315 units can be sold in 24 months (13 units to be sold each month).

168.05 151.38 123.13 115.4

Figure 36. Buyers’ weekly demand index Source: Real Estate Australia, 2020

VITHAUS x StikBilt

page 44

Benefit-Cost Analysis

The factory is expected to have a total of 60-year lifetime with 30 years life of the plant and equipment, and 20-year life of trucks.

Capital Costs Land acquisition

$130,000,000

Working platforms

$35,000

Portal frames

$10,600,000

Steel equipment

$50,000

Gantry cranes

$40,150

Trucks

$415,800

$141,140,950

Replacement Costs Working platforms

$35,000

Steel equipment

$50,000

Gantry cranes

$40,150

Trucks

$2,494,800

Total Costs

$2,619,950 $143,760,900.00

Revenue 315 units / 2 years

$334,644,439.50

Total Revenue

$334,644,439.50

Benefit-Cost Ratio

2.33

Over 60 years, this investment has a projected Benefit to Cost ratio of 2.33. In other words, every dollar invested will generate $2.33 in return. This figure has not considered the land appreciation value over the year. If the value is considered, the benefit-cost ratio will be 5.04 with an assumption of 5% appreciation rate. The land appreciation value is not included in the analysis because it is expected that the business will continue its operation beyond 60 years, hence, there is no plan to sell the land.

VITHAUS x StikBilt

page 45

Barriers KOBEHAUS

4.0

Despite the advantages that have been presented, KOBEHAUS has several limitations: Barrier 1 - In-house workers As KOBEHAUS needs full time workers in the factory, KOBEHAUS needs in-house workers and consultants. Indeed, it results in less dependency to the outsource services. However, it also increases the requirements to take care of the in-house workers. Training, health and safety support, insurances, and other workers allowances are additional aspects we need to consider.

Barrier 2 - Additional designers Referring to the business characteristics, StikBilt must have only a few number of designers either in-house or outsourced. The standard house allows the buyers to make a limited adjustment to their order. However, the size of modules in KOBEHAUS is another variable that designers need to work on.

Barrier 3 - Prefabrication factory To produce KOBEHAUS, an initial investment has to be made to build the factory. This factory requires a significant amount of upfront funding as well as a period of time for the construction. An alternative to this issue is to take senior debt to partially provide the upfront fund.

Barrier 4 - Life Cycle Cost Due to the more investment on assets, implementing KOBEHAUS will incur higher life cycle cost to maintain the assets. Over time, the assets which include the plant and equipment in the factory need replacements. Maintenance and repair fees as well as capital expenditures need to be budgeted. A way to prepare for this issue is by calculating sinking fund and incorporating it in the monthly financial statement. The appreciation of land value can outweigh this expense.

VITHAUS x StikBilt

page 46

Conclusion Report

5.0

Despite its excellence and dominance in Australia’s housing market, StikBilt still implements traditional construction techniques in building its standard house. While the design has been standardised, the fabrication process is not yet standardised. The house is still fully constructed on site. This technique is not only ineffective, it is also inefficient. Constructing the house on site results in a range of dependent aspects that are difficult to control. For instance, weather changes and subcontractors’ availability and quality. An effort given to minimise these aspects will either increase cost or time. This report offers a solution for StikBilt to increase its performance while at the same time reducing time and cost. The proposed solution is to build a partnership with VITHAUS to implement modular prefabrication technique to build StikBilt’s standard house.

The modular prefabrication is assessed as the best method to increase effectivity and efficiency in StikBilt’s business. The outcome of modular prefabrication is a modular building, which in this instance is called KOBEHAUS. The technicalities such as the footing requirements, the fabrication in the factory, transportation and the on-site assembly have been described in this proposal. KOBEHAUS shifts the outdoor on-site construction to the indoor factory prefabrication. As a result, it allows for higher quality and more control, and hence increase the productivity and efficiency. The realistic time reduction is at the level of 60% and the cost saving is at 13%. Based on these figures and by reflecting to the current situation, the breakeven point can be achieved in less than six months. Moreover, KOBEHAUS also brings other benefits such as the reduction of weight, material usage and waste emissions.

