GLOBAL WATCH MISSION REPORT

Modern methods of
construction in Germany –
playing the off-site rule

MARCH 2004
 Global Watch Missions
The UK government Department of Trade and
Industry (DTI) Global Watch Service provides funds to
assist small groups of technical experts from UK
companies and academia to visit other countries for
short, fact finding missions.

Global Watch Missions serve a number of related

purposes, such as establishing contacts with
The DTI drives our ambition of overseas organisations for purposes of collaboration;
‘prosperity for all’ by working to benchmarking the current status of UK industry
create the best environment for against developments overseas; identifying key
business success in the UK. developments in a particular field, new areas of
We help people and companies progress or potentially disruptive technologies; or
become more productive by studying how a specific industry has organised itself
promoting enterprise, innovation for efficient operation or how governments, planners
and creativity. or decision makers have supported or promoted a
particular area of industry or technology within their
We champion UK business at home own country.
and abroad. We invest heavily in
world-class science and technology.
We protect the rights of working Disclaimer
people and consumers. And we This report represents the findings of a mission
stand up for fair and open markets organised by CIRIA (Construction Industry Research
in the UK, Europe and the world. and Information Association) with the support of DTI.
Views expressed represent those of individual
members of the mission team and should not be
taken as representing the views of any other
member of the team, their employers, CIRIA or DTI.

Although every effort has been made to ensure the

accuracy and objective viewpoint of this report, and
information is provided in good faith, no liability can
be accepted for its accuracy or for any use to which it
might be put. Comments attributed to organisations
visited during this mission were those expressed by
personnel interviewed and should not be taken as
those of the organisation as a whole.

Whilst every effort has been made to ensure that

the information provided in this report is accurate
and up to date, DTI accepts no responsibility
whatsoever in relation to this information. DTI shall
not be liable for any loss of profits or contracts or
any direct, indirect, special or consequential loss or
damages whether in contract, tort or otherwise,
arising out of or in connection with your use of this
information. This disclaimer shall apply to the
maximum extent permissible by law.
 Modern methods of
construction in Germany
– playing the off-site rule

REPORT OF A DTI GLOBAL WATCH MISSION

MARCH 2004

Report prepared by
Tim Venables
Roger Courtney
with contributions from
Karin Stockerl
Andrew Ogorzalek
Clive Clowes
Paul Newman
Russell Matthews
John Mitchell
Simon Palmer
Rodger Evans
David Whitton

1
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

CONTENTS

Executive summary 3 4.2.4 WeberHaus – flexible, affordable 35

S.1 Background to mission 3 and good quality!
S.2 OSM in the German market 3 4.2.5 Carl Platz – top of the range, 37
S.3 The OSM industry 4 niche product from a family firm
S.4 OSM technologies 4 4.2.6 ELK Haus – is the technology 39
S.5 Marketing of OSM homes 5 really transferable?
S.6 Conclusions 5 4.2.7 Transferable lessons 41
4.3 Massivbauweise and OSM 42
1 Introduction 6 4.3.1 Introduction 42
1.1 The policy context 6 4.3.2 Prefabricated basements – 43
1.2 UK interest in OSM 6 Glatthaar Fertigkeller
1.3 Aims of mission 8 4.3.3 Large block systems – 45
1.4 Mission participants 8 Hebel Haus
4.3.4 Storey height panel systems – 47
2 Housing in Germany 9 Johanni Ziegelhaus
2.1 Introduction 9 4.3.5 Volumetric units – Veit Dennert 48
2.2 Main supply routes and types 9
of homes 5 Post-production aspects 51
2.3 Tenure patterns 11 5.1 Transport of components 51
2.4 OSM and MMC housing 11 5.2 Assembly processes 52
2.5 OSM and quality 12
2.6 Producer-client relationship 13 6 Commentary and conclusions 58
6.1 Introduction 58
3 Design aspects and 15 6.2 Market aspects 58
customer services 6.3 Business philosophies and 61
3.1 Introduction 16 processes
3.2 Design 16 6.4 Technologies and production 62
3.2.1 Light, space and quality 16 processes
3.2.2 Spaces and fittings 16 6.5 Follow-up actions 64
3.3 Architecture – not just boxes 19
3.4 Customisation 21 Appendices 66
3.5 Housing finance 26 A Acknowledgments 66
3.6 Customer care 26 B Mission itinerary 67
C Host organisations 68
4 Housing technologies 28 D Mission team 70
4.1 Introduction 28 E Glossary 71
4.2 Fertigbauweise and OSM 28 F List of tables and figures 72
4.2.1 Introduction 28
4.2.2 High quality eco-friendly 31
construction – Baufritz
4.2.3 Standardisation and 33
customisation; striking a balance –
Kampa ExNorm
2
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

EXECUTIVE SUMMARY

S.1 Background to mission The mission visited eight suppliers of OSM

housing, a supplier of prefabricated concrete
There is widespread concern that the rate of basements, two ‘show home’ parks each
construction of new housing in the UK is with some 50 OSM houses, and a university
insufficient to meet current needs. The research group.
reasons for this shortfall are the subject of
debate, but it is clear that any significant S.2 OSM in the German market
increase in the rate of construction of new
homes by traditional methods would impose Annual production of new homes in Germany
considerable strain on an industry which is is considerably larger than in the UK, at
having difficulty recruiting sufficient skilled around 285,000 units. Of these, around
labour to meet present rates of construction. 25,000 are constructed from OSM systems,
and this figure is increasing even though the
One means of increasing production without overall market is in recession.
a corresponding increase in the demand for
site labour is to move to off-site OSM is most commonly used in the
manufacturing (OSM). In OSM, the main construction of new detached housing, much
elements of the house are constructed away of which is ’self-procured’, ie purchased by
from the building site in a factory the owner of a serviced plot of land. This
environment. This facilitates the application of contrasts with the normal developer-led
machinery and automation to construction supply route for private housing in the UK,
and reduces the demand for site labour. It and means that OSM suppliers are
provides a better working environment, competing in a market for houses rather than
enhances quality and leads to greater a market for the house-land-location ‘package’
predictability in delivery. as in the UK.

OSM has been more widely adopted in some OSM housing in Germany has a good image,
countries than in the UK, and previous DTI being associated with high quality of
Global Watch Missions have examined its construction. However, this was not the case
application in Japan, northern Europe and in the 1980s; the industry has regained its
North America. This report presents the position through the development of quality
findings of the latest mission, to Southern standards and certification schemes and
Germany, which took place during 14-19 consistent promotion of the merits of OSM.
March 2004.
The houses are generally of ‘chalet’ design
Members of the mission were representative but other forms are marketed, and there is
of major interests in housing, including considerable variety and flexibility in external
private house building, funding and provision features. The housing is characterised by
of social housing, provision of housing open living areas and, often, large areas of
warranties, housing design, research and glazing. Most have basements. Fittings and
technology transfer, and the development of final finish are invariably of a high quality.
housing policy.

3
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

OSM suppliers serve a wide range of energy and water conservation, and most
markets, from ‘starter’ homes to luxury recently in technologies such as external
housing, at prices ranging from €80,000 to envelopes that offer protection from
more than €400,000. Some supply different electromagnetic radiation.
levels of finishing to match customers’
budgets. At the upper end, firms will S.4 OSM technologies
undertake to build to any plan desired by the
customer while the cheaper houses offer less Timber
flexibility, although internal layouts and
specifications can be changed. Timber-based OSM systems take the form of
post-and-beam construction, structural
Generally, firms sell to the final customer but insulated panels, or a combination of both.
one supplier is supplying to a developer in External finishes are normally rendering or
Ireland and another has supplied 3-storey timber cladding. The specifications and
units for a mixed retail/residential dimensions of the timber used exceed those
development. in the UK, with great concern for final quality
in the finished product. Post-and-beam
S.3 The OSM industry systems are aimed at the upper end of the
market, and application in the UK is likely to
There are more than 100 OSM suppliers of be limited. But structural panel systems
timber systems in Germany, with capacities could have wider application, once the
ranging from 50 to 2,800 units annually. Many absence of a cavity is accepted. There is
are family-owned. OSM is viable at low considerable spare production capacity in
production volumes, using the flexibility Germany, so either manufacture in the UK or
offered by modern production systems to import would be possible.
meet customers’ individual requirements.
Concrete and masonry
Component suppliers have production
systems linked to those of the OSM The concrete OSM systems viewed by the
suppliers, so that prefabricated basements, mission were either based on large blocks
for example, can be produced in highly and roof elements manufactured from low-
automated plant to the exact dimensions density concrete (which save labour on site
required. but do not represent the degree of factory
manufacture as other systems) or, at the
OSM firms are product and customer- other extreme, utilise concrete ‘modules’ fully
focused. Their competitive position depends fitted out in the factory. The latter were aimed
on the design, specification and build quality at the lower end of the market, prices being
of their homes, and their ability to in the €80-100,000 range. The technology
accommodate individual customer was transferable to the UK. Some OSM firms
requirements. They invest in research and supply factory-built brick panels; these could
development (R&D) in order to keep their be investigated further but the plant visited by
product competitive and have developed new the mission had largely manual processes.
forms of housing to meet new needs (eg for
two generations living in the same house). Components

OSM has generally been a pace-setter for the A manufacturer of concrete basements for
housing sector, particularly in the introduction OSM housing produced these with an
of environmental technologies; for example, impressive degree of automation, and

4
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

demonstrated the waterproof final product by product, setting standards for housing
having a floating marketing facility. The generally. The same effect in the UK might
technology could be used for above-ground be achieved through relationships between
construction and was particularly relevant to OSM suppliers and developers or social
areas prone to flooding. housing interests.

Production Some of the technologies employed in

Germany – notably for insulated structural
The degree of mechanisation and automation panels, modular concrete housing and
observed, and the balance between factory automated production of concrete panels for
and site activities, varied widely, with firms walls and basements – should be investigated
taking a pragmatic view based on their further with a view to application in the UK.
position in the market. Firms offering a great There is currently spare production capacity,
deal of flexibility tended to undertake more and import of timber units may be economic,
work on site, to be able to accommodate late although concrete units would need to be
changes. But they sought to bring work back manufactured in the UK. In addition, the
to the factory and one firm had developed a advanced environmental technologies now
packaged heating/water supply unit to reduce being deployed in German housing may
installation time on site. warrant further study.

S.5 Marketing of OSM homes The German OSM industry has overcome an
image of poor quality through developing
As in any product-based competitive market, rigorous quality standards and promoting
suppliers invest heavily in marketing and certification schemes; a similar strategy
sales outlets. A distinctive role is played by would assist the UK OSM sector to address
‘show home’ parks. These enable current public perceptions.
prospective customers to view a range of
houses on a single visit and thus help the An industry-wide initiative to establish a
selection process, to the benefit of the OSM ‘show home’ park might also be considered,
sector generally. Firms also have show as a means of raising the profile of OSM and
homes on their production sites, together giving developers and public first-hand
with ‘customer centres’ which exhibit experience of OSM housing.
finishes and fittings. One has constructed a
‘World of Living’ which combines a walk-
through history of housing with exhibition
and conference facilities. Other promotion
takes place through magazines dedicated to
OSM housing.

S.6 Conclusions

Traditional house buying practices, in

particular the practice of purchasing land and
then having the house constructed on it, has
facilitated the growth of OSM in Germany.
The outcome is a highly competitive industry
focused on continuous product development
to improve the design and quality of the final

5
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

1 INTRODUCTION

1.1 The policy context 1.2 UK interest in OSM

Many recent reports, including Kate Barker’s OSM techniques are not novel; off-site
review of housing supply1, the ODPM’s production has been employed in various
Sustainable Communities report2, and the ways in the UK for the past 50 years. But
Joseph Rowntree Land Enquiry3, have drawn with some exceptions (eg temporary
attention to the shortfall in production of buildings), use of OSM has been
housing in the UK as compared with experimental, with both social and economic
estimates of needs, and to the low factors constraining its mainstream
replacement rate of the present housing application, notably in housing. Changes in
stock. While the reasons for this shortfall are both production technologies, and in the
the subject of debate, it is clear that any wider social and economic context as
significant increase in the rate of construction outlined above, have stimulated much greater
of new homes by traditional methods would attention to the potential of OSM in recent
impose considerable strain on an industry years, with significant research investment, of
which is having difficulty recruiting sufficient which the £1.8 million ‘PrOSPa’5 programme
skilled labour to meet present rates of led by CIRIA is the latest phase.
construction.
Within the general concept of OSM, five
One means of increasing production without a subdivisions are recognised6:
corresponding increase in the demand for site
labour is to move to off-site manufacturing Volumetric systems
(OSM). In OSM, the main elements of house
construction take place away from the building The most factory-based form of production,
site in a factory environment, with site works volumetric systems use three-dimensional
confined to the installation of mains services, (3D) modules, either in isolation or in
construction of foundations, and final multiples, to form the structure of the
assembly of manufactured components. building. These modules can be pre-finished
Complementing OSM, forms of site-based in the factory to include all fixtures and
construction (eg large block systems) have fittings, requiring a very limited amount of
been developed which reduce the amount of installation work on site.
labour required. Collectively, these approaches
to housing production are described as Panelised systems
‘modern methods of construction’ (MMC).
Issues relating to the current state of OSM in The construction of the structural frame for
the UK are addressed in the report the building using panels assembled in the
Manufacturing Excellence4. factory. Panelised systems can either be

1 K Barker (2004) Delivering Stability: Securing our Future Housing Needs. London: HMSO.
2 Office of the Deputy Prime Minister (2003) Sustainable Communities: Building for the Future. London.
3 J Barlow, K Bartlett, C Whitehead & A Hooper (2002) Land for Housing: Current Practice and Future Options. York: Joseph Rowntree Foundation.
4 T Venables, J Barlow & D Gann (2004) Manufacturing Excellence – UK Capacity in Off Site Manufacture, Constructing Excellence. London.
5 www.prospa.org, led by CIRIA on behalf of Co-Construct and Loughborough University. Sponsored by DTI.
6 Based on definitions from the Housing Corporation.

6
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

open (typically delivered to the site purely as a technologies is more prevalent. In these
structural element) or closed (typically including countries – notably Japan, the USA and
additional factory based fabrication such as certain countries in northern Europe –
lining materials, insulation, cladding, internal housing technologies and associated
finishes, services, doors and windows). production systems have been refined both
through experience and through suppliers’
Hybrid systems investment in research and development
(R&D). Missions sponsored by DTI have
A combination of volumetric and panelised examined the housing technologies and
systems where the high value areas (kitchen production techniques used in these
and bathroom) are typically formed from countries and identified ways that these can
volumetric units (sometimes referred to as be transferred to a UK context7.
pods) and the rest of the structure from some
form of framing system.

Subassemblies

Major building elements that are

manufactured off site but do not form the
primary structure of the building. Foundation
systems and cassette panels are typical
examples.

Components

Non-structural elements that are assembled

off site. Although currently less common than
structural elements, components such as
mechanical and electrical services
infrastructures are being developed with
significant assembly work being carried out
off site.

Associated with the rise in interest in OSM

has been a desire to learn from the
experience of other countries where the use
of OSM and other non-traditional Figure 1.1 Previous mission reports

7 D Bottom, S Groak, D Gann & J Meikle (1996) Innovation in Japanese Prefabricated House Building Industries. London: CIRIA.
S Palmer, D Gann, C Adams, A McCosh & R MacFarlane (1998) Houses from the Rising Sun. TRADA.
D Gann et al (1999) Flexibility and Choice in Housing. Bristol: The Policy Press.
J Barlow & R Ozaki (2001) Are You being Served? Brighton: SPRU.
S Palmer et al (2002) House Cladding Systems. Dartford: The Palmer Partnership.

