Showing posts with label MMC. Show all posts
Showing posts with label MMC. Show all posts

Sunday, 20 April 2025

Recent Developments in MMC in Australia

  Increasing industry capacity and funding

 



Over the last few months there has been significant progress in advancing the use of modern methods of construction (MMC) in Australia. MMC ranges from products and kit-of-parts to prefabricated components to modular and volumetric buildings. This post looks at these developments and assesses the current use of MMC in Australia.

 

The post has three sections. The first is on the Commonwealth Government and national developments, covering the Australian Building Codes Board’s Prefabricated, Modular and Offsite Construction Handbook, the March budget and National Productivity Fund, the, the National Construction Industry Forum’s draft Blueprint for the Future, and the Commonwealth Bank of Australia’s MMC financing initiative.

 

Ther have also been developments around the states. NSW has a MMC Taskforce, in Queensland there was a change of government however no changes to the MMC policy have been announced. Western Australia is building industry capacity, and there have been deliveries of social housing in South Australia, Tasmania and Victorie.

 

Commonwealth Government and National Developments

 

ABCB Prefabricated, Modular and Offsite Construction Handbook

 

The Australian Building Codes Board (ABCB) is the agency responsible for the National Construction Code (NCC), and the WaterMark (plumbing) and CodeMark (product) Certification Schemes. The Handbook does not introduce any new standards, but ‘has been developed to increase the understanding and effectiveness of existing building standards and regulations’ and to answer ‘questions about determining evidence to support compliance and common NCC compliance risk areas.’

 

The Handbook published in December 2024 is not ‘a document that sets out specific compliance advice for developing solutions to comply with the requirements in the NCC.’ The emphasis is on Deemed-to-Satisfy (DTS) compliance when applying the NCC to residential buildings and shows: 

1. How to determine the evidence required to demonstrate NCC compliance and fitness for purpose through documentation. 

2. How to avoid common NCC compliance risks that affect MMC and other products. 

 

The Handbook notes some products only require relatively simple evidence to demonstrate compliance. However, ‘complex products, including volumetric forms of construction may be subject to multiple NCC requirements and require extensive documentation to demonstrate compliance.’ Key points are 

·      Buildings using MMC, including prefabricated and modular buildings, are regulated in the same manner (except for plumbing products) as other construction products.

·      There are 3 compliance pathways: DTS Solution, Performance Solution, or a combination of the two.

·      The Handbook includes a 4-step approach to assist determining the evidence to demonstrate fitness for purpose and NCC compliance.

·      Fitness for purpose is supported by evidence of suitability and construction/installation in an appropriate manner.

 

The Handbook does not address state and territory legislation covering planning, building and plumbing approvals, licensing, and mandatory inspections, and does not cover ‘the end-to-end process of the use of MMC … nor does it provide a how-to-construct or how-to-install manual for the thousands of products and MMC in use.’

 

Given the extent of what the Handbook does not include, how much of a contribution does it make to promoting MMC? First, it establishes the requirement to comply with current standards using the compliance pathways available, and the explanation of how to establish fitness for purpose is useful. Second, by discussing specific forms of MMC like precast, SIPs, wall panels, floor and roof systems and light gauge steel the Handbook is an important first step in determining evidence on compliance with the construction code. 

 

March 2025 Commonwealth Budget

 

In the pre-election March budget the Albanese Government allocated $54 million to MMC, with $49.3 million to help states and territories develop programs to support MMC, and $4.7 million towards the  voluntary certification process announced in November 2024. There are no details on what exactly this funding will cover, who will do it and  how certification will be done, what might be in the MMC programs and whether they will be coordinated across the states is unknown, and approaches using volumetric, modular and kit-of-parts are not explained. 

 

The budget allocation adds to funding in the $900 million National Productivity Fund announced in November by the Treasurer, which included an unspecified amount for removing barriers to MMC and improving development approval processes. 

 

The Commonwealth also currently has two working groups, One is on MMC as part of a National Construction Strategy. The second is a Federal Treasury Workshop on Removing Barriers to MMC Finance. Ther are no reports from those groups available. 

 

NCIF Blueprint for the Future of Construction

 

In March the National Construction Industry Forum released their draft Blueprint for the Future: A building and construction industry that works for everyone. The Forum is an advisory body under the Commonwealth Department of Employment and Workplace relations with 16 members from industry associations and unions and three ministers. 

