The Value of Prefabricated Modular Construction
How Northland Power Built a New Office and Saved Half a Million Dollars in the Process
Getting a construction project done on time and on budget at the best of times is a challenge. But what happens when your lease runs out in 2020? You’re staring down the barrel of a pandemic, unforeseen supply chain issues, and labor shortages. It doesn’t seem like “on time, on budget” would be on the table. The folks at Northland Power would tell you different.
Back in 2020, they started going month-to-month on their lease, looking for a new space that could accommodate their growing headcount. In a perfect world, they’d stay in the building they called home, a high-rise in the St. Clair neighborhood of Toronto. So, when three floors opened just an elevator ride away from their old office, they made the move.
“They did look around to other locations,” says Angela Kisielewski, senior interior designer at Bullock + Wood Design, “but being able to relocate within the same building allowed for the least amount of disruption to their employees.”
They obviously loved the location, but how could they keep costs down and make the move as quickly as possible? This giant in sustainable energy production had a plan.
CASE STUDY
Building with DIRTT
The three floors they were taking over had been built with DIRTT by the previous tenant. A prefabricated, modular construction system, DIRTT has the innate ability to be easily reused, recycled, and reconfigured. The facilities team at Northland Power knew that managing change was a large part of their portfolio. Renovating rooms to accommodate their team was a drain on their resources. They were looking for a way to create a space that was easier to adapt than drywall.
Knowing DIRTT is designed for disassembly and reconfiguration, Bullock + Wood Design saw an opportunity to reduce project budget and timeline for building Northland Power’s new office.
It also supported Northland’s sustainability goals at the same time. They got further incentive when they learned that another floor comprised of DIRTT within the building was going to be decommissioned. Rolling that opportunity into their new construction project would save them even more time and money. As they moved towards a September 2023 occupancy date, here’s how everything shook out.
Schedule certainty
As Northlanders worked with Bullock + Wood Design and DIRTT Construction Partner, POI, the clock was ticking. Northland acquired three new floors while still occupying their old office. Doubling up on rent isn’t ideal, but they had a solution.
Using the existing DIRTT meant that construction lead times could be greatly reduced. Instead of waiting for the product to travel great distances to site, it was already there or being stored in a warehouse a few miles away ready for deployment.
“We were designing it as they were demoing, so design didn’t have to be complete,” says Shannon Boe, project manager at POI. “We could work with what we have.”
“We already had most of the product here,” says Boe. “So, it was just a matter of coordinating where things were going to fit within the design and then bring the product back and put it in the right spot.”
The other schedule benefit of using DIRTT came from its modular nature. Instead of the dust, debris and noise that comes with studs and drywall, DIRTT wall assemblies simply tip up into place and easily connect to each other and the base building. In this high rise, building management usually won’t allow construction to occur during office hours due to noise. Since DIRTT quietly zips together with a patented connection interface, technicians could work during the week without disrupting other tenants and improving schedule efficiency
Move in faster
To further streamline the schedule, Northlanders started a staggered return-to-office plan while the space was still under construction. To be free from the month-to-month rent in their old space, Northlanders started moving onto the fifth floor. Once again, the DIRTT Construction System was so clean and quiet, there were no complaints.
We had a soft launch for the new space where Northlanders could come into some ready spaces. I was one of them as well, and I'll tell you, it didn't feel like a construction site.
Green building
"The sustainability aspect played a big part here,” says Donna Wood, owner and president of Bullock + Wood Design. “We were working with a renewable energy company.”
“When you think about reconfiguration, you’re not processing raw materials, you’re not transporting product across the globe,” says Boe. “The carbon footprint of extraction and shipping is greatly reduced. And then there is a reduction in landfill because the existing product is being reused instead of disposed of.”
That included the aluminum in the assemblies, the glass in the walls, and the copper wire in the electrical system.
If you can’t reuse it, you can reconfigure it, you can recycle it.
DIRTT also played into green building certification for Northland. “For our project, we wanted to achieve LEED certification,” says Kisielewski. “We were going into these floors knowing that they were LEED Certified by the previous tenant, and the client wished to maintain that. DIRTT played a key role in having us utilize the systems within the space and diverting that from the landfill.” At the time of writing, the LEED Certification application is still under review.
Overall savings
Northland Power has a 30-year history of making responsible financial decisions and this new construction project was no different. Early on, Northland communicated their budget needs to their designer, general contractor, and project management team. Their goal was to bring the project in under budget.
In the end, thanks in part to cost and schedule savings empowered by DIRTT, the project was more than half a million dollars under, despite all the mitigating factors that drove up the cost of construction in the early 2020s.
“Being able to utilize the DIRTT product did help our bottom line,” says Wood. “The budget was established back in 2020 so, we had to be careful of the dollars that we were spending. Needing to do minimal amount of work was incredible to the bottom line of the project.”
“Because of the DIRTT product, we brought it in on the original target budget set in 2020 because we were salvaging so much product.”
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