7
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

This report presents the findings of the latest Germany – the Länder (federal states) of
of these missions, to Germany, which took Bavaria and Baden-Württemberg. In these
place during 14-19 March 2004. regions, most housing is constructed from
timber, masonry and concrete; the mission
1.3 Aims of mission therefore focused on suppliers of housing
made from these materials. Other forms of
The mission examined the factory production prefabricated construction (eg lightweight steel
of new homes and building components in frames) are to be found in Germany, but have
Germany. Its aims were: a very small presence in the market. Steel
framed systems, for example, account for less
• To develop improved understanding of the than 1% of the OSM housing market8.
technologies incorporated in prefabricated
housing in Germany and employed in its Appendix B presents the mission itinerary
design and production and Appendix C provides details of the
• To assess the scope for application of organisations visited.
these technologies in the UK, and the
factors that would promote or inhibit 1.4 Mission participants
take-up
• To disseminate the knowledge gained, and Members of the mission brought to the study
stimulate appropriate debate and of OSM in Germany a range of backgrounds,
application experience and viewpoints. They are listed in
Table 1.1 below, with further details in
To minimise time spent travelling, the firms Appendix D.
visited by the mission were mainly in Southern

Participant Position Viewpoint

Clive Clowes Head of Housing Procurement, Housing Corporation Provider of housing finance
Roger Courtney Consultant, innovation in construction Mission coordinator for CIRIA
Dr Rodger Evans Construction Sector Unit, DTI Policy towards MMC
Prof David Gann Tanaka Business School – Imperial College London Academic advisor
Dr Russell Matthews Taylor Woodrow Engineering Housing developer
John Mitchell Surveying Services Manager, Zurich Building Guarantee Provider of housing warranty
services
Dr Paul Newman Head of Timber Technology, TRADA Research and technology transfer,
timber housing
Andrew Ogorzalek Director, PCKO Architects Housing architect
Simon Palmer Director, Palmer Partnership Consultant on OSM housing
Canda Smith Head of Design and Sustainable Communities, ODPM Policy towards MMC in housing
Dr Karin Stockerl Innovation Coordinator, Southern Housing Group Social housing provider/German
market expert
Tim Venables Tanaka Business School – Imperial College London Academic advisor
David Whitton Group Chief Architect, Home Group Ltd Social housing provider

Table 1.1 Position and viewpoint of mission participants

8 SIZ (2000) Wohnungsbau mit Stahl 073: Reihenhäuser in Villingen-Schwenningen. Stahl-Informations-Zentrum.

8
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

2 HOUSING IN GERMANY

2.1 Introduction The low new-build figures can be partly

attributed to a reduction of public funds for
About 285,000 new homes will be completed social housing coupled with a reduction by
in Germany in 2004. This is a significant the government of financial incentives for
decrease since the mid-1990s, when annual private mortgages. The general economic
new-build figures were as high as 500,000 downturn is also significant and has affected
(Figure 2.1). The decline has been particularly affordability levels, despite (in sharp contrast
marked in the Länder of the former East to the UK) falling house prices.
Germany. Construction of apartments has
shown the greatest decline; the number of New-build prices, excluding land, declined by
detached and semi-detached houses built 7.4% between 1995 and 2002. In part, this
each year has been relatively stable in reflected a reduction in build costs (by 1.4%)
comparison. but also purchasers wished to save money by
omitting expensive fit-out details10.
700
West houses West flats East houses East flats

600 2.2 Main supply routes and types of

homes
500
Number of homes (000’s)

The most significant difference between the

400
German new housing market and that in the
300 UK is the relative share of the three main
supply routes.
200

In the UK, speculative production of new

100
housing is dominant, with about 79% of new
0 homes being provided by developers.
85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 Some 13% of homes are built for non- or
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20

Figure 2.1 Numbers and types of new homes limited-profit organisations, and about 8% are
completed in Germany, 1985-20049 self procured11 (Figure 2.2).

In Germany, the dominant supply route is

As in the UK, the new-build level in Germany self-procurement (ie constructed by their
is well below estimates of number of homes eventual occupants either directly or through
required. These suggest that construction of subcontractors), accounting for about 55%,
between 350,000 and 400,000 new homes followed by speculative developments with
annually is required to deal with the projected 32% and social housing with about 13%
rate of formation of new households10. (Figure 2.3).

9 Statistisches Bundesamt/Verband der Privaten Bausparkassen eV (2004). Note: 2003/2004 figures are estimates. Figures for former East Germany are not
included for 1985-1991.
10 LBS (2003a) LBS Jahresbericht 2002. Berlin: Bundesgeschäftsstelle Landesbausparkassen im Deutschen Sparkassen und Giroverband eV.
11 J Barlow, R Jackson & J Meikle (2001) Homes to DIY for: The UK's Self-build Housing Market in the Twenty-first Century. York: Joseph Rowntree Foundation.

9
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Social that also design the homes they build; this

(13%)
currently discourages the manufacturers of
OSM homes from engaging in speculative
Self procured
(8%) development, an activity that they anyway
consider risky because of the uncertainty in
the eventual sale.

Table 2.1 presents the main forms of housing

and the associated usage of OSM based on
procurement route.

Type of Speculative Social Self-

procurement housing procured
Speculative Main built Flats and Flats Detached or
(79%)
form terraced semi-
Figure 2.2 Market share of various procurement detached
routes in the UK Level of Low Low High
OSM used

There is also a strong link between the Table 2.1 Usage of OSM by procurement route and
procurement route and the type of housing built form
constructed. Both speculative development
and social housing provision tend to focus on Three principal forms of self-procurement are
multiple occupancy buildings rather than employed dependent on the amount of input
detached or semi-detached housing which is the homeowner puts into the construction of
almost exclusively self-procured. In a similar the home:
manner, the uptake of OSM as the main
structural technology has mainly been limited • Self-build, where the owner constructs the
to homes that have been self procured. house
• Commissioned, where the owner prepares
Social
(13%) a design and contracts with a builder (who
Speculative
(32%)
may then use OSM components)
• Catalogue purchase, where the owner
selects from a portfolio of house designs
and types

Table 2.2 shows the usage of OSM under

these three routes

Self- Self-build Commissioned Catalogue

procurement purchase
routes
Self procured Usage of Mainly use Mainly traditional Various
(55%) OSM of traditional methods but types of
methods or some OSM OSM, with
Figure 2.3 Market share of various procurement
kit-houses timber, brick,
routes in Germany for ease of concrete or
self-build steel
process technologies
Additionally, the German taxation system
imposes a second layer of tax on developers Table 2.2 Usage of OSM by self-procurement route

10
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

2.3 Tenure patterns After 1945, the production of homes in a

factory environment attracted the attention of
Social rented American interests who organised an
exhibition of OSM homes in Stuttgart-
About 38,400 social housing units were built Zuffenhausen in 1947. Today, six of the
in 2002, supported by about €7,400 million of eighteen prefabricated homes survive13.
government funds. The last decade has seen
a significant decrease in construction of social In the 1950s and 1960s, the German timber
housing; by about 70% in the former West industry and house builders started to invest
Germany and as much as 90% in Eastern heavily in modern methods of production. The
Germany12. industry is now a significant force in the
German market. In 2002, over 23,000
Home ownership and private rented market lightweight prefabricated homes (ie based on
timber frame or timber panel construction)
In the last decade also, the number of were completed, equivalent to some 13% of
households owning their home has risen all new detached or semi-detached homes
significantly. From a level of about one third in built that year. In Eastern Germany, the
the mid-1990s, by 2003 the figure had risen proportion was higher than the national
to 41%. This trend is expected to continue; average, at around 20%14.
recent surveys have shown that about 40%
of those currently renting had aspirations to The corresponding figures for other OSM
own their own home. technologies (steel, concrete and brick) are
uncertain. However, the overall share of the
About 12% of home owners live in flats and detached and semi-detached housing market
the remaining (88%) in single family houses10. taken by prefabricated homes is estimated to
Home ownership figures vary greatly between be close to one third, with the remaining two
regions and are generally lower in cities, thirds being produced by traditional but
where property values can be significantly increasingly standardised and mechanised
higher than national averages. For example in on-site processes.
Munich, where house prices can be more
than twice those in the surrounding area, the There are more than 100 OSM producers in
level of home ownership is below 20%. Germany, the majority being very small family
firms. The five largest firms (Massa, Elk-Bien-
2.4 OSM and MMC housing Zenker, Kampa, WeberHaus and
Schwörerhaus) each sell between 1,000 and
The history of OSM in Germany extends back 3,000 homes per year and together account
70-80 years. In the 1920s and 1930s the first for more than half of the timber-based OSM
industrially produced homes were seen as a market.
symbol of modernism and progress. Their
development was very much part of the Some German OSM house builders have
‘Bauhaus’ movement; architects such as started to extend their operations to other
Walter Gropius saw prefabrication as the way European countries. In 2002, exports were
to build large numbers of dwellings in a fast twice the level of 2001 but still account for
and effective way. Some examples of this less than 5% of production. Some individual
period survive and are now listed buildings. firms, however, aim to increase export sales

12 Mieterbund (2004) Sozialer Wohnungsbau vor dem Aus? www.mieterbund.de/politik/statistiken/main_politik_stat_sowo2.html (07/03/04)

13 (2003) Samstag, 9 August 2003, 19:15-19:45: Das Heim aus dem Katalog – Eine Geschichte des Fertighauses.
14 DFV (2004) Wir über Uns, www.dfv.com/fertighaus/index.html (07/03/04). Deutscher Fertigbau Verband.

11
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

to 40% of overall turnover rates. Key export • 92% of respondents knew that a factory
markets are the UK, Switzerland and Austria. built home could be planned to their
Homes are also exported to many other specific requirements
European countries, and also to Russia • 84% of respondents perceived current
and Japan. prices as good value
• 95% of respondents saw OSM
Some concentration of suppliers is taking technologies as trustworthy, and a practical
place, with some large companies now and sensible way of building
emerging that have operations across Europe. • 75% believed that OSM homes could be
As an example, Elk-Fertighaus AG, the leading resold in the same way as a traditionally
Austrian OSM house builder, recently built home
acquired the majority share in Bien-Zenker, a • 50% of respondents indicated that OSM
large German house builder, and now the Elk- homes are setting trends in areas such as
Bien-Zenker Group is the largest OSM design and energy efficiency
manufacturer in Europe with a turnover of
about €275 million and 2,800 homes sold in Today, producers of OSM homes in Germany
2002. The group now operates in eight focus on providing high quality products
countries, including Ireland. through continuous innovation supported by
in-house R&D, training, and quality assurance
2.5 OSM and quality processes that are visible to the customer.

As happened in the UK, some first generation Lobbying and coordinating bodies in the OSM
OSM homes in Germany were perceived as housing industry played a crucial role in
being of lower quality than traditionally built achieving higher acceptance for OSM homes
homes. This was exemplified by the fact that in the market. Both the Bundesverband
‘Pappdeckelhäuser’ (literally, ‘cardboard Deutscher Fertigbau (BDF) and the Deutscher
houses’) was once a widely used nickname Fertigbau Verband (DFV) represent suppliers
for off-site manufactured homes in Germany. of timber framed OSM homes and their
However, after some 50 years of development supply chains (eg suppliers of windows,
and experience by manufacturers, this internal drywalls, basements, garages,
perception seems to have been more than heating, ventilation and electrical systems).
overcome. The BDF, for instance, has about 40 main
members and 78 supply chain members.
Today, the image of OSM has changed very
significantly. A recent survey by LBS (a large Both are concerned with marketing and
German mortgage lender) amongst 6,300 quality assurance issues related to the OSM
readers of its mortgage magazine Das Haus products of their members, and have
revealed current perceptions about the subsidiaries providing quality inspection and
popularity of OSM homes15: testing services. The Gütegemeinschaft
Deutscher Fertigbau (GDF), a subsidiary of the
• 20% of respondents lived in a factory built DFV, has its own widely recognised ‘seal of
home quality’ which it awards to OSM homes that it
• Almost all the respondents knew someone inspects directly or which are inspected by
living in a factory built home independent experts on its behalf. About 80
• 82% of respondents would consider producers are members of the GDF. A number
buying a factory built home of other quality marks apply to timber frame
15 BDF (2003a) Leserumfrage fon ‘Das Haus’ bestätigt: Bauherren schätzen die Vorteile des Fertigbaus, 24, September 2003,
www.bdf-ev.de/menue/presseberiech/pmarchiv/2003-09-24-50.pdf. Bundesverband Deutscher Fertigbau.

12
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

OSM homes but only three or four are widely systems, photovoltaic panels and solar heating,
recognised, such as the RAL sign assuring the and heat pumps.
quality of timber components used.
2.6 Producer-client relationship
Similar associations represent suppliers of
OSM housing based on other materials: As discussed above, clients choosing the self-
bricks (brick panels for walls, ceiling and roof), procurement option to home ownership have
steel (panelised and modular applications) and essentially three major sub-routes16. The first
concrete (panelised and modular concrete one is self-build, the second is to commission
systems). a building company, and the third is to order
an OSM house from a ‘catalogue house
Training builder’. The third option is growing in
popularity and the majority of OSM homes in
OSM housing suppliers regard training as an Germany are procured this way.
important investment for sustaining quality
and their ability to maintain production in the A prospective purchaser can order a house
future. The BDF reported in 2002 that its from a catalogue house builder or supplier
members had 520 apprentices, an increase of just like any other product. The land upon
6% over the 2001 figure. Total employment which to build the house is sourced and
had risen by 7% to 9,300 in contrast with a purchased separately by the prospective
decline amongst traditional builders. On homeowner. Statutory permissions and
average, each BDF member organisation had approvals together with any infrastructure
14 apprentices15. costs are also the responsibility of the
prospective homeowner. In this instance it is
Energy efficient OSM homes the design quality, aesthetics, functionality
and durability of the house as a product that
OSM housing producers have set new are the prime considerations of the
standards in a number of areas including the prospective purchaser and consequently of
environmental performance of new homes. the house builder or supplier. These factors
Many offer homes built to the German are at the heart of the interface between the
‘Passivhaus’ standard, which requires a high customer and the house builder and/or
level of energy efficiency equivalent to oil supplier in Germany.
usage of less than 1.5 litres per square metre
of living space. (This corresponds to annual New houses in Germany can be bought at
energy consumption of 10-15 kWh/m2). different stages of the construction process.
Compared with traditional homes, this is a One particular form of procurement is
saving of up to 90%. Between 1998 and ‘Ausbauhaus’ where the shell of the house is
2002 the number of homes built to this constructed by a contractor but the interior fit-
standard doubled each year, aided by out has not been, or is only partially,
government grants to purchasers. completed. This is an increasingly popular
choice for homebuyers. It allows them to
Features of a Passivhaus can include: highly save between €10,000 and €35,000 in labour
insulated walls (U-value of 0.125 W/m2K), highly costs by doing their own tiling, decorating,
insulating windows (triple glazing, maximum installation of heating system, etc. It also
U-value of 0.70 W/m2K), external doors which allows them to get even more involved in
minimise heat losses, heat recovery ventilation choosing the detailed fit-out products.
16 Stockerl & Barlow (1999).