 

‘The Blueprint sets a path to address challenges and build a stronger construction industry. The NCIF identified eight themes, with associated challenges that included insights like contracts are unfair, procurement focuses on price, there are skills gaps, and under Financial Viability ‘Limited investment in innovation e.g. modern methods of construction, digitisation.’ This is the sole mention of MMC in a document called Blueprint for the Future. The following section on Opportunities includes contracts, security of payment, phoenixing and insolvencies, but not MMC. 

 

Figure 1. NCIF themes

 

Source: NCIF Blueprint

 

The Blueprint is the latest in the long sequence of worthy, wordy, and optimistic documents that clearly explain the issues and problems, identify potential responses and remedies, and promote collaboration and cooperative tripartite solutions. How many of the 45 Opportunities it suggests exist will be realised is an open question, but the history of these proposals is not encouraging. For example, security of payment and the apprenticeship system have been reviewed and recommendations made but little has changed, phoenixing has not been addressed by ASIC for decades, proactive enforcement of regulations requires resources, and there have been numerous industry charters and codes of conduct. There is no commitment to any specific action by the members of the NCIF, and not recognising MMC (if done well) as a major element in future construction is a glaring oversight. The NCIF future looks very much like the present.  

 

Commonwealth Bank MMC Financing

 

In January the Commonwealth Bank of Australia became the first bank to endorse MMC and provide financing, when CommBank announced a partnership with prefabAUS, and became the organisation’s first bank member. The bank agreed to sponsor the development of a standard form contract for MMC to simplify and speed up the process of financing a prefab home. 

 

Limited to fixed price contracts for offsite work up to $1.5 million, CommBank offers construction financing while a prefab home is being built offsite, for the lowest of 120% of the land value or up to 60% of the contract price, or 150% and up to 80% from a manufacturer accredited by the bank. After final completion the home is inspected and the rest of the construction finance is released. 

 

In October National Australia Bank announced $6 billion in funding for affordable and specialist housing by 2029, with modular construction playing a key role. 

 

ABCB Building Product Registration Scheme Proposal 

 

In September the ABCB opened public consultation for a month on a proposed risk-based Building Product Registration Scheme, aimed at addressing product conformity and traceability issues. Minimum standardised information for all building products would be required, with traceability through labelling and a national product register, compulsory registration of high-risk products, and voluntary registration for other products. It will take years for the scheme to be implemented.  At the Offsite 2024 conference Gary Rake, the CEO of the ABCB, included the slide below. 

 

Figure 2. Building Product Registration Scheme

 

Source: G. Rake Offsite 2024

 

On building products, in January 2025 the European Union’s Construction Products Regulation replaced the 2011 framework. This introduced Digital Product Passports (DPPs) to provide performance metrics, and compliance with sustainability and safety standards. For modular construction, DPPs presents significant opportunities because they enable tracking of prefabricated components through their lifecycle. 

 

 

Around the States 

 

New South Wales

 

In March 2025 the NSW government released its industry policy, covering housing, net zero and the energy transition, and local manufacturing, The policy links modular construction to increasing housing supply and affordability. 

 

In August 2024 the Building Commission NSW released a position paper for consultation on Regulation of Prefabricated Buildings for a new building bill that would include MMC. The paper redefined prefabricated buildings as ‘building work’ not ‘building products’, and showed the stages in the delivery of a prefabricated building (Figure 1A), highlighted the role of the certifier and proposed consumer protections (Figure 1B). The draft of a new building bill has not yet been released. 

 

Figure 3A. MMC stages

 

 

Figure 3B. MMC certification and consumer protection

 

Source: NSW MMC Position Paper

 

 

In the 2023-24 budget the Minns government committed $10 million for modular social housing trials. In July 2024 four sites in Port Macquarie and three in Wollongong were announced. 

 

The Modern Methods of Construction Taskforce was established in November 2023 to investigate the ‘use and potential for off-site manufacturing in NSW Government housing projects.’ The Taskforce has met twice, with the last meeting in June 2024. Meeting notes are on the website. 

 

In May 2024 the Homes NSW MMC Procurement list was opened for suppliers who provide off site manufacturing and prefabricated products. In March 2025 there were 28 suppliers on the list.  