Indeed, there are barriers and limitations in implementing modular prefabrication techniques. However, these barriers can be overcome by proper planning. VITHAUS’s eighteen-year experience in delivering modular building, moreover, is valuable in overcoming these barriers.

“

How can the construction industry become faster, more reliable, more sustainable and safer?

All those aspects come together in prefab in modular.”

VITHAUS x StikBilt

page 47

List of Appendices

6.0

Appendix 1: KOBEHAUS Floor Plan Appendix 2: KOBEHAUS North, South Elevations Appendix 3: KOBEHAUS East, West Elevations Appendix 4: KOBEHAUS Sections Appendix 5: Pilot and Escort Guide - VicRoads Appendix 6: Vehicle Configurations - NHVR Appendix 7: Draft Feedback

VITHAUS x StikBilt

page 48

Appendix 1 KOBEHAUS Floor Plan

N PLAN

VITHAUS x StikBilt

page 49

Appendix 2 KOBEHAUS North, South Elevations

NORTH ELEVATION

SOUTH ELEVATION

VITHAUS x StikBilt

page 50

Appendix 3 KOBEHAUS East, West Elevations

EAST ELEVATION

WEST ELEVATION

VITHAUS x StikBilt

page 51

Appendix 4 KOBEHAUS Sections A

B

B A

SECTION A

SECTION B

VITHAUS x StikBilt

page 52

Appendix 5 Pilot Escort Guide - VicRoads Pilot and Escort Graph Guide Over 6m wide or 60m long - a combination of certified pilots and/or VicRoads escort vehicles will be required 6.0 5.51

3 Certified Pilots

5.5

5.0

2 Certified Pilots*

4.51

4.5

4.0

Width In Metres

1 Pilot

3.51

3.5

3.0

No Pilot or Escort 1 Pilot

2.5

Overall Length of Vehicle and Load in Metres

26 26.01

3 Certified Pilots

2 Certified Pilots* 30 30.01

35 35.01

NOTE: * When travelling on a freeway outside the Melbourne and Geelong Urban Areas, only one (1) Certified Pilot Vehicle is required Note: - Number of pilot/escort vehicles required may depend on variable circumstances and will be considered on a case by case basis.

This guide does not apply to mountainous areas

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Appendix 6 Vehicle Configurations - NHVR National Heavy Vehicle Regulator

Common Heavy Freight Vehicle Configurations

Disclaimer: This diagram shows some of the common heavy vehicle combinations used in Australia. Access for some illustrated vehicles and configuration is subject to an access authorisation (notice or permit). Other heavy vehicle configurations may not be represented. The mass and length limits shown are from the Heavy Vehicle (Mass, Dimension and Loading) National Regulation (the MDL Regulation) and are provided for general guidance only. These limits are available only to vehicles that comply with all other regulatory requirements (e.g. width and height limits, tyre width, vehicle standards, load restraint, suspension type etc). In some circumstances, access may be considered under a different vehicle class or other mass concessions and length limits may also be available. The NHVR website provides links to the MDL Regulation and to national and state Notices which may apply, depending on individual circumstances. For further information, contact the NHVR at 1300 MYNHVR (1300 696 487) or info@nhvr.gov.au or www.nhvr.gov.au/contact-us

Description

Maximum Length (metres)

Maximum Regulatory Mass under GML (tonnes)

Maximum Regulatory Mass under CML (tonnes)

Maximum Regulatory Mass under HML (tonnes)