13
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

OSM suppliers offer additional services by A key characteristic of German OSM housing
providing various types of ‘all-in-one’ products that has made them attractive to
packages. These can include the following clients is the flexibility in production and
products and services: design, which makes it possible to achieve
high levels of customisation. With the aid of
• Site finding/estate agent service CAD/CAM technology, plans and designs can
• Mortgage finance packages: for instance, be produced to fulfil individual customer
the Deutsche Fertighaus Holding (three preferences17.
OSM manufacturers/builders and one
refurbishment organisation) offer
mortgages for 1.99% fixed for the first five
years (Hausbau, 2003)
• Fit-out centres and show homes for
clients, 3D visualisations, and individual
floor plans

17 T Drexel (2003) Das individuelle Fertighaus. Stuttgart: Deutsche Verlangsanstalt.

14
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

3 DESIGN ASPECTS AND

CUSTOMER SERVICES

Figure 3.1 Single occupancy house

Figure 3.2
Family home

15
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

3.1 Introduction without the other considerations of land and

location that typically enter the new housing
In this chapter, we summarise the general market in the UK. This is not to suggest that
design characteristics of the houses that we the product is unimportant in the UK
saw – these varied from small single- market, but clearly the competitive position
occupancy starter homes through to large of housing developers in the UK is
luxury homes. The chapter focuses on the dependent on many other factors whereas
significant differences in design between in Germany the suppliers of manufactured
Germany and the UK, many of which arise houses stand or fall on the way that their
from differences in cultural context and delivered product meets the customer’s
aesthetics. Additionally, we review the requirements and expectations, at a price
interactions between the housing suppliers level set by competitors.
and their customers.
3.2.1 Light, space and quality
3.2 Design
Three words can sum up lasting impressions
Most of the housing that we saw was for of the housing studied in Germany – Light,
single families, although some larger homes Space, Quality. Whilst there were variations
were designed for two generations or multiple according to the particular part of the market
families living in a single building (multiple being targeted, these features were always
family homes). This reflects the market being present, whatever the type of construction –
addressed by manufactured housing suppliers, post and beam, timber panel, concrete panel
which is predominantly the ‘family home’ or large thin-joint block.
market. However, the technologies employed
in both the products and production processes The typical house type was the ‘chalet’, with
were applicable to other forms of housing. upper floor bedrooms in the roof space.
Larger homes had a full second storey and
We describe below some of the main design we saw some examples of bungalows. Floor
features that we observed. Some derive from areas were generous by current UK
local traditions and expectations, which differ standards, ranging from 110 m2 upwards,
from UK requirements and expectations. They with a cellar providing a further 50 m2 or
illustrate the ability of the manufactured more. However, prefabrication techniques
housing sector to serve a highly competitive were also being applied to one-bedroom
and demanding market, with products that ‘entry level’ homes of 60 m2.
address a wide range of individual
requirements and price brackets. While 3.2.2 Spaces and fittings
individual designs had been developed to
match requirements in the particular sector of Ground floor accommodation
the market that the supplier wished to
address, every supplier had a strong focus on This was generally open plan, with a
the quality of the final product, and sought living/dining/kitchen area and flexible filling of
within the economics of the production space. The entrance hall was normally a good
process to accommodate as many individual size with a prominent entrance feature: a deck
variations as possible. or podium, with an attractive porch or canopy
and a substantial external door. The main
This focus on the product is, of course, a entrance hall always incorporated substantial
consequence of suppliers competing in a storage; off it was the ground floor
market defined entirely by the product, WC/shower room. Most houses had one

16
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

height space or stairwell) creating a feeling of

openness, space and connectivity. Double
height spaces within the roof shape often
allowed an additional play area as an
extension of bedroom space.

Several houses provided a large landing area

as an extension of the living space. This
would be arranged as a sitting area or play
space and was often linked to double height
spaces, overlooking the ground floor
accommodation.
Figure 3.3 Open living area
Bathrooms

additional room on the ground floor, for use as To UK eyes, it was surprising that most
a study, guest bedroom, hobby room, etc. houses, even at the top end of the market,
did not offer en-suite bathrooms. In most
First floor accommodation houses, only family bathrooms were
provided, but these were normally a very
This was generally the bedroom level. The good size, and fully equipped with bath,
first floor was in most cases accommodated Jacuzzi and shower, and in some cases linked
within the roof space with the roof slope to a hot tub, a Jacuzzi on a balcony, etc.
starting at a height of around 900 mm. Hence Some homes had an additional bathroom or a
most rooms had sloping ceilings and the roof sauna in the basement.
volume was generally used for habitable
space rather than for loft space or storage.

There was often a visual and spatial link

between ground and first floor, achieved
through an interesting staircase/gallery
arrangement or double rooms linked to a
conservatory, sunspace or double height
living space. Sometimes one of the
bedrooms was open plan (open to a double

Figure 3.4 Use of roof volume Figure 3.5 Balcony bathroom

17
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Storage

Storage was provided in all main areas of the

house: entrance hall, living/dining/kitchen,
bedrooms, bathrooms and circulation spaces.
It was generally part of the main fabric of the
building, forming an integral part of the
partitioning system, as a definition of
circulation areas or accommodated in the
construction of internal or external walls.

Basements

Most houses had basements; overall, around

Figure 3.6 Basement sauna
80% of new housing in Germany has a
basement, and one basement supplier
claimed that a quality cellar raised the resale
value of a house by as much as 30%. They
substantially increased the usable space of
the house at a relatively low cost. Automated,
prefabricated construction kept the cost down
while enabling individual layouts to be
accommodated. Not all basements were of
insulated construction; it depended on the
intended use.

Basements generally matched the footprint of Figure 3.7 Basement playroom

the building and provided the substructure for
the main house. However, we saw some
basements that were larger than the main
house, extending under patios, terraces, etc.
On flat sites, basements were provided with
high-level windows, either by excavating an
area outside the window (taking full account of
drainage requirements) or by having the ground
floor raised above ground level. On sloping
sites, windows could be up to full height.

From observation, basements were used for

a variety of functions:

• Extension of living space

– home cinema, games, hobbies, etc
• Recreation complex
– sauna, Jacuzzi, gymnasium
• Home office – this appeared to be a
principal use, particularly in situations
where natural light is available Figure 3.8 Basement plant room

18
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 3.9 Chalet bungalow

• Plant room – central ‘House Engine’ cantilevered eaves, creating the flow of
combining heating, water saving services, external and internal spaces, provided the
heat pumps, heat recovery systems, IT main architectural attraction and individuality
controls, ventilation systems, electrical of the houses. The range of options available
panels, etc included glazed sunspaces and bay windows,
• Storage – household goods, cold storage, decks and terraces to the ground floor, and
wine store, etc balconies to the first floor. Roof windows and
• Laundry room glazed roof sections were often used to
complement the fenestration of the houses.
3.3 Architecture – not just boxes

Architectural concept

As noted earlier, most prefabricated homes

took the form of the ‘chalet bungalow’, ie a
rectangular box covered with double pitch
roof with cantilevered eaves. This is
eminently suited to factory production, since
it requires only a small number of wall and
roof components, which can be produced in
differing sizes to cover a range of house
sizes and layouts. It is also very suited to
modular construction.

The treatment of the space under the Figure 3.10 Balcony under eaves

19
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 3.11 Solar shading

Light, sun, energy conservation Detailing

All the designs that we saw, aimed to take Attention to detail and quality was a universal
full advantage of natural light and to secure characteristic. Since the internal finishes and
the energy benefits of direct solar gain. The details came predominantly from factory-
most successful designs provided spacious, installed components, the quality of finish
airy, light and open interiors through having a was very high. Window joinery and
large proportion of glazing on external balustrades for staircases and landings were
elevations, with a natural extension of internal of high quality. Manufacturers have
space to the external deck and patios. Solar developed their ‘signature’ details and
gain was controlled by systems of external components, and their designs are
grilles and brises-soleil, creating an attractive recognisable through these. Examples are:
element of architectural detailing.
• Carl Platz: large timber sections,
All full-height windows were equipped with consistency of detail throughout – both
integral blinds, and most windows were also internally and externally
equipped with electronic security/energy- • Hebel Haus: double height sunspaces
saving shutters. The latter were considered a
standard fitment; all structural systems,
including those in prefabricated masonry,
provided space and boxing for shutters as
part of window installations.

External glazing, full-height glazed walls, and

double-height glazing often formed the main
architectural feature of the houses, being
complemented by internal glazing, glazed
partitions and screens, high-level glazing and
internal windows. These added to the
integration of spaces, enhanced openness
and transparency, and facilitated the
penetration of natural light deep into the plan. Figure 3.12 Double height spaces

20
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 3.13 Exposed structural elements

• Huf Haus: main structure exposed and Suppliers recognised that customers did not
integral with external glazing, balconies, necessarily come with fully formed ideas.
balustrades, lighting, blinds, etc They therefore offered a design service,
generally provided through retained architects
This emphasis on quality, although most rather than directly employed staff.
noticeable in the houses aimed at the top end Alternatively, customers could have a plan
of the market, was consistent throughout all prepared by their own architect. This would
of the homes seen on the mission. be examined for compatibility with the
supplier’s construction system and, once
3.4 Customisation agreed, put into production.

Each manufacturer offered a range of standard Customer choice could readily extend to
products, which could then be customised to a external features and internal fixtures and
greater or lesser extent. Broadly, suppliers fittings. Options included different external
addressing the upper end of the market offered finishes, bay windows, dormers, roof lights,
greater flexibility. At the top end, they would sunspaces, balconies, decks, etc. Similarly,
provide a house that was entirely determined there were options for internal finishes,
by the customer’s wishes; at lower levels, equipment and accessories including
there were more constraints on size, plan, etc. kitchens, bathrooms, joinery, blinds, louvres,
The modular houses produced by Veit Dennert mechanical and electrical specification,
came essentially in two sizes, but even then energy conservation features, IT equipment,
the customer could change the position and sauna, solarium, gymnasium, etc.
size of windows, and alter internal layouts.

21
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Hebel Haus. Hebel have four show houses in

a mature woodland setting on the edge of the
factory complex. The ‘Passiv’ house, built to a
particularly high energy specification, is left
only partly internally finished in order that
potential customers may see the ‘big-block,
thin-joint’ construction. This also aids
customers who may be considering
undertaking finishing works themselves since
it demonstrates the product as delivered by
Hebel Haus. In addition, a substantial
demonstration area exists within the customer
selection area. This includes not only options
for finishes and fittings but also full-size cut-
away sections of rooms to demonstrate
exactly how the house is constructed, from its
foundations through to the roof.

WeberHaus. Alongside their production plant,

Figure 3.14 Section through house construction WeberHaus have built the ‘World of Living’, a
landmark building in its own right designed by
a prominent Italian architect. Two extensive
Customer centres and model houses floors of customer choice products
encompassing the widest possible range of
To facilitate these choices, suppliers have house fit-out from transparent ‘teddy-bear’-
show homes on their production sites and filled toilet seats to the latest in computerised
extensive showrooms for the various in-house technology. But the World of Living
external and internal options. Notable is more than a demonstration centre; it aims
amongst these were: to be a ‘theme’ experience for the whole

Figure 3.15 The World of Living

22
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

family, with features including an interactive

museum of the history of housing. In
addition, it has high-tech conference facilities
in order to attract business users (and
prospective purchasers).

In the adjacent extensive landscaped area,

a wide variety of fully furnished show
houses have been constructed, ranging
from a small two-person ‘starter’ house
capable of extension to a large ‘mansion’ in
traditional style.

Figure 3.16 Bathroom display area The image of housing supply presented by
the World of Living and its counterparts is a
world away from that presented by the
average house construction site in the UK,
where the show home is often an island
surrounded by a sea of mud.

Figure 3.18 Show home at World of Living

Figure 3.17 Suppliers exhibiting at the World of Living Figure 3.19 Show home at World of Living

23
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 3.20 Show village house

Figure 3.22 Map of Fellbach

Figure 3.21 Show village house show village

24
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Show villages

A distinctive feature of the customer interface

in Germany is the role played by show
villages. Six such ‘villages’ are operated by
Ausstellung Eigenheim & Garten in locations
near Hannover, Leipzig, Wuppertal, Frankfurt,
Stuttgart and Munich. Each presents between
40 and 70 houses, from nearly that number
of suppliers. The villages visited by the
mission, in Stuttgart and Frankfurt, were two Figure 3.24 Show village house
of the larger sites.

The show villages enable customers to view

products from many suppliers in one location.
Every house is set in its own plot and is fully
furnished. The villages are the largest source
of orders for new-home suppliers and
complement the opportunities for viewing
provided at individual plants.

Participation in a show village represents a

large investment for the suppliers. Fittings in
Figure 3.25 Show village house under construction
the show houses are generally of superior
quality (even though the customer is more
likely to specify more standard fittings) ‘Lifestyle’ magazines
although the cost can be shared with
suppliers. Houses have to be upgraded Magazines devoted to manufactured housing
regularly and are typically replaced at around provide a further marketing route, and the
seven-year intervals. House suppliers manufacturers use these to maintain a high
commented that marketing costs could absorb profile. Whilst the UK has an active market in
16% of revenue, much being accounted for by general lifestyle magazines such as ‘Home &
the show villages. But they have to have a Garden’, there is nothing like those available
presence in these locations, and the larger in Germany such as ‘Pro FertigHaus’ (ie About
suppliers have several houses in each. Prefabricated Housing).

This 80-page glossy magazine, published

bimonthly and with a circulation of 80,000,
specialises in covering detailed issues in
house design including alternative layouts and
styles, and product innovations. Customer
feedback reports feature strongly as do
comparative reports on particular popular
house types. House plans and layouts
showing room floor areas, specifications and
prices are reported on in detail. There is a
wealth of house builder and product supplier
Figure 3.23 Show village house advertising material in such magazines that

25
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

clearly have an influence on customer Its mortgage magazine features regular

perceptions and aspirations. In one recent items on OSM house building, and
issue, 84 individual house builders or Schwäbisch Hall had itself invested in a
suppliers had advertising space. number of steel-frame methods in
combination with external wall panels.
Other such magazines are ‘Haus Test’ and They also offer additional services such as
‘Fertig-Häuser’. The former is the German assistance in finding sites, and quality
equivalent of ‘Which?’ for housing. The latter assurance check on completed works.
provides detailed descriptions, photographs
and reports on 100 house designs available Partnership with OSM manufacturers such as
in the market. Bien-Zenker allows Schwäbisch Hall to act as
a one-stop shop for assistance in housing
And now supermarket sales? procurement18.

