Enhancing high-rise residential construction through design for manufacture and assembly – a UK case study

Buildings forms are often complex and a result of end user needs, local surroundings and aesthetic aspirations. The individuality of buildings has therefore posed challenges with respect to harnessing the desired mass production and standardisation linked with off-site manufacture. However, through design for manufacture and assembly (DfMA), construction can be linked with industrial processes and deliver projects that are safer, cleaner and more efficient. Furthermore, successful DfMA projects minimise disruption within the local environment while delivering not only improved quality, cost and programme certainty, but also a more sustainable form of construction. The Two Fifty One project is a 40-storey mixed-use development in central London, UK, that has successfully embraced the principles of DfMA across all engineering disciplines. As a result, the delivery team has developed effective off-site construction solutions for superstructure, facades, bathrooms and mechanical and electrical services. All have been designed, coordinated and facilitated through advanced digital engineering and building information modelling techniques. Overall, the project has been delivered with reduced programme and cost, while simultaneously improving safety, quality and reliability in a more sustainable way through reduced vehicle movements and greater efficiency in site logistics. This case study describes this exemplary project and the design delivery model.