2 Axle Rigid Truck

≤ 12.5

15.0

CML does not apply

-

3 Axle Rigid Truck

≤ 12.5

22.5

23.0

-

4 Axle Rigid Truck

≤ 12.5

26.0

27.0

-

4 Axle Twinsteer Rigid Truck

≤ 12.5

26.5

27.0

-

5 Axle Twinsteer Rigid Truck

≤ 12.5

30.0

31.0

-

3 Axle Semitrailer

≤ 19.0

24.0

-

-

4 Axle Semitrailer

≤ 19.0

31.5

32.0

32.0

5 Axle Semitrailer

≤ 19.0

35.0

36.0

37.5

5 Axle Semitrailer

≤ 19.0

39.0

40.0

40.0

6 Axle Semitrailer

≤ 19.0

42.5

43.5

45.5

1. COMMON RIGID TRUCKS - GENERAL ACCESS (a)

6.0t

(b)

9.0t

6.0t

(c)

16.5t

6.0

(d)

20.0t

10.0t*

(e)

10.0t*

16.5t

20.0t

2. COMMON SEMITRAILER COMBINATIONS - GENERAL ACCESS (a) 6.0t

9.0t

9.0t

(b) 6.0t

9.0t

16.5t

(c) 6.0t

9.0t

20t

(d) 6.0t

16.5t

16.5t

(e) 6.0t

16.5t

20.0t

3. COMMON RIGID TRUCK AND TRAILER COMBINATIONS (General access when complying with prescribed mass and dimension requirements) (a)

6.0t

(b)

9.0t

6.0t

(c)

9.0t

6.0t

(d)

6.0t

(e)

6.0t

(f)

16.5t

6.0t

(g)

16.5t

6.0t

(h)

16.5t

10.0t*

(i)

15.0t

16.5t

16.5t

16.5t

10.0t

16.5t

*

4. COMMON B-DOUBLE COMBINATIONS - CLASS 2

9.0t** 9.0t**

9.0t 9.0t

15.0t

9.0t** 16.5t**

18.0t

16.5t** 16.5t**

9.0t 16.5t

16.5t

**

16.5t

**

(a) 6.0t

16.5t

16.5t

16.5t

20.0t

16.5t

16.5t

20.0t

(c) 6.0t

16.5t

(d) 6.0t

16.5t

5. COMMON TYPE 1 ROAD TRAINS - CLASS 2

20.0t

20.0t

16.5t

16.5t

16.5t

20.0t

(a) 6.0t

16.5t

16.5t

(b) 6.0t

16.5t

20.0t

(c) 6.0t

16.5t

20.0t

20.0t

16.5t

20.0t

20.0t

16.5t

20.0t

20.0t

20.0t

(f) 6.0t

16.5t

20.0t

16.5t

20.0t

20.0t

6.0t

16.5t

20.0t

20.0t

20.0t

20.0t

(g) (h)