While IKEA have commenced marketing flat- 3.6 Customer care

pack housing kits in some countries, several
companies in Germany have taken the idea of We were informed that many purchases of
using retail outlets to sell houses forward by manufactured houses are the result of
at least two steps. The first step is being personal recommendations or may be
demonstrated by the cooperation between attributed to ‘brand loyalty’. Housing
DIY store Praktiker Baumarkt and house suppliers take pride in this and are
manufacturer Massa, in which ‘house packs’ concerned to maintain the reputations that
are being sold in the DIY store. The second, lead to such sales.
more radical, step breaks even the link with
DIY. The superstore chain Allkauf is marketing While this effect is not unknown in the UK, it
manufactured houses through their retail is more difficult for most house builders to
outlets. Manufactured housing is truly a benefit from such a reputation because of the
consumer product. intrinsic connection between land and
housing in the UK; they may just not be
3.5 Housing finance building houses in the area desired by the
prospective purchaser.
Some suppliers offered financing
arrangements in liaison with partner banks. German housing suppliers therefore have
A feature of the German market was the way good commercial reasons for cultivating long-
that some of the financing bodies actively lasting relationships with their customers:
encourage the use and development of OSM
housing solutions. A good example of this is • Satisfied (enthusiastic, even) current
Schwäbisch Hall. customers are more likely to provide
references and recommendations to other
Although we did not have the opportunity prospective customers, thus providing free
to visit Schwäbisch Hall, members of the marketing
mission had previously visited the • Current customers are able to give
company and were able to observe the feedback which leads to changes in
active role the lender plays in informing standard layouts or specifications offered
prospective house buyers of the variety of to future potential customers (eg Weber
different construction options available. Haus operate a ‘Customer Club’)

18 K Stockerl (1998) Brave new world: Germany, Building Homes Magazine, June 1998, pp 50-51.

26
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

• Current customers may need extensions, • WeberHaus offered a two-year

specification upgrades or refurbishments in maintenance-free period. Like most other
the future suppliers, they also offered a 30-year
• Current customers’ children and relatives warranty on the external structure,
may need their own home in the future including work carried by their
subcontractors. They also offered an
This long-term ‘family friend’ relationship with interior design service for a fee
the customer is reinforced in many instances • Elk offered a maintenance service to
by the evident pride in their history shown by customers. Its own warranty was for ten
the private family-owned businesses that we years on the external structure, and three
visited, where the firm has passed down years on the rest
through four or five generations, each new
generation bringing with it new ideas, skills We formed the impression that suppliers met
and enthusiasm. All showed a desire to meet the post-sales requests of customers when it
the challenges of the present decline in the was reasonable to do so. They would attend
housing market, and had the freedom of their to minor problems and continue to offer
private status to support investment in state- advice on operational matters.
of-the-art equipment, R&D and marketing
facilities, without the need to raise capital Overall, it was clear that the firms in the
from financial markets. industry saw product design and construction
quality as the principal pillars of market
However, it did not appear that the suppliers success, with customer care before and after
differed radically from those in the UK in their the sale being also important. In this, they
approaches to after-sales service. Generally, emulated product manufacturers the world
they offered some form of charged over. Some of their marketing approaches
maintenance check or service following a required heavy investment but were clearly
one-year free maintenance period, but all said considered essential, although some
that there was by no means 100% take-up of innovative and lower cost approaches were
these services. Arrangements varied, for now being explored. Further substantial
example: investment in product development kept
them competitive. The parallels with other
• Baufritz stated that their follow-on consumer product sectors – white goods,
maintenance contract cost as little as €300 cars, etc – are almost exact.
a year, but this was thought to be a service
which included only a ‘health check’ of
structures and systems rather than for
actually carrying out any servicing or
maintenance
• Carl Platz offered maintenance and an
interior design service for a fee. It supplied a
free maintenance handbook, and observed
that wooden cladding panel surfaces with a
rough finish normally required repainting
every ten years, depending on orientation.
Panels with a smooth finish needed more
regular repainting

27
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

4 HOUSING TECHNOLOGIES

4.1 Introduction Clay brick and block 45.2%

Limestone brick 25.5%
Housing in Germany can be split into two
main forms of structural technology: Aircrete 18.0%
Concrete 1.3%
• ‘Fertigbauweise’ Table 4.1 Market shares of different types of block
• ‘Massivbauweise’ for ‘Massivbauweise’19

Fertigbauweise 4.2 Fertigbauweise and OSM

The term Fertigbauweise literally means 4.2.1 Introduction

prefabricated construction, with ‘Fertighaus’
the term for the final product, the actual Timber frame manufacturers in Germany
home. Fertigbauweise is often associated produce a vastly different product to that in
with ‘traditional’ prefabrication industry in the UK. Like all good manufacturers, the
German housebuilding. This almost product they produce is designed and
exclusively relates to timber panel or timber manufactured to meet the needs and
framed homes. Its share of the new build expectations of their customers. These, in
market, currently (Chapter 2) around 13%, turn, are driven by the market structure
is expected to grow further. discussed in Chapter 2.

Massivbauweise The principal difference between timber

frame produced in Germany and the UK is in
The second category of structural the degree of prefabrication provided in the
technologies is called Massivbauweise – factory. However, there are also significant
literally, heavy construction. This produces a differences in design and quality, and one is
‘Massivhaus’. Nearly 90% of all homes built inexorably drawn to the conclusion that each
fall into this category, which includes of these aspects is inextricably linked.
traditional brick and block technologies such
as clay and limestone brick and blocks, and all During the mission we visited four timber
forms of concrete (including lightweight frame manufacturing facilities and the
concrete and ‘aircrete’). The market shares of associated manufacturers’ show homes. In
the different types of block are shown in Table addition, we had an extensive meeting with
4.1. While Massivbauweise is predominantly one other timber frame manufacturer at their
constructed on site, the development of house in a show village.
manufactured panel systems and large block
systems to satisfy demand for faster
construction times is leading to an increase in
market share of these systems.

19 Bauen (2004) Bauherren sehen rot bei Baustoffen, Bauen Magazine, Jan/Dec 2004, p18; quoting research by Unipor.

28
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

6-mm synthetic 12-mm breathable 160-mm stud with

render wood-based sheathing insulation between

60-mm rigid vapour control layer

insulation 18-mm gypsum board

Feature Observation
1 Rigid insulants A wide variety, including foams, mineral wools
and wood wool slabs
2 External cavities Sometimes used, depending on manufacturer
and type of cladding
3 Breathable wood-based panels Sometimes replaced with OSB or chipboard,
and in these cases was protected by a
breather membrane
4 Vapour control layer Not always present; sometimes the wall was
constructed as a breathing wall
5 Stud insulation Either mineral wool or cellulose-based
(paper or wood shavings)
6 Renders Sometimes cementitious rather than synthetic
7 Service cavities Generally created using battens on
internal surfaces

Figure 4.1 Typical German timber frame wall build-up

29
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Technology overview and sealants used to create sealed joints. This

enhances thermal performance significantly
The UK market for timber frame buildings is and would represent a significant
almost overwhelmingly dominated by factory- improvement on current practice in the UK.
manufactured open-panel platform-frame
systems where insulation, services, linings,
windows, doors and cladding are site-
installed. In contrast, a typical German timber
frame manufacturer produces a post-and-
beam/closed-panel hybrid system. The hybrid
nature of the system gives designers
increased flexibility, and the capability to
produce closed panels facilitates the inclusion
of insulation, services, linings, windows,
doors and claddings in the factory. However, Figure 4.2 Gasket sealant on joint
it must be emphasised that in many cases
the product leaving the factory is a basic
frame with only linings, insulation and service
conduits pre-installed.

A detailed review of building performance

and comparison of UK and German building
regulations is beyond the scope of this
document. However, the ‘sketch review’ of
specific highlights given below will provide Figure 4.3 Floor construction detail
the reader with a feel for the performance
of the buildings compared with timber The acoustic performance of typical intermediate
frame in the UK. floors in Germany is likely to far exceed that in
the UK. They often contain large volumes of solid
Most of the timber frame produced in timber, and efforts are made to include
Germany is for single family homes – isolation/separation layers, additional mass in the
detached houses. We did not see any ‘party’ form of plasterboard, and a floating top surface.
floors or walls. In many respects, most of the intermediate
floors seen reflect constructions more
Most timber frame wall panels manufactured commonly found as ‘party’ floors in the UK.
in Germany use similar width studs to the UK Within-dwelling acoustic performance was
– 160 x 140 mm – and the same insulation further improved by the use of ‘sealed’ doorsets.
material. Thus the basic U-values of the
timber frame component of the wall will be Individual company reviews
similar (U = 0.30 – 0.27 W/m2K). Many of the
German manufacturers utilise insulated The individual company reviews that follow,
render systems on the outside of the frame each take a theme and explore it considering
and this reduces the U-Value to around 0.2. how and why the companies have positioned
Where timber or other forms of cladding are themselves by occupying niche markets
used, a ventilated cavity is often provided. and/or by providing some form of
differentiation from their competitors. The
In contrast to the UK, a significant amount of differentiation does not necessarily come
attention is paid to air-tightness, with gaskets from the technology of the timber frame

30
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

system used but might instead be related to Their design approach is oriented around
finance provision, interior design services or the system but sufficient flexibility is
other aspects of customer service. Although incorporated to enable customers to employ
we have highlighted a theme for each their own architects and produce ‘bespoke’
company, it does not follow that the features designs. However, the architects employed by
described are unique to that company. the customer are recommended by Baufritz
and ‘steered’ by them to work within the
4.2.2 High quality eco-friendly limits of the system.
construction – Baufritz
Baufritz present themselves to customers as a
Introduction one-stop shop although, in reality, much of the
on-site work is carried out by subcontractors.
Baufritz are a private company established in
1896, with the fourth generation of the family
beginning to enter senior management. They
aim to produce approximately 220 units in 2004,
which represents growth of approximately 10%
on 2003 figures, and to maintain this rate of
growth over the next few years.

Their product is a high quality, large-panel

timber-frame system aimed at the very top
end of the market.

Figure 4.5 Wall panel during construction

Post-construction contact with customers is

recognised as an increasingly important
means of marketing the company, and
Baufritz are more developed in this regard
than most as they already employ in-house
‘service teams’ who inspect and maintain
customers’ properties on an ongoing contract
basis. Most of the buildings are sold to
Figure 4.4 Baufritz demonstration house customers within a 100-km radius of Munich
or Stuttgart.
Markets and customers
Construction technology
Baufritz differentiate themselves from their
competitors at the top end of the market by The Baufritz timber frame system is typical of
focusing on a range of sustainable other German systems in many ways. It is a
development issues around which they large-scale panel, single-skin system with a
produce innovative systems and products good degree of prefabrication undertaken in
and protect them with patents. As theirs is a the factory, eg external cladding installed, dry-
top-end product, the quality of the raw lining and insulation in place. However, there
materials and the manufacturing process are are also some important differences which
taken as givens. characterise the system and are used

31
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

extensively in marketing the product to • A bespoke dry-lining, providing the building

potential customers. occupier with protection against radiation
from electronic devices, has been
The major differences between the Baufritz developed and protected by Baufritz
system and those of their competitors are: working in collaboration with their supply
partners. The product incorporates fine
• The use of wood shavings, treated with carbon particles into a conventional gypsum
soda and whey, as an insulant. The soda board. The carbon absorbs radiation from a
and whey are reported to improve reaction wide variety of sources, eg overhead
to fire performance and provide protection power lines, mobile telephones and their
against biodegradation. Baufritz have transmission equipment, and microwave
protected this innovation with patents and communication equipment.
supported its acceptance in the
marketplace with test evidence and • The houses are all clad with timber
independent certification. As further (European whitewood) finished and
support for the green credentials of this detailed in a variety of different ways to
innovation, the insulation is manufactured offer a range of appearances. The
for Baufritz using their own off cuts and cladding, which does not receive any
‘waste’ wood shavings. preservative treatment, contributes to the
racking resistance of structure through the
use of dovetailed joints.

• The major building service connections are

integrated in a double storey service panel
which means that many of the most
complicated building elements are
contained with a single zone and can be
quickly and easily accessed for
maintenance and upgrading.

• The wall construction adopted by Baufritz

may be conveniently described as a
breathing wall. The construction does not
contain a separate vapour control layer but
manages the risk of interstitial condensation
by ensuring that the warm-side construction
is considerably more vapour resistant than
the cold-side. Similar timber frame
constructions have been available in the UK
for many years. The design adopted by
Baufritz incorporates a significant amount of
insulation into the wall panels, manages solar
gain effectively, and through the effective use
of gaskets and sealants delivers airtight
constructions. High-quality manufacturing
and construction processes on site ensure
that these aspects of energy efficient
Figure 4.6 Model of Baufritz wall construction construction are achieved in the final building.

32
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 4.7 Baufritz demonstration house

The floor and roof constructions adopted by process takes approximately one week but
Baufritz are typical of those used by other currently there is a waiting time of around
timber frame manufacturers visited during the five months from order.
mission. Roof structures are standard purlin
roofs with tongued and grooved internal 4.2.3 Standardisation and
linings, with the insulation above protected by customisation; striking a balance
a breather membrane. The floors are much – Kampa ExNorm
more massive constructions than those
typical in UK buildings, and even in single Introduction
dwellings would reach performance levels
similar to those for ‘party’ floors in the UK. The Kampa Group consists of five companies –
Typical floor constructions consist of a thick Kampa, Creativ, Libella, ExNorm and Novy – who
(eg 75 mm) structural deck supported on all produce manufactured homes. They have a
beams, topped with a gypsum screed or a combined output of ~100 houses per month,
floating floor on a resilient layer. more than half of which come with cellars
manufactured by another subsidiary company,
The basic frame of a smaller Baufritz house Kellerbau. To further the integrated offering,
can be erected in one day but the entire another company – Kampa Baulogistik – builds
construction process normally takes around most of the houses on site, and Hausbaufinanz
three months – especially for larger sites – provides related financial services. The group
this is consistent with timescales reported by employs in total ~1,000 people, and in 2003 had
other manufacturers. The manufacturing a combined turnover of €3.1 million.

33
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Sensibly, the published strategy is to:

• Increase pre-tax profits to more than 6%

• Expand within the EU
• Increase capacity utilisation
• Improve operational efficiency
• Exploit group synergies more effectively

Markets and customers

Across the group, Kampa provide houses to

most market sectors. The ExNorm factory
produces houses specifically directed at the Figure 4.8 The ExNorm factory, frame assembly
lower end of the market. They currently
produce ~500 units per year from their highly
automated factory and aim to increase this to
a perceived maximum of ~1,100 units shortly.
Interestingly, the original design capacity of
the factory they now own was stated at
2,000 units per year. It is important to note
that Kampa did not build the factory; they
bought it after the business that
commissioned it went into receivership.

Kampa believe that overall the German

housing market will remain stagnant in the Figure 4.9 The ExNorm factory, timber preparation
medium term, that any growth will take place
at the expense of other forms of construction would still perform better than
construction, and the best opportunities lie at typical intermediate floors in the UK.
the top and bottom ends of the market.
The Kampa factory is almost unique. Almost
Construction technology every aspect of the design and manufacturing
process has been automated, including
The overall form of construction adopted by material preparation, frame assembly,
Kampa is similar to that of the other timber sheathing, service conduit installation and
frame manufacturers visited, although in lining. The automation process is not easy.
some ways it also more closely resembles Any timber frame factory produces a large
common practice in the UK. The wall number of house types and an even larger
construction is conventional timber frame number of panel types. In order to ensure
with both a vapour control layer and a that the factory has a future as an ongoing
breather membrane. However, there is no concern, Kampa ExNorm have decided that
drained and vented cavity between the they need to produce a limited range of
external cladding and the timber frame standard house types and offer only limited
structure. The intermediate floor construction modifications or ‘tailoring’ to those.
adopted reflects the more affordable nature
of ExNorm houses when compared with This cleverly achieves two things. One, it
products from some of the other helps to ensure that a complicated and
manufacturers visited. Nevertheless, the expensive factory runs at as close to

34
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

optimum as possible. Two, it addresses the West Germany. The company has a turnover
more affordable end of the German housing of around €150 million and produces over
market with a good quality product. People 800 houses per year. The staff for the
purchasing houses in this sector are more factories in the former East Germany
likely to accept the limited tailoring offered. received 18 months training in the main
Those purchasing houses at the top end of Rheinau-Linx factory prior to returning to the
the market will want bespoke options. facilities in East Germany. The East German
factories were built in 1995 and 1997. The
The production of a good quality product is unique marketing facility ‘World of Living’
important to Kampa ExNorm. Being a public was created in 2000 (see Section 3.4 for
company has helped them to provide a more detail).
quality product due to the increased exposure
and attention from the public, lenders and Markets and customers
insurers. There is no corporate belief in ISO
9000 management standards – they have an The company maintains four brands which
in-house standard and work hard at achieving target different market sectors. The three
results rather than investing in formal housing brands use the same timber
documented systems. They can provide frame technology.
independent checks on quality of construction
but charge extra for these and state that WeberHaus
there is no need or demand as quality is More than half of the homes produced by
good. Although this was a standard response WeberHaus are bespoke and designed by
during the mission when anyone was asked architects that are recommended to potential
anything about quality, it began to transpire customers by the company. Their experience
that they were serious! is that customers come with a wide variety of
design aspirations. Some have no idea, some
A range of tailoring options are possible want to lead the process, and others have
including basements, conservatories, concepts they wish to pursue. Architects
balconies, roof windows, changes to window employed by the customer only take the
sizes, roof overhangs and external claddings. building up to planning stages. Post-planning
Judicial mixing of these enables customers to work is done by WeberHaus staff.
create sufficiently flexible houses that they
provide a degree of individualism, and the Twinhaus
limited number of construction details Standard house types with limited tailoring
required means that Kampa ExNorm can possibilities similar to Kampa ExNorm.
optimise their factory production to produce In-house technicians provide the customer
a good quality affordable product. with advice on the range of tailoring
options possible.
4.2.4 WeberHaus – flexible, affordable
and good quality! Objektbau
Commercial buildings and developer-led
Introduction contracts, eg for mixed use projects, retail,
hotels, offices, apartments. Building
The WeberHaus company was founded in regulations limit timber frame to three
1960; the first customer was the founder’s storeys, so for taller buildings the lower floors
sister in 1961. They have grown consistently are typically constructed from concrete.
since then and now employ just over 1,000
staff at sites in both the former East and

35
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Weberith
Basements and special projects.
Approximately half of all WeberHaus
properties have basements.