 

The Homes NSW MMC Program commenced in May 2024 as a partnership with the Building 4.0 Cooperative Research Centre (CRC) focused on developing strategies and methods to utilise MMC to deliver quality social housing faster.The Program aims to define products and components for design and construction of medium density homes (4-6 storey buildings) using a standardised kit-of-parts manufactured offsite (i.e. bathroom, kitchens, balconies).

 

NSW Department of Education 2024 Pattern Book set out standardised, repeatable designs for schools and preschools, and promotes modular and prefabricated construction for 3 storey new schools. Other school buildings including halls, COLAs, pre-schools, single and double storey buildings will be added to the 2025 Pattern Book.

 

 

Queensland

 

There was a change of government in October 2024 when the Crisafulli LNP replaced the Miles Labor government. So far there have been no changes to the MMC programs of Homes for Queenslanders or QBuild announced. 

 

The Homes for Queenslanders policy aims to deliver 53,500 new social homes by 2046, The Miles Government June 2024 budget included $2.8 billion for up to 600 modular homes in 2024-25, with the goal of social housing production of 2,000 homes by 2027-28. There are 11 industry partners: Ausco, Fleetwood, Hutchies Modular, Modscape, Blok Modular, Eco Cottages, James Engineering, ModnPods, Saltair Modular, Volo Modular, and WestBuilt.

 

In February two modular homes were delivered to Thallon in South West Queensland, as part of the Quickstarts Queensland initiative, built by Oly Homes. By October 2024 Fleetwood had delivered 40 of 60 homes contracted. In September a Cairns project commenced for 490 homes built by Modscape and FCC Construction, funded by ANZ, Housing Australia and the Commonwealth and State Governments. 

 

QBuild has three Rapid Accommodation and Apprentice Centres for MMC, in Brisbane at Eagle Farm and Zillmere, and Cairns. Qbuild has standardised floor plans for four house types: studio; 1 bedroom; 2 bedroom; and 3 bedroom.  

 

Victoria

 

In December 2024 the Federal and Victorian governments announced joint funding for a $50 million Future of Housing Construction Centre of Excellence (FHC CoE) at Melbourne Polytechnic’s Heidelberg campus, the first training facility in Australia focused on MMC, expected to start in a temporary location in mid 2025.

 

In September 2024 the Victorian Prefabricated Construction Directory was published, with profiles of 24 firms using MMC in Victoria. All were manufacturers, eight firms coved all five capabilities of architecture, assembly, engineering, manufacturing and project management. 

 

Western Australia

 

Before the March election the Cook Government said If re-elected it will commit $50 million to boost modular and prefabricated housing. The Housing Innovation Program will provide competitive grants of up to $3 million for WA-based businesses involved in modular or prefabricated housing. 

 

In addition to grants, the government will allocate $20 million in low-interest loans to help businesses adopt new technologies and expand their operations. Opportunities identified include automation in steel frame and concrete slab manufacturing, enhanced wall and ceiling construction processes, and expanded capacity for window, door, and cabinetry production. There is already an $80 million allocation for transportable classrooms by 2026. 

 

In February 2025,16 modular tiny homes for Geraldton were commissioned from Summit Modular for delivery in mid-2025. In January three new modular homes in Manjimup were delivered by Fleetwood. 

 

In October 2024 eight two-bedroom modular social homes in were completed, built by Murray River North and Modularis. In September the Federal and WA Governments provided $6.3 million for 12 social modular homes built by Dale Alcock Homes in Perth.  In August Sheraton College opened a modular two storey building from Ausco Modular. 

 

South Australia

 

In March Renewal SA’s Office for Regional Housing began a pilot program of six homes, expected to be completed by September 2025, constructed using SipForm structural insulated panels (SIPs), a prefabricated building system manufactured in Perth. 

 

Tasmania

 

In February six new modular units were installed in Burnie, built offsite by Podmatrix. The government has a target of ‘more than 200’ modular homes over the next four years.

 

The Chandler Critique

 

David Chandler became the inaugural NSW Building Commissioner in 2019 after the Mascot Towers building failure highlighted the extent of building defects and non-compliance with the NCC. He was responsible for implementing the NSW construction reform strategy, establishing the Building Commission with 400 inspectors, introduced the iCIRT ratings scheme for developers and contractors, and decennial liability insurance for apartment buildings. By the time he stepped down in 2024, his focus on consumers and compliance had begun restoring public confidence in new housing.