6.0t

16.5t

16.5t

6. COMMON TYPE 2 ROAD TRAINS - CLASS 2

16.5t

16.5t

16.5t

(a) 6.0t

16.5t

20.0t

16.5t

20.0t

16.5t

16.5t

20.0t

20.0t

20.0t

20.0t

6.0t

16.5t

20.0t

6.0t

20.0t

16.5t

20.0t

16.5t

20.0t

16.5t

20.0t

20.0t

16.5t

20.0t

16.5t 20.0t

16.5t

6.0t

16.5t

20.0t

20.0t

20.0t

20.0t

20.0t

20.0t

20.0t

20.0t

(g) 20.0t

16.5t

(h) 6.0t

16.5t

20.0t

20.0t

20.0t

20.0t

40.5

41.0

-

3 Axle Truck and 2 Axle Pig Trailer

≤ 19.0

37.5

CML does not apply

-

3 Axle Truck and 3 Axle Dog Trailer

≤ 19.0

42.5

43.5

-

3 Axle Truck and 3 Axle Pig Trailer

≤ 19.0

40.5

CML does not apply

-

3 Axle Truck and 4 Axle Dog Trailer

≤ 19.0

42.5

43.5

-

4 Axle Truck and 3 Axle Dog Trailer

≤ 19.0

42.5

43.5

-

4 Axle Truck and 4 Axle Dog Trailer

≤ 19.0

42.5

43.5

-

7 Axle B-double

≤ 19.0

55.5

57.0

57.0

8 Axle B-double

≤ 26.0

59.0

61.0

62.5

8 Axle B-double

≤ 26.0

59.0

61.0

62.5

9 Axle B-double

≤ 26.0

62.5

64.5

68.0

9 Axle A-double

≤ 36.5

72.0

74.0

74.0

11 Axle A-double

≤ 36.5

79.0

81.0

85.0

12 Axle A-double

≤ 36.5

82.5

84.5

90.5

12 Axle Modular B-triple

≤ 35.0

82.5

84.5

90.5

12 Axle B-triple

≤ 36.5

82.5

84.5

90.5

14 Axle AB-triple

≤ 36.5

99.0

101.0

107.5

15 Axle AB-triple

≤ 36.5

102.5

104.5

113.0

11 Axle Rigid Truck and 2 Dog Trailers

≤ 36.5

88.5

90.5

91.0

16 Axle A-triple

≤ 53.5

115.5

117.5

124.5

18 Axle A-triple

≤ 53.5

122.5

124.5

135.5

15 Axle AB-triple

≤ 44.0 – Classified by the NHVR as Type 1 when L ≤ 36.5m

102.5

104.5

113.0

13 Axle Rigid Truck and 2 Dog Trailers

≤ 47.5 – Classified by the NHVR as Type 1 when L ≤ 36.5m

95.5

97.5

102.0

17 Axle BAB-Quad

≤ 53.5

119.0

121.0

130.0

18 Axle BAB-Quad

≤ 53.5

122.5

124.5

135.5

17 Axle ABB-Quad

≤ 53.5

119.0

121.0

130.0

18 Axle ABB-Quad

≤ 53.5

122.5

124.5

135.5

20.0t

(f) 6.0t

≤ 19.0

20.0t

(e) 6.0t

-

3 Axle Truck and 2 Axle Dog Trailer

20.0t

(c) (d)

-

CML does not apply

20.0t

(b) 6.0t

-

30.0

20.0t

(e) 6.0t

30.0

≤ 19.0

20.0t

(d) 6.0t

≤ 19.0

2 Axle Truck and 2 Axle Pig Trailer

16.5t

(b) 6.0t

2 Axle Truck and 2 Axle Dog Trailer

20.0t

Add one tonne if twinsteer axle group is load sharing.**The mass of a dog trailer shall not exceed the mass of the towing vehicle under Schedule 1, Part 1, section 2(4) of the Heavy Vehicle (Mass, Dimension and Loading) National Regulation.

Please note, additional limits are allowed for steer axles under Schedule 1, Part 2 of the Heavy Vehicle (Mass, Dimension and Loading) National Regulation. © Copyright National Heavy Vehicle Regulator 2019, creativecommons.org/licenses/by-sa/3.0/au

*

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Appendix 7 Draft Feedback Structure Table of Contents entry in Table of Contents

v

Background is not part of Introduction

v

Missing citations

v

Caption on images

v

Missing quantified benefits

v

Missing Conclusion

v

Formatting Cover page, table of contents,

v

Font style, headings and sub-headings (preferably numbered)

v

Paragraph justification

v

Appropriate use of captions and annotation in figures, charts and tables

v

High-resolution images with proper captions and annotations

v

Contents Technical drawings: plans, elevations, sections

Appendix 1 - Appendix 4

Member schedules and choice of materials

section 1.0 Proposed Technique

Joints and connections

section 2.1 Prefabrication in Factory

Performance and efficiency diagrams

section 3.0 Why KOBEHAUS?

Assembly charts

section 3.1 Time effective

Production procedures

section 2.1 Prefabrication in Factory

Transportation packing

section 2.3 Transportation

Installation process

section 2.4 On-site Assembly

Benefits

section 3.0 Why KOBEHAUS?