WeberHaus are working hard to improve the

range of services that they offer to new and
existing customers, eg Customer Club,
ongoing maintenance, financing and interior
design, and see developments in this area
intensifying over the next few years.

Construction technology Figure 4.11 Frame assembly

WeberHaus have recently launched a new

product – Option. The Option house provides
entry level affordable housing for the German
market. The timber frame system used is
identical to that used in the other company
brands, so basic build quality is good. They
have employed an external, high profile
architect to work with them to develop a
concept which is based around a series of
‘modular’ units that can be assembled in a
variety of different ways to create attractive,
flexible homes. Figure 4.12 Frame assembly

The timber frame construction used by

WeberHaus is similar to that adopted by
Kampa ExNorm.

Figure 4.10 Option house Figure 4.13 Option house module layouts

36
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

4.2.5 Carl Platz – top of the range, niche

product from a family firm

Introduction

Carl Platz are a medium sized family

company trading from Bad Salgau, their
base since 1931. They turn over around
€60 million, directly employ 300 staff, and
are a top-10 house manufacturer (based on
turnover). In addition to the manufacturing
facility, their impressive operation includes
a show village of their standard house
types and a sales centre to assist potential
clients with visualising and selecting
finishes for their home. Carl Platz are one
Figure 4.14 Option house interior of the few manufacturers that follow the
manufacturing process through from
The Option houses have an undeniably small sawmill to finished home.
footprint but it is easy to envisage how, with a
bit of careful thought, the range of ‘modules’ Markets and customers
available could be extended to enable more
accommodation for larger family groups, or Company size puts Carl Platz firmly within a
even that the building could be re-engineered group of around a dozen manufacturers in the
to provide apartments. This or similar derivative 200-500 unit range. In such a competitive
products must be able to provide good quality, market, with a cautious consumer, both
affordable and flexible accommodation to meet product and company differentiation was
a variety of end-user needs. The principal viewed as critical to their future success. This
drawback of this and similar systems is that it was evidenced within the marketing strategy
needs informed architectural input if it is to via a heavy reliance on the historical
achieve a desirable output. importance of being a family business and

Figure 4.15 Raw material at factory

37
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 4.16 Carl Platz demonstration homes Figure 4.17 Interior of a Carl Platz house

aiming to produce a high quality top-of-the- traditional product in the marketplace. Overall,
range product. the product provided a contemporary
appearance with high-quality finishes. This was
A typical home is around 140 m2 with the achieved in part via a combination of large-
addition of a 70 m2 basement. 90% of the scale off-site manufacture (typically 40% of the
homes are bespoke in specification and sales value was direct from the factory) and
design, with the remaining 10% using a use of in-house follow-on trades (rather than
series of templated designs to assist the cost subcontractors), although as sales are achieved
effectiveness of manufacture. The average further from the factory location, this becomes
home is priced at approximately €250,000. less viable and more subcontracting occurs.

Sales are generated via regional sales centres ‘Customers don’t want to see services or
based around show villages and show homes hear services.’ This market focus had led to
on their own sites. Partnerships with architects the development of serviced panels from the
were also a common sales route, with 2% of factory as a standard across the product
sales value being architects’ fees. Typically, range. The cisterns and associated first-fix
around 80% of their production is for the home pipework are all constructed in the factory.
market, with the remainder being exported –
primarily to Switzerland and Austria. With the When the panels are installed on site, the
current dip in the home market, Platz are now second-fix sanitary fittings are hung directly
focusing on export to deliver continuing from the wall panel, with no visible pipework
sustainable growth for their business. on show. When asked about leaks within the

Interestingly, a maintenance package option

was available on all new homes.

Construction technology

The key design features of the core product

concentrated on providing excellence in the
internal environment. This was achieved by
large glazed wall sections providing
tremendous light quality and use of large-
section exposed timber which is the more Figure 4.18 Insulated sanitary ware being fitted

38
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

wall panels the response was an incredulous

but interesting – ‘Why would we put
something in the wall that would leak?’

The panels are fitted with windows, and

special feature windows are also assembled
on the lines.

They then proceed to have rendered or timber

external rainscreen claddings applied; the final
paint finishes are spray applied in booths at
the end of each line. Heavy finishes such as
masonry are site-applied as in the UK. Figure 4.20 Elk factory in ireland

Figure 4.19 Wall panels ready for first coat of render Figure 4.21 Interior of Elk factory

Despite the general media presentation of units), Czech Republic (300 units), Germany
homes that are erected in a day, the reality is (400 units), Poland (50 units) and Ireland (250
that the homes are often watertight in a day units). In Austria they have 25% share of the
but still require all the internal finishing. prefabrication market, and in Germany 11%.
This can take 8-13 weeks to complete –
again, similar to the UK As stated earlier, the company has grown
by acquisition and is familiar with entering
4.2.6 ELK Haus – is the technology new overseas markets. It entered the
really transferable? German market in 1987, the Czech market in
1997 and, most recently, the Irish market in
Introduction 2003. The group of companies has a
turnover of around €350 million making
Elk Haus were historically a family company them possibly the largest in Europe. They
originally based in Austria that commenced have strategic plans to expand into other
trading in 1959. Since then, the company has markets in the near future. Usually this
grown by acquisition and merger and now expansion is in partnership with a local
has six plants producing a total of 2,472 units provider. The company is still 100% owned
in 2003. Of these, only 100 are apartments, a by the Weichselbaum family, and typically
new market for the group. The plants are aims to achieve a 4% pre-tax profit on its
located in Austria (two plants producing 1,500 trading activities.

39
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Markets and customers

Elk operate across all the market types,

including luxury housing, schools and other
commercial buildings and apartments – a
new market for them. Their market entry
approach is simple – to partner with a local
provider to ensure a secure supply chain for
the production facility. This is an approach
that has worked well for the group and is
the model being followed for the Irish
production plant.
Figure 4.22 Wall panel assembly
The key differences between Elk and a typical
UK provider are:
Construction technology
• Effectively act as a design-and-build
contractor for the superstructure (rather A typical facility would be 8-9,000 m2 which
than just supplying the timber frame) can produce 250 units single shift (maximum
• Capability to produce a closed-panel timber 450). The facilities have the capability to
frame system produce two types of product, ie:
• Products developed in partnership with key
customers • Basic timber frame (open panel)
• Continual programme of innovation • Single wall (closed panel)

Figure 4.23 External finishing of wall panel

40
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

The basic timber frame is as the UK product.

The closed-panel frame is manufactured from
a 150-mm stud frame sheathed with OSB-3
material on the exterior face. Insulation,
vapour barrier, gypsum board linings and
external joinery are all added in the factory
environment. External rainscreen render
cladding can also be added if required.

For the Irish market, their largest learning

curve has been accommodating the current
health and safety requirements that are not
designed for (and in many cases, are Figure 4.26 Elk house in Ireland
incompatible with) closed-panel construction.
Scaffolding, in particular, is not compatible 4.2.7 Transferable lessons
with lifting closed panels, and many consider
it actually more dangerous to have the A number of transferable lessons can be
scaffolding in place during lifting. drawn from the timber frame manufacturers
visited. The most important of these are
mentioned below. Interestingly, many of
them have a foundation in some aspect of
marketing rather than the nature of the
technology used.

• Having identified and occupied a

niche you will need to continue to
innovate to maintain differentiation
from your competitors
• Strategic partnership with customers helps
ensure sufficient ‘pull’ for new factories
• The timber frame manufacturer gets a
significant proportion of the value from
Figure 4.24 Elk apartments in Ireland properties even if much of the work is
done on site
• Highly mechanised plants can reduce
production and lead times
• Tailoring provides a means of achieving
balance between standardisation and
customisation
• Affordable housing can be modular, flexible
and of a good quality – but it’s not easy
• Sustainability can be made to pay
• Maintenance packages for new homes
help to improve customer loyalty
• Closed-panel technology gives structures
that are rapidly watertight and facilitate
follow-on work
Figure 4.25 Elk houses in Ireland

41
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

• Lightweight cladding systems, eg timber Companies manufacturing concrete or brick-

and render, can successfully be factory based homes recognised that they were in
applied and should be explored in more increasing competition with suppliers of OSM
detail in the UK timber housing, and therefore needed to
• Prefabricated service walls improve quality match them on price, specification (eg
by reducing the amount of follow-on trades insulation levels and environmental features)
active on site and construction quality. These companies
• The implications of closed-panel considered that ‘prefabricated’ or, as they
technology on current timber frame preferred, ‘factory made’ houses still had a
erection practices should be explored negative market image (in contrast to the
survey results summarised earlier), and that
4.3 Massivbauweise and OSM they needed to make extra efforts to
overcome this by ensuring quality and value.
4.3.1 Introduction
All were responsive to customer demand
The large majority of ‘Massivhaus’ homes and offered customers a range of options.
are built using brick and block components, For one manufacturer, this included options
assembled in a traditional manner. However, on the extent to which the house was
to meet the challenge of the ‘Fertighaus’ finished; the basic shell could be supplied,
producers, suppliers have needed to develop leaving the customer to arrange or carry out
products that reduce the amount of labour installation of all finishes and services. This
required on site, and to increase the speed had proved a popular option in the new
of assembly. Länder as it permitted early occupation at
low cost, with other costs being incurred at
The various approaches range from large the owner’s discretion and over a timescale
block systems through to volumetric units of their choosing. Standard designs offered a
constructed of concrete. The mission visited a range of options such as ‘winter gardens’ or
number of manufacturers, and saw housing conservatories, balconies etc. It was clear,
produced by a wide variety of construction though, that if the customer wanted a
techniques, from fairly simple structural units design that was outside the standard design
to highly finished modules. envelope, there would be a significant cost
premium, although variations could generally
As noted earlier in relation to OSM housing be accommodated.
generally, the manufacturers of concrete and
masonry housing were strongly focused on The producers of concrete housing we
the quality of the final product and the way observed had invested heavily in their
that their production processes enabled manufacturing facilities. Factories were
them to meet customer requirements. The generally modern, and substantial investment
extent to which individual preferences could had been made in production machinery and
be met was a matter of positioning in the automated equipment. Standards of lighting
market; the lower-priced housing was more and environmental conditions were good, and
standardised. But even at the most offered the possibility of all-year-round
‘affordable’ end of the spectrum, the working, a significant advantage in Germany
suppliers were promoting a lifestyle, not where winter conditions can be more severe
simply selling rapidly erected housing which than in the UK. They considered that factory
could be completed by the purchaser. production enabled them to supply better
products to a more consistent finish; supply
to site was more reliable and erection on site

42
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

was far quicker than with traditional The company’s success has been founded
building techniques. on a patented design for a 100%
waterproof cellar, together with continual
The cost of transporting heavy concrete units, attention to product quality. To remain
however, was an important factor in business competitive, it invests about 2% of turnover
development. Some producers had in R&D, with its product development
addressed this by focusing largely on their activities now resulting in four patents and
local (within 150 km) market whilst others several registered designs. Development of
(eg Glatthaar Fertigkeller) had developed a the foaming process for its ‘Thermo-safe’
network of manufacturing facilities in order to product (see below) cost in excess of
reduce transport distances to 100 km or less €2 million. Other innovations and
(see further discussion of transport issues in proprietary techniques include a land drain
Section 5.1). used adjacent to the basements, the
concrete mix used in factory production,
Investment in research and product the site assembly process, and a specially
development was also evident. Most designed temporary support beam.
companies had taken out patents on their key
products and processes. As a demonstration of its basement
technologies, Glatthaar has built a
In general, companies had few problems 300-tonne floating show-house, used as a
attracting and retaining a skilled workforce. marketing suite, at its factory headquarters
Unemployment in Germany is significantly site in Schramberg-Waldmössingen.
higher than in the UK, and labour mobility is The floor slab of the basement floats 40 cm
lower. Many companies still make a above the bottom of a pond; windows in
substantial investment in apprentice training, the basement show the water level. By
and expect their apprentices to remain with moving a water tank mounted on rails in
the company for many years on completion the basement, the whole structure is made
of their training. to tilt, the change in water level
demonstrating that it is indeed floating.
4.3.2 Prefabricated basements –
Glatthaar Fertigkeller

Glatthaar Fertigkeller is the largest

manufacturer in Germany of prefabricated
basements, with an annual production of
7-10,000 basements from 12 locations in
Germany – 2,000 from three highly
automated plants owned by the company and
an additional 5-8,000 from nine franchised
operations. The company is privately owned
and has been trading for 25 years. Whilst it
specialises in the supply of prefabricated
basements, it can also undertake planning,
structural engineering, and ground-works.
Glatthaar Fertigkeller supplies cellars for some
40 OSM housing producers, these cellars
incorporating stairs, ceiling, light-shafts,
chimneys and service shafts as required. Figure 4.27 Floating demonstration facility

43
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Glatthaar’s systems are priced at a premium,

just above traditionally constructed
basements. Typical prices are in the region of
€250/m2 with an additional €2,000 for
excavation. Its main product is ‘Aqua-safe’, a
prefabricated, panelised cellar that can be
constructed in one day following excavation.
A more complex product is ‘Thermo-safe’; in
this, a patented foaming process is used to
produce highly insulated panels for cellars
which include living space. It has other
product lines including a 3D modular
basement and an associated ‘mini-basement’, Figure 4.28 Machine laid reinforcement
a single module with dimensions of 5 x 3 m.

The factory process is highly automated, with

computer-controlled equipment taking the
required panel dimensions from files supplied
by the housing suppliers. These also provide
information on the position and size of
openings. We were informed that the
investment in the factory, which produced
three complete cellars daily with only eight
workers, was around €8.5 million.