 

Soon after finishing as Building Commissioner, he gave a presentation on MMC at the Offsite 2024 Conference. His concern was that ‘An unregulated MMC market could introduce a new cohort of modular building defects.’ Chandler has supported MMC for many years, for example he was involved in setting up the Centre for Smart Modern Construction at the University of Western Sydney in 2017. However, in his presentation he argued there are unresolved issues with MMC, such as integration of components, fire and water management, training and qualifications of workers, compliance of offshore suppliers and quality of components. He emphasised the lack of performance measures and data on MMC. The slide below is from the presentation with a list of issues that he believes need to be addressed.

 

Figure 4. Chandler MMC issues

 

Source: D. Chandler Offsite 2024

 

Since then he has frequently posted on LinkedIn about his concerns with MMC and its focus on producers rather than consumers. A lightly edited version of his post in response to the announcement of the CommBank financing of MMC is below:

 

‘Funding for prefab leaves many questions unanswered. Bringing Prefab Housing into the mainstream construction domain has been the quest of many for nearly 2 decades in Australia. Despite government endorsement, research grants, policy announcements and uptake by social housing organisations, there is still no clear regulatory or legal framework for this procurement method. 

 

The first question deals with what building contracts are proposed to be covered by the prefab off-site payment arrangement? Who are the parties to these transactions. Will the home purchaser be required to authorise these payments? Will the home purchaser be protected by a Home Building Insurance Scheme if the builder of record has engaged or has been given permission by the home purchaser to procure between 60 to 80 percent of the build cost by way of prefab. Will the builder of record (which may include a licensed prefabricator) be satisfied that the on-site components of the work are adequately provided for? How might unforeseen variations be dealt with, especially with high LVR loans. 

 

What criteria will CBA deploy to distinguish an accredited v unaccredited player? Will off-shore prefabricators be included in the mix? What happens if the prefab provider goes broke before the house is completed? There could be the discovery of building non-compliances post the occupancy of substantially prefab buildings. There could be a mixture where both on-site and off-site inputs give rise to a serious defect. What then? 

 

There is a need for a full disclosure about all these issues, not just in the lender's interests, but more importantly for the borrowers. I am a proponent of modernising Australia's construction industry including the embrace of MMC. This evolution must start out as customer facing, or it runs the risk of undermining years of good work … unless consumers, compliance and public confidence become the centrepiece of these conversations, they are bound to end in tears.’

 

In a September 2024 interview Chandler argued for single-point accountability, ensuring one entity is responsible for the entire project, from design and manufacturing to onsite assembly, to create clear lines of responsibility and reduce the chaos caused by fragmented accountability.

 

Conclusion

 

In April 2025, what progress has been made in the promotion of MMC in Australia over the last year or so? One positive development was the Commonwealth Bank agreeing to provide mortgage finance for prefabricated houses. Another was the ABCB Prefabricated, Modular and Offsite Construction Handbook on determining evidence on MMC compliance with the construction code, a first step in the long process to arrive at a set of standards for MMC and a product compliance regime with digital product passports in Australia. There was also an unspecified amount for removing barriers to MMC and improving development approval processes in the National Productivity Fund announced in November.

 

Funding of $160 million for industry development is promised from governments. There is $50 million on offer from both the Albanese Commonwealth Government (if re-elected in May) and from the recently re-elected Cook Government in Western Australia, and $10 million from the Minns Government in NSW for social housing trials. The Federal and Victorian governments are funding a $50 million Future of Housing Construction Centre of Excellence in Melbourne. 

 

In Queensland QBuild has three MMC centres operating and the Homes for Queenslanders program is still running, which will deliver possibly hundreds of prefabricated houses this year. Western Australia is building capacity and has delivered several projects over the last year. NSW, South Australia, Tasmania and Victoria have small scale prefabricated social housing programs. There continues to be demand for institutional buildings like schools and hospitals, particularly for regional and remote locations. All this adds up to steady if not spectacular production of MMC buildings for the public sector. However, the number and value of private sector deliveries of prefabricated buildings is unknown, as is the extent of prefabrication 

 

NSW established a MMC Taskforce and in mid-2024 released a position paper for consultation on Regulation of Prefabricated Buildings for a new building bill that would include MMC. The paper redefined prefabricated buildings as ‘building work’ not ‘building products.’ The 2024 Homes NSW MMC Program is a partnership with the Building 4.0 Cooperative Research Centre on developing strategies and methods to utilise MMC to deliver social housing. The 2025 industry policy linked modular construction to increasing housing supply and affordability.