Limitations and solutions

section 4.0 Barriers

Cost-benefit analysis table

section 3.2 Cost Effective

One key area of improvement in the building in full details using proper forms of communication.

section 3.0 Why KOBEHAUS?

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page 55

References

7.0

Build, C. S. (2020). Shed Cost Per Square Metre. Retrieved from https://www.centralbuild.com.au/shedcost-per-square-metre/ Domain. (2020). 1241 Vacant Lands for sale in Truganina, VIC, 3029. Retrieved from https://www.domain.com. au/sale/truganina-vic-3029/vacant-land/?sort=price-desc Girmscheid, T. R. a. G. (2010). Business Model: The Cooperative Production Network That Enables Mass Customized Production Methods in the Swiss Precast Concrete Industry. Paper presented at the 18th CIB World Building Congress, Salford, United Kingdom. http://site.cibworld.nl/dl/publications/tg57_pub354. pdf#page=43 Glenn. (2018, 3 May 2018). The 50 largest cities and towns in Australia, by population | 2018 update. Retrieved from https://blog.id.com.au/2018/population/population-trends/the-50-largest-cities-and-towns-inaustralia-by-population-2018-update/ Hofstede. (2020, 2020). Compare Countries. Retrieved from https://www.hofstede-insights.com/product/ compare-countries/ Homes, Q. (Producer). (2019, 21 September 2020). Tour Our Quality Homes Factory Building Process. [Video] Retrieved from https://www.youtube.com/watch?v=Kg8_yagUBo4 Klopp, P. (Producer). (2016, 16 October). Modular Home Delivered and Set Up. Retrieved from https://www. youtube.com/watch?v=JVcvCWY14XY Kusher, C. (2020, 14 October 2020). October 14 REA Insights Weekly Property Demand Report, 2020. Retrieved from https://www.realestate.com.au/insights/october-14-rea-insights-weekly-property-demandreport-2020/ LandtoHouse (Producer). (2016, 15 October). Set the House on the Foundation - Modular Home #35. Retrieved from https://www.youtube.com/watch?v=KPXsTuz39aw Machines4u. (2020). Retrieved from https://www.machines4u.com.au/browse/construction-equipment/ crane-296/gantry-crane-839/ ModularTransportCanada (Producer). (2016, 17 October). Modular Transport Canada Delivers a house in the woods. [Video] Retrieved from https://www.youtube.com/watch?v=Gc4O-5l5c3s&list=TLPQMDkxMDIwMj BtvKtxgCVLNw&index=2 NHVR. (2019). Common Heavy Freight Vehicle Configurations.

Ogden, R. M. L. a. R. G. (2010). Sustainability and Process Benefits of Modular Construction Paper presented at the 18th CIB World Building Congress, Salford, United Kingdom. http://site.cibworld.nl/dl/publications/ tg57_pub354.pdf#page=43 R., A. (2020, 24 April 2020). The Journey Home: All About Manufactured Home Foundations.

Simonsson, J. L. a. P. (2012). DECREASING COMPLEXITY OF THE ON-SITE CONSTRUCTION PROCESS USING PREFABRICATION: A CASE STUDY. Paper presented at the 20th Annual Conference of the International Group for Lean Construction. https://iglcstorage.blob.core.windows.net/papers/attachment-7a5f023b4d30-4576-8d66-5aa3f0cb8de1.pdf trucksales. (2020). 2,634 Trailers for sale in Australia. Retrieved from https://www.trucksales.com.au/ items/trailers-category/ VicRoads. (2020). Pilot and Escort Graph Guide. Retrieved from Australia: Victoria, S. G. o. (2020, 2020). Victoria’s restriction levels. Retrieved from https://www.dhhs.vic.gov.au/ victorias-restriction-levels-covid-19 VITHAUS, S. (2020, 2020). Prefabricated Homes - design, manufacture, sale. Retrieved from https://vithaus. eu/ VITHAUS x StikBilt