In the production process, 50 mm thick Figure 4.29 Concrete panels being moved in factory
reinforced concrete panels are created on steel
former beds with exposed reinforcing wire.
Metal edge plates, automatically positioned by
computer controlled machinery and held in
place magnetically, determine the size and
shape of the panel and any openings.
Reinforcing meshes are similarly cut and
positioned automatically. Once the base unit
with exposed reinforcing has been completed
and cured, it is picked up by large suction pads
and turned through 180 degrees and the
exposed reinforcement inserted into a newly
poured second bed of concrete 50 mm thick.
Figure 4.30 Cured panel being inserted into
The automated rotation ensures the correct
second skin
spacing between the slabs. Concrete pouring is
controlled manually using an overhead hopper On site, water protection is assured both by
system. The completed two-leaf composite the pouring of concrete between the leaves
panel is then transferred into a drying chamber of the prefabricated panel and by the use of a
for eight hours. The flexible production process patented hinged plastic sealing strip fixed to
enables special fittings such as windows, doors the panels by a specially formulated silicone
and electrical conduits to be pre-installed to the adhesive derived from the aerospace
customer’s requirements. industry. Glatthaar claim (and demonstrate)

44
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 4.31 Model of basement Figure 4.32 Insulated basement panels

that either means of waterproofing is 100% as this would bring them into direct
effective, but both are used for added competition with their customers.
assurance. They have experience in building in
earthquake zones, areas prone to subsidence, 4.3.3 Large block systems – Hebel Haus
on slopes and in areas with high water table.
Hebel Haus is principally a manufacturer and
A team of four with a mobile crane complete supplier of porous concrete (aircrete) blocks
a cellar in an 11-hour day commencing at 7am and products and the market leader in
with laying the polythene sheeting and fixing Germany in porous concrete building materials
reinforcement for the base, continuing with and components. They have developed a
erection of the panels and permanent reputation as a leader in innovation in this
formwork for the ceiling and sealing all the material, having developed and extended their
joints, and finishing with pouring the concrete product range from standard block sizes to
for the base, the panels and the ceiling. This reinforced aerated concrete floor and roof
produces a complete foundation on which the panels, and now to the supply of complete
house supplier may erect the house. houses. The Hebel Haus factory employs
113 workers on three shifts and has 20 office/
Almost 70% of panels leaving the factory are management staff. Output is currently
now insulated. A layer of polyurethane foam 215,000 m3 per year on two shifts, with a
to a patented specification is produced on maximum capacity of 300,000 m3.
the concrete panel in an automated foaming
unit, which was said to be one of only three The production facility for blocks is modern
built in the world. The process is largely and highly automated. Aggregate is sourced
enclosed and requires good ventilation. As from the company’s own sand quarry; it has
well as wall panels for cellars intended to been ground on site to the specific
provide living space, the foam is added to requirements of their manufacturing
ceiling panels which form the ground floor of processes since 1926. All of the aerated
the completed house in order to provide concrete products are manufactured on a
enhanced thermal and noise insulation. A top production line by casting into pre-prepared
layer of concrete for the floor is added on moulds, curing in a heated environment, and
site. This process is in principle capable of then cutting to size before finally being
producing wall panels for above-ground use, autoclaved at 16 bar for eight hours. Larger
but Glatthaar have specifically chosen not to panels are reinforced with steel cages
diversify into production of housing panels, manufactured on site from coiled wire and

45
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 4.33 Reinforcement cages being lifted Figure 4.35 Bar coded panels
into position
coated with water-based paint prior to Through market research, Hebel Haus identified
casting. Very little manual labour is used in a desire for a complete building product from
this process, and research is underway to people building their own homes. This matched
see if some of the remaining manual their wish to diversify into higher value
activities (such as loading reinforcement products, and the company have over the last
cages into moulds) could be automated. 30 years developed a complete building
Products are tracked automatically using system. This uses large aerated concrete blocks
barcodes as they go through the production and reinforced aerated concrete panels of up to
process and into inventory. 6.5 x 1.5 x 0.75 m to construct the basic
building structure. They now market a complete
house product constructed using this system.
Prices depend on the size, the specification of
finishes and fittings and the degree of finishing,
but a finished house (excluding land) with
standard fittings may be purchased for around
€1,230/m2: for a house of 130 m2, a complete
cost of €160,000.

The Hebel Haus system, utilising porous

concrete panels/blocks offers considerable
flexibility to the purchaser, with almost
unlimited variations being possible, but at the
expense of requiring more on-site labour than
Figure 4.34 Aerated concrete curing some other systems. Only the panels are

46
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 4.36 Panels ready for delivery

prefabricated in the factory. The basic 4.3.4 Storey height panel systems –
structure of the house can be assembled in Johanni Ziegelhaus
one day on site, using thin jointing techniques
for the walling, and reinforced panels for both Johanni Ziegelhaus entered the OSM housing
the floors and roof, but there is no scope in market on the back of their existing business
the process for incorporation in the factory of of precast concrete fabrication. They have
additional items such as services. licensed a production system from its
inventors, Winklmann, for a panel system that
Of particular interest in the products uses specially designed clay bricks set in a
produced by Hebel Haus is their range of reinforced concrete panel. These panels can
energy performance levels offered through then be used to form the external envelope
the specification of different thicknesses of and internal walls of a home, with precast
structure. Hebel Haus were the first concrete panels used for the floor structures.
Massivhaus manufacturer to achieve the
demanding ‘Passiv Haus’ requirements.

Figure 4.37 Hebel Haus’ Passiv Haus Figure 4.38 Clay bricks designed for
casting into concrete

47
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Perforated clay bricks are placed in a grid Additionally, the Winklmann facility internally
pattern onto a steel form. The shape of the finishes the panels and fits doors and
bricks allows for reinforcement and conduit to windows in the factory.
be inserted where appropriate between
bricks. Precast lintels are placed over any The system used by Johanni Ziegelhaus and
openings and concrete is cast over these Winklmann can be applied to panels up to
components to form a solid panel. Once the 3.6 m high and 12 m long. It is specifically
concrete has cured, any formwork can be aimed at consumers that want a masonry-
stripped, and the panels lifted and moved to constructed home but assembled in a similar
vertical storage racks where external timescale to those constructed from timber.
insulation is applied.
4.3.5 Volumetric units – Veit Dennert

Founded in 1933, Veit Dennert is a third

generation, family run, private company.
Initially, Dennert was a supplier and
manufacturer of concrete-based building
components and products. From the 1990s
onwards it has developed into a supplier not
only of components but also of complete
concrete-based building systems and now
has a turnover of around €100 million, with
some 850 employees in 10 precast plants in
northern Bavaria and Thuringia in the centre of
Figure 4.39 Cast wall panel
Germany. Its range of components is very
wide, and includes floors and ceilings, walls,
basement walls, blocks, stairs, lintels, garage
elements, etc. Dennert is focused solely on
Germany but has licensed its products to
companies around the world.

In response to a market for complete

systems from those building their own
houses, over the last 15 years the company
has developed three main product lines:

• ‘Big block’ – a type of panelised system

Figure 4.40 Insulated wall panel
using large blocks of up to one-third storey
height which also makes use of other
The factory at Johanni Ziegelhaus relied components in the product range to create
heavily on manual labour to produce these the basic structure of the building
panels, and only manufactured them as • ‘ICON-haus’ – a volumetric system fully
structural elements with all finishes being fitted out in the factory and assembled on
applied on site. However, the facility operated site with a minimum of labour
by Winklmann, which the mission members • ‘ALFA-haus’ – a panelised version of ICON
were unable to visit, features a much higher giving greater flexibility at the expense of
level of automation with extensive use of manufacturing efficiency
robotics to place formwork and the bricks.

48
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Like other manufacturers, Dennert are very

focused on product quality and on keeping
competitive through innovation. They have
undertaken R&D into lightweight concrete,
including the use of expanded clay and glass
granules, and have patented and licensed
production processes. These developments
have been used in their block and wall
system products (‘Big Block’ and ‘PORAVER’)
to give increased thermal efficiency, and have
been important factors in the development of
the ICON and ALFA housing systems.

We particularly noted the ICON system for

its distinctive approach to OSM housing.
About 300 ICON units are produced each
year, the selling price being around €840/m2
(excluding land).

The ICON-haus is a volumetric system,

utilising concrete modules with a high level of
internal completion in the factory. Flexibility in
size and layout is limited; only seven variants
of two basic house sizes (110 and 140 m2) are
offered, using limited differences in module
size and internal layout. Much greater flexibility
in finishes is available, however, with three
basic specification levels and a menu of
choices both within each level and for extras –
emulating the automobile industry.

The ICON factory comprises a panel Figure 4.41 ICON house sizes
production circuit, an assembly and fit-out
line, and outside space for storage and
dispatch of units. The panel production were bolted, with a mortar bed. The modules
technology was fairly advanced, although not were 8.2 x 3 m in plan, and weighed up to
as automated as the Glatthaar process for 24 tons each.
production of basement panels (for example,
automatic positioning of magnetic formwork The modules then moved down a production
was not used). The panels were cured for line comprising 11 stations, at each of which
eight hours at 450°C. they were progressively fitted-out. The
production line did not move continuously;
The panels passed from the curing area to instead, the modules were moved
the beginning of the module production line, incrementally by a jacking bogey running
where they were framed and assembled into along a trench underneath the line. By the
modules. There was no automatic framing end of the line, the modules were fully fitted
equipment evident; workers assembled the out, including kitchens, bathrooms,
panels using the overhead crane. The joints plumbing/heating etc. Also, 200-mm

49
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Figure 4.42 ICON house

polystyrene insulation was directly bonded to ‘ALFA-haus’, a panelised version of ICON, is

the units, and one coat of render applied produced on an adjacent production facility,
before leaving the factory. and offers greater flexibility in design but with
less potential for fitting out in the factory.
The factory had an area of ~10,000 m2, with ALFA units are typically supplied with service
a total of 50 workers and 30 administrative/ conduits, internal (bare concrete) finish, and a
management staff. Production takes place first coat of external render.
over two shifts, with the ‘third shift’ being set
aside for essential maintenance. An ICON
house can be produced in a total of five days:
one in the factory, and four on site (one for
assembly, and three for completion).

50
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

5 POST-PRODUCTION ASPECTS

5.1 Transport of components At the bottom end of the weight spectrum

are companies such as Purholz who produce
Once the factory process is complete, three timber panels specifically designed for
considerations impact on haulage: manual handling at less than 100 kg per
panel, with doors and windows fitted on site
• Weight of units (eg timber/lightweight (this allows the panels to be transported
steel v concrete) horizontally, maximising the load per lorry).
• Panelised v modular systems
• Logistics Panelised v modular systems

Weight A typical modular dwelling takes about six

lorry loads compared with a panelised
At one end of the spectrum are concrete dwelling of equivalent area which averages
modules which, if fitted out at the factory, can only two loads. Continental European
weigh between 18 and 24 tonnes each. The restrictions on loadings are generally less
ground floor of a typical house might consist onerous than in the UK, allowing modular
of three modules. Less onerous are concrete dwellings to be transported in fewer, but
single-storey and whole-façade panels such larger, lorry loads.
as those from Johanni Ziegelhaus weighing
between 6 and 7 tonnes. Module sizes varied widely. At one end of
the spectrum was Veit Dennert, producing
Continuing down through the spectrum are only two plan forms primarily for sale within
whole-wall timber panels requiring far central Europe only, with consequently very
lighter craneage (but if factory-fitted with specific haulage requirements. At the other
doors and windows, the panels will require extreme was Cadolto, who work with a wide
to be transported vertically which reduces variety of building forms, from hospitals to
the load per lorry). housing to laboratories, and supply across

Figure 5.1 Purholz wall panels Figure 5.2 Vertically stacked wall panels

51
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

the whole of Europe. Interestingly, this

diversity has generated an approach to
manufacture and to design that is
determined, not by manufacturing issues
such as jig sizes or formwork but, at least
initially, by the route between factory and
site, maximising the module sizes within the
constraints of transport logistics.

Logistics

Distance from production unit to site is

generally not a particularly significant factor
(particularly if external haulage companies are
used and lorries are able to return with other
loads). One company quoted the total cost of
haulage from their plant to Munich (a distance
of approximately 100 km) as being €1,500-
1,800 compared with an identical load to Berlin
(approximately 670 km) at €2,000. More
significant is the number of loads required and
the handling plant needed at both ends.
Figure 5.3 Finished wall build-up

However, a sea crossing can add at least site assembly. Since nearly all manufacturers
another €800 per lorry load. This led Elk to (panelised or modular) went from serviced
open a factory in Ireland since it was more slab to watertight shell within one day on
economic to transport the raw materials that site, water damage on site was not a
were sourced from central Europe to the Irish serious problem.
plant than to fabricate in Germany or Austria
and then distribute to Ireland. Some companies chose to shrink-wrap
individual wall panels or floor/roof cassettes
The only company visited that had a specific while others only protected exposed, leading
policy of creating production units no more edges with temporarily-stapled polythene.
than (in their case) 100 km from likely These precautions sufficed for erection in
markets was Glatthaar Fertigkeller. For them, ‘normal’ wet conditions. Only in the most
however, transport costs were a higher extreme weather might erection have to be
proportion of the selling price of their product delayed to avoid water damage.
than would be the case for the supplier of a
complete housing system, and they had 5.2 Assembly processes
needed to increase the number of production
plants to meet demand. The firms visited exhibited large variation in
the extent to which final assembly was carried
Damage in transit and on site out on site. At one end of the spectrum was
Veit Dennert whose factory-finished modules
All the companies visited used dense minimised on-site working (see ‘Timescales
gypsum board as an internal, factory-fitted for erection/fit-out’, following) but offered a
lining, and none reported any particular limited range of client choices: two dwelling
problems with damage in transit, or through plans available to three levels of finish.

52
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

At the other end of the spectrum were both decreased factory efficiency and
companies like Purholz who produced for the increased on-site labour. Some companies
self-build market, with systems based on built ‘non-standard’ components such as bay
small panels capable of being manually windows, balconies or dormer windows in the
handled and not incorporating services, doors factory as complete 3D modules, ready to
or windows. This approach has the offer up to the completed envelope on site in
advantages of lower initial cost, maximising order to minimise on-site working.
haulage loads, and greater flexibility, but relies
on relatively high levels of on-site labour with Interestingly, more than one company that (in
attendant issues of workmanship, order to facilitate greater client choice) had
vulnerability to the weather, etc. consciously shifted the balance from off-site
to on-site working, was now trying to find
Within the spectrum were some companies ways of pulling that back into the factory
whose processes were relatively inflexible whilst not compromising customer choice, in
and labour-intensive in the factory, but whose order to increase the cost efficiency of the
systems still required a high degree of site- overall process.
finishing. Masonry and concrete panel
systems aimed to compete with traditionally The following sections illustrate some of the
built homes based on these materials, but it ways different companies had approached
was not clear whether in practice they offered this balance of off-site to on-site working.
sufficient advantage to outweigh the lack of
flexibility for the purchaser. Achieving construction quality

Again as a generalisation, there was a trade- The key factor in achieving the quality desired
off between the flexibility offered to in the erection of components was
customers and the proportion of work carried preparation. There was close liaison between
out in the factory. Bespoke products were factory-based staff and site workers; products
fitted out on site, and some manufacturers left were manufactured to close dimensional
the associated decisions to that stage, tolerances, and there were ‘fail-safe’ devices
realising from experience that customers to ensure the correct interlocking of all
might wish to change their initial choices. Cost structural elements within those tolerances.
uplifts of 10-15% were quoted for diverging Within the range of systems experienced,
from standard details, eg non-standard storey modular approaches offered the least
heights or junction detailing, taking account of potential for site error, and whole-wall panels
were preferable to small panels in this regard.