 

Therefore, on the one hand, there is currently substantial funding on offer for industry development from the Commonwealth and three state governments, and there continues to be institutional buildings and prefabricated social housing in regional areas delivered. On the other hand, when and what that funding will actually be used for is still unclear, and prefabrication is still reliant on public sector clients. There are also many unresolved issues with MMC, such as certification and product compliance, the regulatory and legal framework (which is what the funding seems to be directed at), the lack of standards and slow progress on updating the National Construction Code. 

 

 

 

Friday, 7 June 2024

MMC in Australia: State of Play 2024

Recent data on offsite manufacturing and modern methods of construction

 


The Australian Bureau of Statistics annual Australian Industry data is now available for the 2022-23 financial year. This data includes output as Industry value added (IVA, in current dollars for the financial year) and employment in June for industries and their sub-divisions. For manufacturing the data is more detailed with output and employment at the level of industry class.

 

There are 12 construction related manufacturing industry classes, such as those producing paint, cement and structural steel. Two of those classes are Prefabricated wooden structures and Prefabricated metal buildings, and this post first presents the data for those industry classes up to 2023. However, as well as manufacturing, other industries involved in offsite manufacturing (OSM) are construction, design services and business services. Therefore, the second part of the post collects recent information on prefabricated and modular building at the state level to get a wider view on current industry trends, with a focus on prefabricated buildings recently delivered for State Governments, typically under a modern methods of construction (MMC) policy. The third section looks at possible actions by government and industry that would increase the use of MMC in Australia. 

 

The ABS data is limited to the relatively small number of firms that classify themselves as prefabricated building manufacturers, and thus excludes offsite work by firms that are classified as building or trade contractors (e.g. Hickory Building Group), architectural (e.g. Dimension X) or engineering (e.g. James Energies) practices. It also excludes OSM done inhouse by other industries like hotels for tourism, student housing, manufactured housing estates, retirement and aged care accommodation. 

 

Therefore, unfortunately, the actual extent and depth of prefabrication and OSM used in Australian construction cannot not found from ABS data. The lack of accurate and up to date data on how many and what type of prefabricated buildings and components are produced each year in Australia is a significant gap in knowledge and understanding of the industry. Because OSM and prefabrication have an important role to play in increasing housing completions, particularly social housing, and addressing the industry challenges of sustainability, productivity and skills this gap also has important policy implications. 

 

 

Prefabricated Wooden Structures and Prefabricated Metal Buildings

 

In June 2023 total employment in the two industry classes was 10,048. The great majority are employed in Prefabricated metal building with 8,636 people, compared to Prefabricated wooden building with 1,412. However, since 2015 employment in Prefabricated wooden building has doubled, increasing by 102%, while Prefabricated metal building employment increased by 59%. While these employment figures are fully representative of the industry, they may be the one of the best indicators available for the growth of OSM in Australia. 

 

Figure 1. Employment in prefabricated building

Source: ABS.

 

When Prefabricated metal building and Prefabricated wooden building are combined, their percentage in IVA and employment of total construction related manufacturing has been gradually increasing since 2018. As Figure 2 shows, IVA growth dipped in 2017 and 2018 and employment was the same in 2016 and 2017. From 2018 to 2023 there was continual year on year increases in the shares of IVA and employment. Although not spectacular, this growth is indicative of wider industry growth.  

 

Figure 2. Prefabricated building manufacturing industry share

Source: ABS.

 

There are other, much larger, ABS construction related manufacturing industry classes that produce building components with some unknown proportion of OSM and prefabrication in their output. These other industry classes include Wooden structural fittings and components (employs 27,908 people), Concrete products (employs 8,133 people), Structural steel fabricating (employs 21,521 people), and Architectural aluminium products (employs 16,703 people). 

 

Measured as IVA per person employed (in current dollars), the productivity of the prefabricated building industries is higher other wood and metal manufacturing industries. As Figure 3 shows, Prefabricated wooden building has 60% more IVA per person than Wooden structural fittings and components, and 40% more than Veneer and plywood manufacturing (employs 1,268 people).

 

Figure 3. Wood product manufacturing productivity

Source: ABS. IVA in current dollars. 

 

There is a similar story for metal products, in Figure 4. Prefabricated metal building has 45% more IVA per person than Architectural aluminium products and around 11% more than both Structural steel and Metal roof and guttering manufacturing (employs 4,162 people). 

