Technological leap halves construction time and cuts costs

Applying state-of-the-art production technology, based on the systems used in the manufacturing industry, NCC is taking a gigantic leap in increasing the efficiency of the construction process. Construction time will be halved, costs reduced and quality enhanced when NCC uses industrial construction for the production of personal buildings.

In Hallstahammar, Sweden, a new chapter in the history of construction is being written. NCC is changing the construction process by introducing a leading-edge production technology inspired by the technology used by the leading companies in the manufacturing industry. In 2002, NCC started from scratch in its efforts to create a world-leading method for the production of apartment blocks. The solution was a construction system that is called NCC Komplett (NCC Complete). The hub of the new construction process is the newly built factory in Hallstahammar, where about 60 employees can produce up to 1,000 apartments per year. From Hallstahammar, it is possible to reach several densely populated areas where the need for new housing is considerable. This is how it works The factory purchases all input materials directly from material manufacturers, which generates substantial cost savings by avoiding costly intermediaries. The factory’s brain is the IT-based system for fault-free project planning. Using state-of-the-art 3D software, architects can create buildings with unique characteristics and design. For example, the length of the walls can be varied from 60 cm to eight meters, and the maximum building height is eight stories. When the architect has drawn the desired building, production can start in the factory. The company’s own concrete plant guarantees the quality of the high-performance concrete that is required. Each wall is customized in accordance with the architect drawing and, following assembly of, for example, electrical installations, the wall is caste. In the factory, complete ceiling and floor sections, walls and kitchens are produced. Installations such as electricity, plumbing and ventilation are performed in the factory. In addition, all surfaces, such as wallpapering and flooring, are completed in the factory. Radiators, windows and doors are also fitted. Completely finished bathrooms are delivered from the bathroom manufacturer. High-tech production lines facilitate the work process and ensure that a consistently high quality is maintained. A total of 90 percent of the building is completed before it leaves the factory. Using sophisticated production planning, up to eight buildings can be produced in parallel. Four fitters per building When the finished modules leave the factory, they are ready for assembly on the building foundation. Covered trucks transport the flat packages to the assembly site. Final assembly of the residential buildings takes place in fully weather-protected halls. The various modules are lifted into place using overhead cranes and are attached to each other with the help of specially developed connecting devices. The entire assembly process is performed by four (4) fitters, with one assembly manager per building. A work team assembles three to five apartments per week. All installation work is conducted in the factory, which enables the work to be conducted without the need for traditional occupational categories, such as electricians, plumbers, tilers, painters or carpenters. When the building is fully assembled, insulation materials and façade cladding can be added. By installing the insulation separately, buildings can be adapted to future energy requirements. The total work time required at the construction site is reduced by approximately 75 percent and the total construction period is reduced by an average of 50 percent. Construction site of the future NCC Komplett (NCC Complete) represents a tremendous leap in efforts to improve the work environment within the construction sector. All manufacturing and assembly is performed in-doors or in heated halls, which protects production from damp-related damage and ensures good working conditions throughout the year. The duties conducted in the factory are more ergonomically designed, compared with traditional construction sites. Conditions are clean and tidy and assemblers wear white gloves to ensure that the surfaces of walls and floors are not damaged. Strenuous duties and heavy lifts during final assembly are eliminated because all lifting activities are performed with the help of the overhead crane. Personal buildings rather than type buildings In contrast to other industrial construction systems, NCC will not work with choice-limiting serial type buildings. Modern 3D technology and leading-edge production processes will provide the customers’ architects with considerable latitude in efforts to create personal and attractive multi-family dwellings. An investment of SEK 300 million NCC is investing approximately SEK 300 million in Hallstahammar. During 2006, about 200 apartments will be produced. The first residential building is already on site in Hallstahammar, while Eskilstuna and Sundbyberg are next in line. NCC has already received orders for approximately 600 apartments for production in 2007. Read about NCC Komplett (NCC Complete) and down-load photos and graphics at www.ncc.se For further information, please contact: Ulf Thorné, Press Relations Manager, NCC Group, +46 8 585 523 46, +46 70 214 77 27