Air permeability between site-assembled

elements received close attention. The highest
performing systems had factory-fitted gaskets
at wall/floor, floor/roof etc junctions rather than
relying on site-applied sealing devices.

Manufacturers of timber-based systems

generally provided insulated, felted and
battened roof panels requiring only on-site
tiling, where interlocking tiles were
specified. We noted also that, while most
Figure 5.4 Bay window assembly concrete-based manufacturers also offered

53
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

concrete roof panels, 85-90% of customers,

given the choice, opted for timber roof
structures for cost reasons.

External cladding and internal finishes

Companies offering external cladding systems

in timber had the advantage that these could
be totally factory-finished and decorated
leaving only panel/module erection and internal
finishing/decoration to on-site labour. By
contrast, most companies offering externally
rendered walls only applied the first coat of
render to each panel in the factory, leaving
taping of joints and the second coat render to
site workers. Some companies such as Huf
and Davinci avoided the attendant problems by
using rendered elements only within post and
beam panels so that they could be totally
factory-finished. All site-formed junctions were
then effected frame to frame.

The render coats seen ranged from a variety

of traditional, trowel-applied systems through
to thin, two-coat flexible polymer systems
applied onto insulated substrates which
varied from dense mineral fibre boards to
expanded polystyrene batts. Figure 5.5 Pre-finished panel ready for assembly

Activity Week

1 2 3 4 5 6 7 8 9 10

Erect structure

First-fit plumbing

First-fit electrical

Floor screed and cure

Decoration

Tiling

Second-fit services

Final finishing

Figure 5.6 Timescales for erection/fit-out of a 230-m2 property

54
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

For internal finishes, the best-thought through Servicing

processes achieved almost complete factory-
fitting of plasterboard with only minimal A wide variety of approaches was observed.
piecing between panels on site. Generally, For electrical service, suppliers generally
this left only taping and jointing of major provided factory-fitted conduits, leaving wiring
junctions on site, together with internal entirely to site. Some companies provided
decoration of panel-based systems. draw wires in lieu of conduits to avoid issues
of air permeability through service routes. Two
companies had achieved full factory-wiring
based on junction boxes, necessitating only
on-site connections between the building
elements. Some companies commented that
it caused problems when electrical outlets
were factory fitted, since when ‘non-
professional’ one-off clients saw the product
‘in the flesh’, they wanted them moved.

It was noted that the common German

practice of distributing electrical service in floor
ducts and positioning outlets at skirting level
on site is not transferable to the UK owing to
the regulatory requirements for higher outlet
Figure 5.7 Panel taped and jointed in factory
positions on accessibility grounds.

Only suppliers of modular based systems

fully fitted plumbing in the factory. The most
integrated plumbing installations from panel-
based manufacturers consisted of storey
height boiler/control system/vertical waste
and plumbing modules constructed in
lightweight steel which were offered up to
the completed shell apertures on site,
requiring only pipe couplings and horizontal
pipe distribution to be carried out.

Timescales for erection/fit-out

Again, a wide variety of practices was

observed depending on the degree of factory
finish and customer choice. Overall time to
completion varied widely.

Almost all manufacturers (timber, steel or

concrete; panelised or modular) designed
their product around a one-day erection
period from serviced slab to watertight shell.
Thereafter, fit-out and finishing to the point of
Figure 5.8 Toilet panel ready for installation hand-over took anything from three days (for

55
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

factory-finished modules) to five months (for All companies used dedicated trades
block-panelised systems requiring full in-situ (whether own labour or subcontract) rather
servicing and fit-out). Typical times for fit-out than multi-skilled operatives even where
of panelised timber systems were four to there was only a limited requirement for a
eight weeks allowing for service installations, particular trade. And it was interesting to
kitchen and sanitary appliance fittings, second observe that these separate trades often
fix, making good and decorating. worked sequentially, with only a single trade
being present in the home at any one time.
Figure 5.6 shows an example programme of A few companies offered the option of fit-out
fit-out works based on a 230-m2 property. by clients.
The client would typically be quoted 12 weeks
duration to give some flexibility in return dates As noted above, WeberHaus sought to
for labour. integrate off-site and on-site joinery skills.
This integration was enhanced by their policy
Labour, skills and subcontracting of retaining older, skilled labour in the factory
when health or age precluded their working
In every company visited, the assembly of on site. They thus transferred their
components to form the structure of the knowledge within the company as ‘master
house was carried out by labour directly joiners’ heading the apprentice teams (there
employed and trained by the manufacturer. were 30 apprentices on the company’s
Generally, this consisted of roving ‘assembly books) and using the ‘non-standard’
teams’, but in the case of WeberHaus the prefabricated modules referred to earlier to
factory-based staff were rotated through the provide a thorough grounding in trade skills
on-site teams in order to provide feedback for all future factory/site crews. Not only did
into the factory production processes. this approach transfer valuable skills within
the company, it resulted in a very high
None of the housing manufacturers directly degree of labour retention in an area of high
contracted to provide foundations or cellars. employment with a keenly competitive
Instead, they tended to have strong links labour market.
with a number of groundworks companies
who were aware of the specific Quality assurance and health and
requirements of their system. These safety issues
contractors, particularly firms like Glatthaar
installing prefabricated components, Interestingly, in a culture renowned for its
employed their own labour. quality control, none of the companies had
opted to adopt formal QA systems. Rather,
On-site fit-out was handled in a variety of they relied on training and integrated
ways. Companies that serviced and fitted out teamworking to minimise errors. The
to a high degree in the factory, or which generally high degree of factory finishing was
operated at a larger scale, generally used relied on to minimise the opportunities for
their own labour for the limited works site errors. Some manufacturers offered
required for completion on site. Smaller independent DFV (Deutsche Fertigbau
companies, and companies with more ‘open’ Verband) site-certification where specifically
systems, used partnered, subcontract labour required. This is based on unprogrammed
on site to balance the requirements of labour inspections of site activities by DFV staff.
availability across wide geographical areas,
with the need for consistent quality control
and product familiarity.

56
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Likewise, there was a perception that the

high factory-based component in the housing
systems minimised health and safety risks
on site, although, as noted earlier, no data
were available to support this, However, one
company said that its insurance premium for
accidents at work had recently reduced by
15% since it had switched to a higher level
of off-site manufacture (closed, timber wall,
floor and roof panels with factory-built
‘plumbing modules’).

While health and safety provisions were in

general good throughout production and
assembly processes, there were evident
differences from UK practice, with examples
of unguarded machines and poor fume
extraction. From informal comments, and
the experience of individuals that had
worked in both Germany and the UK or
Ireland, it would appear that there was a
lower level of enforcement of health and
safety regulations in Germany. But it also
seemed that, in contrast to the UK, accident
rates were not at a level which stimulated
concern and public debate.

57
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

6 COMMENTARY AND
CONCLUSIONS

6.1 Introduction Quality standards

While some features of the OSM housing This position has been reached after a long
that we saw in Germany are a reflection of process of product development, extending
local traditions and preferences, many of the back more than 80 years. As in the UK,
technologies and business processes however, the industry has had to work hard
demonstrated deserve further consideration to overcome perceptions that OSM homes
for potential application in the UK. And the are cheap and of poor quality. This image was
experience of Germany in developing a created by insufficient attention to quality
significant OSM sector is particularly relevant amongst some suppliers and led to the
now, when the UK is experiencing rising creation of quality standards and associated
demand for new homes coupled with a certification schemes. There are lessons here
shortage of traditional construction skills. for the UK supply industry. The German
experience is that with a focused and
We record our conclusions under the sustained effort to improve quality, and
following headings: consistent marketing, it is possible to change
the image of OSM homes and to put the
• Market aspects sector on a rising curve in a domestic market
• Business philosophies and processes that is famed for its demand for high final
• Technologies and production processes quality in manufactured goods.
• Follow-up actions
It was clear that concern for quality ran
6.2 Market aspects through the whole production process, from
the selection of materials to final
Market share workmanship on site. Firms knew that their
reputations depended on maintaining their
The share of the overall housing market high standards. At the same time, they were
taken by OSM housing in Germany is similar very aware that they were competing in a
to that in the UK but the use of OSM in the highly demanding marketplace, and needed
principal structural system is limited in continuously to research and develop new
Germany to detached and semi-detached designs and technical solutions that would
homes whereas in the UK usage is spread distinguish their products from those of other
across all forms of housing. However, at a suppliers and give them competitive
time where housing production in Germany advantage. As in other sectors, informed and
is in decline, the production of OSM homes demanding clients have driven up
is increasing and its market share is specifications and quality and stimulated a
growing. This reflects the public perception continual search for higher value for money.
of OSM as a high quality form of production
with fast site assembly times and greater
certainty of cost and quality as compared
with traditional forms of house construction.

58
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Product development a clear business incentive to invest in

technologies and processes that will give
This focus on the performance, quality and their house an edge over its competitors. In
value of the final product has led to the the UK, the same market drivers are of
OSM sector being a market leader in the course present, but are diluted by the other
introduction of new technologies – for aspects of the house-land-location package.
example for energy and water conservation. As a consequence, there is not the same
Similarly, the structural systems employed in history of product development by housing
some OSM housing have enabled firms to developers; however, with greater use of
offer great flexibility in internal layout and to OSM, this may change.
provide large areas of glazing. OSM firms
have invested in R&D, both to improve ‘Dream homes’
products and to create more efficient
production processes, and some hold Although OSM firms strongly promote
multiple patents. In Germany, OSM has distinctive features of their houses, it is clear
been a pace-setter in design and from the product literature and advertising
specification for the whole housing sector; that overall each firm is marketing a ‘lifestyle’
suppliers of traditionally built homes have choice, and this was reinforced by design
had to introduce similar features in order to features such as the light and open living
remain competitive. OSM could have the areas noted earlier.
same effect in the UK.
The concept of the ‘dream home’ in which
However, the focus on the final product also to bring up one’s family, and which
is a reflection of the fundamental difference represents the summit of aspirations, is a
between the OSM market in Germany and powerful one. This again reflects a marked
the developer-led market for new housing in difference between the German housing
the UK. OSM housing firms in Germany market and that in the UK, in that it has
compete in a market for houses, divorced been traditional in Germany for house
from the market for land. Prospective purchase to be deferred until the family is
purchasers examine alternative housing settled in a location, when a plot of land is
‘products’ in order to find the one that best selected and the ‘dream’ house purchased.
matches their needs and budget, just as they
would when purchasing a car. The tendency for purchasers to regard the
house as their ‘permanent’ residence and
Because the firms are selling only the therefore to live in it for many years
house, and not (in contrast to the norm in prevented our investigating some aspects of
the UK) offering a package which is a the housing market that would be more
combination of the house, the land and the significant in the UK. Firms supplying OSM
location, their competitive position is based housing had no perception of whether
entirely on the house and associated manufactured houses commanded a
customer-related services (delivery premium over traditional housing in the
processes, maintenance etc). They thus have second-hand market, or were regarded as a

59
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

less desirable purchase, and owing to House types

shortage of time, the views of lenders or of
building professionals on this subject could Because OSM firms aim to satisfy the
not be explored. specific requirements of the purchaser, the
predominant house form supplied is the
While some ‘dream’ houses were aimed at detached house. Generally, this is of ‘chalet’
the more affluent sectors of the population, appearance and the OSM production systems
other suppliers aimed at a different income that companies have evolved are at times
level, including purchasers who were tailored to this style.
prepared to install finishes and services
themselves. The image in the UK of German However, other designs are readily available
manufactured homes has been shaped in and we noted particularly the way in which
particular by the promotion of houses aimed suppliers had recognised a developing market
at the top end of the market. Certainly, this is sector and had developed a new type of
a key market sector for some OSM ‘two-family’ house, suitable for two
companies but the OSM sector serves a generations living in the same property. With
wide range of market needs, including (in one many commentators predicting a rise in the
example explained to us) the supply of average age for first house purchase in the
housing to the developer of a mixed UK, this is perhaps a housing concept that
retail/residential development. We also saw will be emulated here, whether through OSM
examples of OSM ‘starter’ homes. or traditional construction.

However, whatever the target income Matching the variety of house types possible,
bracket, the houses were marked by the OSM housing in Germany – even from a
same focus on quality: in construction, in single supplier – demonstrates none of the
fittings and in customer service. poor appearance or uniformity feared by
some when the subject is raised. The houses
Pricing are indistinguishable externally from
conventionally constructed houses, and most
The range of prices quoted for OSM housing manufacturers offer considerable choice in
reflected the different markets. At the dimensions, finishes, external features such
bottom end, it appeared possible to as balconies, the size and position of
purchase a fully fitted concrete modular windows etc. Some indeed make a feature of
house for around €80,000, or around being able to accommodate any plan desired
€900/m2. At the top end, there was no limit by the customer.
but ‘luxury’ houses were priced in the region
of €350,000, or around €1,200/m2. Flexibility is correlated with price; the lowest
price houses come as ‘standard’ packages but
While these appear in the UK context to be even then there is external variety through
very competitive prices, they exclude the cost choice of windows, doors and finishes.
of purchasing and servicing the land, which
will vary widely according to location. Market summary
However, the general impression given was
that OSM housing was marginally more Overall, therefore, manufactured housing in
expensive to purchase than traditionally built Germany is a significant and growing sector
housing, the extra cost being justified by the within the housing market. While at present it
higher quality and more assured delivery that is particularly established at the upper end of
could be provided through the OSM route. the market for new housing, we saw

60
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

sufficient examples to demonstrate that it can This longer term view, coupled with a
address a wide range of market needs, but determination to ensure that the firm retained
always with high quality of construction, its reputation for quality and customer service,
matching high customer expectations. OSM led firms to be flexible in meeting customers’
housing in Germany demonstrates all the after-sale requests, thus building up a stock of
attributes of a highly competitive product goodwill which they hoped would in due
sector, with suppliers investing in the course be translated into future orders. It is
technologies and processes that will create understandable that this is a stronger driver in
market advantage, and developing new self procured, rather than developer led
housing forms in order to keep pace with housing, since the product is independent of
customer needs. location and there is a greater possibility of
selling again to an existing customer. As with
6.3 Business philosophies and the introduction of new technologies,
processes however, it illustrates how OSM can lead to
real customer benefits, not only for
Two aspects of the OSM housing industry purchasers of OSM homes but, through
seemed to us of particular note: setting the competitive standard, more
generally.
• the role played by long-established family-
owned firms The desire to be a good employer was
• investment in marketing manifest in firms’ considerable investment in
training and in the way that workers who
Private, family-owned firms were no longer able to undertake site work
were retained in the factory, passing on their
With two exceptions, the firms visited were skills and experience to others. In return,
privately owned, some being in the fourth of firms enjoyed considerable stability in their
fifth generation of family ownership. A labour force, aided perhaps by being situated
typical pattern in OSM timber housing was in areas where there were few alternative
that the firm had been originally founded as opportunities for factory employment. These
a carpentry business or sawmill, and had may be features of German employment
steadily diversified and expanded, to practice generally, rather than of the OSM
become a significant employer in the housing sector, but they undoubtedly aided
(generally rural) locality. the drive for quality in the final product.