 

Figure 4. Metal products manufacturing productivity

Source: ABS. IVA in current dollars. 

 

 

Queensland

 

QBuild’s modern methods of construction (MMC) program is building homes in a factory at Eagle Farm in Brisbane, opened in 2022. There is also a Rapid Accommodation and Apprentice Centre that provides training.A second, smaller RAAC operates at Zillmere. A third factory and RAAC in Cairns will open in mid-2024. There are 11 industry partners: Ausco, Fleetwood, Hutchies Modular, Modscape, Blok Modular, Eco Cottages, James Engineering, ModnPods, Saltair Modular, Volo Modular, and WestBuilt Homes. 

 

The government’s Homes for Queenslanders initiative aims to deliver 53,500 new social homes by 2046, with more than 100 modular homes built in 2023 and more than 150 homes expected by mid-2024.  The June 2024 budget includes $2.8 billion for up to 600 modular homes in 2024-25, and the medium term goal is to increase social housing production to 2,000 homes by 2027-28, a goal that puts Queensland at the front of housing policy in Australia. 

 

In Hervey Bay, 11 Volo Modular homes manufactured at Volo’s Yatala facility were delivered over two days in November 2023. Volo is also producing seven homes to go to Eidsvold. Also in Hervey Bay, a modular 24-bed medical ward is expected to be completed by the end of 2024 as part of the expansion of the hospital. In Gladstone, six two-bedroom modular homes constructed in Hutchinson Builders’ Toowoomba factory have been completed. 

 

New South Wales

 

In May the NSW Government and the Building 4.0 CRC committed $2 million each to developing and testing prototypes of medium-density social housing projects that incorporate MMC.

 

In May forestry company Pentarch group invested in Green Timber technology (GTT), a modular builder fabricating a timber kit of parts of walls, roofs and floors that is setting up a new factory in Orange. GTT has been prequalified for the School Infrastructure NSW scheme that uses a standardised design for buildings. 

 

Through Homes NSW the Government opened an offsite procurement list in April as part of a $10 million MMC development programme. The procurement list covers 3D primary structural systems (volumetric or modular), 2D primary structural systems (kit-of-parts), additive manufacturing, and non-structural assemblies and sub-assemblies like floor and wall cassettes and kitchen and bathroom pods. Applications are to include a description of ‘how your business contributes to the skills development of the MMC workforce, and the NSW Government’s skills and training policy’.

 

The Manufacturing for Schools program incorporates prefabricated elements to deliver new and upgraded school buildings for School Infrastructure NSW. In February the APP Group was awarded the Manufacturing Partner contract, responsible for connecting the supply chain to deliver the ‘kit of parts’, with partners including Lipman, Ark, MBM, WSP, Woods Bagot, Bennett and Trimble, Richard Crookes Constructions, and Roberts Co.

 

In November 2023 a modular construction taskforce was set up, with representatives from PreFab Aus, Shelter NSW, Community Housing Industry Association, Local Government NSW, Property Council of Australia, Government Architects, Industry suppliers and union representatives. alongside people with lived experience of social housing. In the 2023-24 NSW budget $10 million was allocated to new social housing supply and innovative solutions to get people off the social housing waitlist. 

 

Victoria

 

Melbourne-based Modscape opened a new Modbotics division in a 20,000 square metre facility in Essendon Fields in May 2024, after a two year installation and commissioning period. Modbotics was established to manufacture open and closed walls, passive house walls, and floor and roof cassettes, using a Randeck Robotics production system. Randeck are a leading provider of automated production systems and equipment for prefabricated house production. 

 

In March 2024 Homes Victoria announced an Expression of Interest for supply of 250 modular homes in Regional Victoria as part of the Modern Methods of Construction (Modular) Regional Victoria project, aimed at supporting the provision of social housing in the region. The project aims to deliver the homes by no later than 2026-27, with a phased delivery program expected. The Office of Projects Victoria's goal is for all projects to use offsite construction techniques where feasible and efficient. 

 

The first of 25 dwellings for the Homes Victoria and Haven Home Safe social housing project in Horsham, Victoria, built by modular builder, ARKIt, arrived on March 29. The tender process involved both traditional and modular builders, and the ARKit proposal, including all site and civil works, was approximately 8% lower in cost.

 

In what was the Ford factory in Geelong, Cross Laminated Offsite Solutions (CLOS) is installing an automated production line to produce modular and flat-pack buildings. Their Homag-Weinmann panelised manufacturing wall line can cut a kit of parts for a modular home in a single day or a three-storey townhouse in three days. Homag is a leading automation and timber frame construction company. CLOS have partnered with Geelong’s Gordon TAFE for a Construction Pathways Programa course for new workers. However, on May 28 CLOS announced it was going into ‘voluntary administration to restructure and stabilise the business and seek investment for future growth’. More capital is needed because of the cost of establishing the new factory. CLOS claims it has a significant order book of future work. 

 

South Australia

 

Timberlink’s new cross-laminated timber (CLT) and glue-laminated timber (GLT) manufacturing plant in Tarpeena, South Australia, opened in February. The NeXTimber facility is Australia’s only combined CLT and GLT radiata pine mass timber facility, integrated with a structural timber manufacturing plant. Capable of producing CLT panels up to 16 metres long and 3.5 metres wide, and GLT beams up to 12 metres long, the project was supported by a $2 million grant from the South Australian government under the Strategic Business Round 2020 of the Regional Growth Fund. 

 

Fusco Constructions is building a modular construction factory of 4,000m2 at Tonsley Innovation District, a former Mitsubishi car manufacturing site. Fusco Constructions was a plumbing business that expanded into civil, commercial and development projects, and now modular construction.

 

Western Australia

 

The Western Australian government took delivery of 19 new social homes in Hamilton Hill, Western Australia in April. The 19 homes were manufactured by Perth-based panelised timber specialist manufacturer, OFFSITE.  Their manufacturing process uses Homag-Weinmann timber processing machinery with an integrated ‘digital twin’ software solution by hsbcad that connects the process, from design through to manufacturing and assembly.

 

Ausco Modular is delivering a $15 million double-storey school building in Kwinana, Western Australia. The modular school building is part of their Progress-ED range, developed by in-house engineers and designers. In March the WA government announced Highgate Primary School will receive a similar two-storey building. Budgeted at $12 million, the building will be constructed using the MMC methods demonstrated with the Kwinana project. 


Tasmania

 

Property developer David Marriner currently owns a factory in Brighton producing concrete segments for Tasmania’s Bridgewater Bridge. Upon the bridge’s completion, he intends converting the factory into an automated facility capable of producing precast panels for 1,700 houses annually. The conversion of the factory will require investment of approximately $30 million, and Marriner is not seeking government funding for the conversion but is looking for government support in housing orders to ensure a stable financial base for the factory. 

 

Bridges

 

Australian company InQuik has built over 200 bridges using a modular system with prefabricated formwork trays with reinforcing steel that are placed onsite and filled with concrete, reducing construction time. The formwork is made from Magnelis, a corrosion-resistant material from ArcelorMittal Europe, and remains in place after concrete is poured. The system has now been used in the United States, where a 9-metre-long, 8-metre-wide bridge in, Eau Claire County, Wisconsin, was completed in a month, compared to three-to-four-months for a traditional bridge.

 

Mass timber

 

In May Cedar Pacific, an Australian property investment firm, and Sumitomo Forestry Co., a Japanese forestry and wood management firm, entered a strategic partnership to develop a $1.2 billion portfolio of build-to-rent apartments, in Australia and New Zealand using mass timber buildings. Sumitomo Forestry will acquire just under 50% equity in the BTR projects, starting with a $375 million development in Brisbane. The joint venture has a pipeline of projects in Melbourne, Canberra, Brisbane, and Auckland. 

 


What Could the Commonwealth Government Do? 

 

In March 2024 Building Ministers ‘agreed to work together to cut red tape and enable further expansion and growth in Australia’s prefabricated and modular construction industry.’ The Australian Building Codes Board is to ‘work closely with industry bodies and jurisdictions to reduce barriers’. The next Building Ministers meeting is in June. 

 

The Commonwealth Government is responsible for the National Construction Code and the Building Code of Australia. Revising and updating these is a slow, consultative process from initial proposal through technical advice, impact analysis, comment and review, and the process would be speeded up with more resources. These would allow the Australian Building Codes Board to develop performance standards for prefabrication and modular construction for inclusion in the NCC, and Standards Australia to review relevant standards and develop a set of ‘deemed to satisfy’ construction solutions for prefabrication and modular construction. A set of standards for MMC would be the basis for a quality assurance scheme like the UK‘s Buildoffsite Property Assurance Scheme (BOPAS) discussed below. 

 

What Could State Governments Do?

 

State governments could identify unused land or repurpose appropriate sites for housing development with MMC. By specifying the use of prefabrication, modular construction or 3D concrete printing these developments would be demonstration projects for MMC. Access to data on costs of construction for different versions of MMC for researchers should be a contract condition so a credible evaluation of comparable delivery costs can be published. There are also Commonwealth Government sites this applies to.

 

Technology and training centres like the Queensland RAAC can be established to produce social housing or essential worker housing. A version of this model could also be used for training workers and producing indigenous housing in regional areas. 

 

Institutional projects like hospitals and schools can be built with prefabrication and modular construction, the NSW Schools Infrastructure program is a model for this. Again, these can be used as demonstration projects and data on costs and defects should be published for the finance and insurance industries to assess risk associated with MMC.

 

What Could Industry do?

 

The UK Buildoffsite Property Assurance Scheme (BOPAS) was developed to address the risks associated with MMC. It provides firms independent third party accreditation to industry standards and allows access to mortgage financing and insurance for MMC projects. The scheme was developed by MMC industry association Buildoffsite with insurance companies and finance industry associations input, and started in 2013. A similar certification scheme is needed for Australian MMC producers.

 

 

Conclusion

 

The scale and extent of offsite manufacturing and MMC in Australia is not well defined at present. There are many producers, ranging from large contractors like Hutchinson to architectural practices like Dimension X. New factories are being set up in 2024 in NSW and South Australia by builders and contractors, and by government in Queensland. How many producers there are and what type of prefabricated and modular construction (volumetric, panelised, pods etc.) they are producing is not known.

 

That is because ABS industry data does not include offsite work done by firms classified as building or trade contractors, architectural or engineering practices, or work done inhouse in industries like hotels for tourism, student housing, manufactured housing estates, retirement and aged care accommodation. The ABS problem in measuring the prefabricated building industry is that the industries firms involved come from include manufacturing, construction, professional and design services, and this sort of detailed data spread across different industries is hard for the ABS to collect.

 

With OSM and prefabrication being seen as important to addressing the industry challenges of providing affordable housing and improving sustainability, productivity and skills, this lack of data is regrettable. The lack of data on how many and what type of prefabricated and modular buildings and components are produced each year in Australia is a problem if an objective of industry policy is to increase the use of prefab and modular construction. 

 

Nevertheless, there is good evidence that MMC is growing strongly in Australia, both from the ABS data and from reports from industry. State governments have started sponsoring prefabricated and modular buildings, although some of these programs are small scale, toe in the water trials where a few buildings have been procured for regional centres. On the other hand, the NSW schools program and Queensland’s housing policy are major policy commitments to MMC. Some state government owned sites should be used for housing developments specifying MMC for demonstration projects, and researchers given access to cost data for evaluation and credible comparisons. 

 

Queensland is leading in promoting MMC. Qbuild has established three factories and training centres, and produced over 100 houses in the last year. There are 11 industry partners in the Homes for Queenslanders MMC program, which has the goal of delivering 53,500 houses by 2034 through a combination of contractor and government production, and the 2024 state budget has funding for 600 prefabricated houses.

 

Timberlink’s new cross-laminated timber (CLT) and glue-laminated timber (GLT) factory in South Australia joins Xlam in NSW and Cusp in Tasmania as Australian manufacturers. There is also Crosslam Australia manufacturing CLT panels in Perth and Hyne Timber in NSW making GLT beams. The number of high-rise buildings using mass timber is growing with current projects like student accommodation for La Trobe University and the T3 office block in Melbourne, residential tower C6 in Perth, Atlassian’s new Sydney headquarters (the world’s tallest hybrid timber tower), the Sydney Fish markets, and Cedar Pacific’s build-to-rent development in Brisbane.

 

At the May Building Ministers meeting enabling growth of MMC was agreed. The Commonwealth Government should increase the resources available to the Australian Building Codes Board to develop performance standards for prefabrication and modular construction for inclusion in the Construction Code, and to Standards Australia to review relevant standards and develop a set of ‘deemed to satisfy’ standards for MMC. These would be the basis for an Australian quality assurance scheme like the UK ‘s Buildoffsite Property Assurance Scheme.