As a consequence, tradition, reputation and Stable relationships were also evident in

the desire to be a good contributor to the local the way that OSM suppliers featured
economy were important factors underpinning products by their suppliers in their
the business philosophies and practices of the customer centres and show houses. These
firm, but this did not prevent their seeking out were partnership arrangements, with
new technologies and products, in order to manufacturers having their own exhibition
ensure that the firm remained fully spaces in the customer centres.
competitive. The present generation of
owners were determined that they would Investment in marketing
pass the firm on to the next in good health,
and private ownership appeared to give them Turning to the marketing of OSM housing, it
considerable freedom to invest heavily in was clear that suppliers of OSM homes saw
research, technologies and marketing; without the need to invest heavily in marketing and
calling on investors or bank loans. sales outlets, and this has led to the creation

61
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

not only of the ‘show-home’ parks but also to The quality of the timber used was high, and
elaborate customer centres such as the the sections employed for structural
WeberHaus ‘World of Living’. This level of members exceeded those required in the UK.
investment is again typical of a One firm, now working in Ireland essentially
manufacturing sector marketing a consumer to UK specifications, had found that they had
product, and reflects both the competitive needed to reduce their normal specifications
nature of the market and the fact that the to comply with commercial requirements.
cost can be spread over a relatively large
number of unit sales. The structural systems employed were not
innovative, but some of the technologies
The ‘show-home’ parks, in particular, play an incorporated in them demonstrated the
important and distinctive role in the promotion suppliers’ quest for features that would
not only of individual firms’ products but of the distinguish them in the market. This was
OSM sector generally. By offering the illustrated by the insulation employed by
opportunity for rapid comparison of homes Baufritz, which is manufactured from its
from different suppliers, they ease the process waste timber. The same firm offered roof
of selection and make choosing an OSM home panels which incorporated a conducting mesh
an easier process than if customers had to to protect against electromagnetic radiation.
visit a number of demonstration sites.
The scope for application of post-and-beam
Could the ‘show-home’ park concept be systems in the UK appears limited. They are
emulated in the UK? It would be more difficult typically aimed at the upper levels of the
to justify the investment as a marketing aid for market and – as demonstrated by the
individual firms, since sales to final purchasers response to the TV programme on the Huf
would be constrained by the lack of a ‘self- house – a niche market exists in the UK for
procure’ tradition in the UK. On the other hand, houses based on such systems. But they are
the concept might have merit as a tool (a) for unlikely to have wide application.
helping the public to gain first-hand experience
of OSM homes, and overcoming some of the By contrast, systems based on structural
current perceptions, and (b) for marketing the panels are much more similar to current UK
concept of factory production both to the technology. Such systems could be adopted
public and to developers. Developing such a in the UK, either through licensed
park might be a collaborative initiative by the manufacture or through taking advantage of
OSM housing industry. the considerable spare capacity that
currently exists in the German OSM sector,
6.4 Technologies and production and importing from Germany. While
processes transport costs would need to be taken into
account, these do not appear to rule out the
Timber systems import option.

Most of the housing systems viewed were Concrete systems

based on timber – either post-and-beam
structures or insulated structural panels. In More radical innovation was to be seen in the
Southern Germany, which has extensive concrete OSM sector, where fully fitted
forests, there is a tradition of building in modular housing was being supplied by
timber, and many OSM producers have come Dennert, at very competitive prices. As put into
from that background. However, Scandinavian practice by Dennert, this concept offered less
timber is now supplementing local sources. flexibility to the user, but it would seem that a

62
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

combination of the Dennert modular concept Housing systems without cavities are being
and the high degree of automation exhibited in used in the UK, but generally warranty
the Glatthaar factory making prefabricated providers look for the extra barrier to water
basement panels, might offer the customer the ingress associated with the cavity. It is
best of both worlds. Certainly, the latter factory possible that modified systems, with a cavity,
was a very effective demonstration of the would find more ready application.
application of modern manufacturing methods
to the production of concrete units. Environmental features

While Glatthaar focused on basements, the Within the houses, we have commented
same technology could in principle be earlier on the emphasis placed by some
applied to above-ground construction. The suppliers on environmental features, and
ability, using the patented sealing indeed all suppliers made reference to
technologies, to create completely environmental aspects in their marketing
waterproof prefabricated structures could be literature. Some had built demonstration
very relevant in areas at risk of flooding. facilities and show homes to demanding
energy standards, and there was
Application of these technologies in the UK widespread demonstration of energy saving
would need to be through local measures such as photovoltaic systems.
manufacture, since transport costs would Systems for the re-use of water were also
otherwise be excessive. to be found in the show homes; these
along with the heating system occupied a
Brick systems ‘plant room’ in the basement, with ready
access for maintenance.
We visited only one supplier of OSM brick
housing, and at that factory there was While environmental technologies fell
extensive use of manual processes. However, outside the scope of the mission, it seems
we understand that elsewhere in Germany, likely that some of the energy and water
automation has been applied to the systems now being developed in Germany
manufacture of brick panels. With the could find application in the UK.
extensive use of brick for housing in the UK,
this is clearly worthy of further investigation. Technologies within the factory
As with concrete housing, however,
application would need to be through A common perception of factory-built
manufacture in the UK. housing is that it is only viable when
produced in large volumes, leading to a
Cavities fear of uniformity, with housing
developments constructed from identical
The introduction of any new technology into units (as happened in many
housing would need to follow careful conventionally constructed developments
investigation and testing, in particular to from the 1930s to the 1970s). The German
satisfy regulatory authorities and warranty OSM housing sector shows this fear to
providers. One particular aspect of German be unwarranted.
housing would represent a move from UK
norms, and that is the absence of a cavity in Several of the factories visited produced
most of the systems studied. German only 2-300 units annually, while the largest
housing relies on the external render to had an annual capacity of around 1,400 units
provide a waterproof external surface. although it was operating at below that level.

63
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

And within this range of outputs, there was Firms clearly considered that they had little to
little repetition; the computer-based production learn from other sectors. In a country noted
systems permitted a high degree of for its advanced manufacturing technologies,
customisation even at these small production exchange of information or personnel
levels. Thus factory production is viable at between OSM housing firms and other
volumes far lower than those conventionally manufacturing sectors seemed to be at a very
associated with off-site manufacture. low level, and it was notable that much of the
equipment in the factories visited came from
The firms visited demonstrated an the same small number of suppliers.
essentially pragmatic approach, based on
experience, towards the balance between Technology summary
automated and manual processes in the
factory and between factory and site-based Overall, the conclusion drawn from the visits
operations. Some had attempted to increase was that OSM housing can be produced very
the factory component, only to find that late flexibly using modern manufacturing
variations made this uneconomic. technologies, with many options for changing
the balance between factory and site-based
Generally, they were seeking ways of adding activities and between automated and manual
more value in the factory and reducing the activities in the factory. ‘Mass-customisation’,
site content – such as through the even at small volumes, is viable and there
development of packaged heating and water should be no fear that OSM leads to uniformity
supply systems – but they did not wish to in output or loss of customer choice.
prejudice their ability to tailor the final product
to customers’ requirements, or to reduce their 6.5 Follow-up actions
ability to cope with changes in demand. It was
notable that Kampa, which had purchased a This report has summarised findings from a
highly automated factory when the downturn short but intense visit to OSM housing
in the housing market had forced its owner supplier firms in only one part of Germany.
into bankruptcy, had substituted manual for It found a highly competitive, product and
automated processes in some areas. customer-focused industry, able to meet a
wide range of market requirements. Further
There seemed little pressure for reducing investigations in other Länder would no doubt
the time spent on site, even if the labour add to this picture, and reveal further
element were reduced. While the technologies for potential application in the
waterproof shell of the house was typically UK. However, based on our observations and
constructed in a day, it was accepted that it conclusions from this first visit, we set out
would then take six weeks or more for final below some actions that would build upon
completion. Again, this enabled late changes the contacts made during the visit.
to be accommodated.
Timber systems
The production processes observed
therefore reflected the characteristics noted Housing developers, providers of social
earlier in the firms. Advanced technology housing and suppliers of timber-famed
was sought and used, but only to the extent systems may wish to make contact with
that it enhanced the firm’s ability to serve German suppliers of timber structural panel
its customers. The focus was on the systems to discuss the feasibility and
product and the customer, and the economics of supply to the UK from existing
production process followed. but under-used manufacturing facilities,

64
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

or alternatively the establishment in the UK Show homes

of new facilities. There is already an example
of a commercial relationship between one The ‘show-home’ park is a powerful
such supplier and a developer, which has led marketing tool, capable of changing
to the construction of a factory in Ireland. perceptions about OSM housing and
Another firm is supplying from Germany for benefiting the whole OSM sector. It would
a hospital project in the UK. require careful appraisal, but the development
of an OSM show park could be an action
We saw no desire by German OSM which would provide focus and profile for the
companies to take the place of developers – industry, and a means of demonstrating to all
they recognised that theirs was a different stakeholders – regulatory, financial,
business – but certainly they were open to professional, consumer etc – the merits of
approaches to exploit their technologies and OSM housing.
production facilities.
Quality standards and certification
Concrete systems
Certification of OSM housing systems has
Similarly, there is potential for the exploitation commenced in the UK, but the German
of the German experience in producing experience of changing the public image of
modular concrete housing, and this could be manufactured housing reinforces the case for
investigated further, building upon studies the development, application and promotion
already undertaken within the UK. of rigorous quality standards in the OSM
sector. Manufacturers who have yet to
The technologies used in the prefabricated embark on this route would be well advised
concrete basements, and in their to do so.
manufacture, also warrant further
examination. As noted earlier, this could be Environmental technologies
employed either for sub-surface works, in
basements and underground garages, or in While the investigation of environmental
above-ground wall construction, and would technologies was not the subject of this
be very relevant to the construction of mission, it is clear that considerable
housing in areas prone to flooding. A joint investment in these technologies has taken
venture or licensing arrangement might be place both by public bodies and industry
the exploitation route. (including housing suppliers) in Germany.
Equipment supply interests might undertake
Area development further investigation of the technologies now
being incorporated in German homes.
As a means of stimulating investment in the
kinds of technologies that have been
discussed in this report, we suggest that one
of the bodies responsible for the
development of major sites in the South
East, identify specific areas for development
by the private sector or housing associations
using OSM methods, and encourage the
development of partnerships between UK
and overseas interests.

65
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Appendix A
ACKNOWLEDGMENTS

The mission members would like to express The report includes inputs provided by all the
their thanks to all the German companies mission members and was edited by
(see Appendix C) who gave up their time to Tim Venables and Roger Courtney.
welcome us into their organisations. Particular
thanks are extended to the individuals in Finally we would like to thank the staff at the
these companies who acted as impeccable DTI’s Global Watch Service for their help and
hosts and provided such valuable information financial support in arranging the mission and
and insight, much of which has been used in the team at CIRIA for their assistance in
the formation of this report. coordinating our activities both before and
after the mission.
The arrangement of the mission itinerary was
greatly assisted by Karin Stockerl’s knowledge Any errors or omissions are of course solely
of the German industry, and the help and the responsibility of the authors.
support of Nicola Smoker – the DTI
International Technology Promoter for
Sustainable Energy and Environmental
Technologies in Europe – whose efforts at
arranging and coordinating the visits in
Germany leave us in her debt. Special thanks
are also extended to our interpreter
Jane Mountford for her patience and skill in
translating for such a large group.

Figure A.1 Mission participants at Hebel Haus

66
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Appendix B
MISSION ITINERARY

Sunday 14 March
Arrival at Munich: Mission briefing for all
participants

Monday 15 March
0830-1200 Munich Technical University
• Professor Thomas Bock
• Cadolto Flohr & Söhne GmbH
& Co KG
• Purholz Verbundelemente
GmbH
1330-1600 Baufritz – Erkheim
1700-1800 Ziegelmontagebau Johanni –
Deisenhausen

Tuesday 16 March
0830-1130 Platz Haus – Bad Salgau
1500-1800 WeberHaus GmbH & Co KG –
Rheinau Linx

Wednesday 17 March
0830-1100 Glatthaar Fertigkeller GmbH –
Schramberg
1230-1800 Fellbach Show Village

Evening: Midweek review of progress

by team

Thursday 18 March
0900-1130 Kampa AG (at NovEx Hausbau
GmbH) – Steinheim
1430-1730 Veit Dennert KG – Schlüsselfeld

Friday 19 March
0900-1200 Hebel Haus GmbH – Alzenau
1330-1600 ELK Fertighaus – at Frankfurt
Show Village

Depart Frankfurt Airport

67
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Appendix C
HOST ORGANISATIONS

Baufritz Kampa AG
Alpenstrasse 25 Uphauser Weg 78
87746 Erkheim/Allgau D-32429 Minden
GERMANY GERMANY
T +49 8336 900 – 0 T +49 571 955 7229
F +49 8336 900 – 260 F +49 571 955 7476
www.baufritz.de www.kampa.de

Cadolto Flohr & Söhne GmbH & Co KG Lehrstuhl für Baurealisierung und
Wachendorfer Strasse 34 Bauinformatik
PO Box 25 Technische Universität München
D-90553 Cadolzburg Archisstrasse 21
GERMANY 80333 München
T +49 9103 502 265 GERMANY
F +49 9103 502 120 T +49 89 289 22100
www.cadolto.com F +49 89 289 22102
www.bri.ar.tum.de
ELK House Ireland Company Ltd
Athy Business Park NovEx Hausbau GmbH
Athy Schwabstrasse 37-45
County Kildare 89555 Steinheim
IRELAND GERMANY
T +35 5359 8633 840 T +49 7329 951 405
F +35 5359 8633 841 F +49 7329 951 419
www.elk.at www.exnorm.de

Glatthaar Fertigkeller GmbH Platz Haus

Im Moos 17 Platzstrasse 2-16
71713 Schramberg D-88348 Bad Salgau
GERMANY GERMANY
T +49 740 2929 473 T +49 7581 2010
F +49 740 2929 424 F +49 7581 201 123
www.glatthaar.com www.platz.de

Hebel Haus GmbH Purholz Verbundelemente GmbH

Brentanostrasse 2A Bahnhofstrasse No 69
63755 Alzenau Mittweida
GERMANY GERMANY
T +49 6023 940 611 T +49 372 794 620
F +49 6023 940 612 F +49 372 751 65
www.hebelhaus.de www.purholz.de

68
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Veit Dennert KG
Veit Dennert Strasse 7
96132 Schlüsselfeld
GERMANY
T +49 9552 71 108
F +49 9552 71 125
www.dennert.de

WeberHaus GmbH & Co KG

Eschweg 8
77866 Rheinau Linx
T +49 7853 83 346
F +49 7853 83 7346
www.world-of-living.de

69
70
Name Job title/Company Website Telephone E-mail

Clive Clowes Head of Housing Procurement, www.housingcorp.gov.uk 020 7393 2025 [email protected]
Housing Corporation

Dr Rodger Evans Construction Sector Unit, DTI www.dti.gov.uk/construction [email protected]

MISSION TEAM

Dr Russell Matthews Taylor Woodrow Engineering www.taylorwoodrow.com 01785 223 261 [email protected]

John Mitchell Surveying Services Manager, www.zurich.co.uk 01252 377 474 [email protected]
Appendix D

Zurich Building Guarantee

Dr Paul Newman Head of Timber Technology, www.trada.co.uk 01494 569 600 [email protected]
Timber Research and
Development Association

Andrew Ogorzalek Director, PCKO Architects www.pcko.co.uk 020 8861 1444 [email protected]

Simon Palmer Director, Palmer Partnership 01322 280 510 [email protected]

MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Canda Smith Head of Design and www.odpm.gov.uk [email protected]

Sustainable Communities,
ODPM

Dr Karin Stockerl Innovation Coordinator, www.shgroup.org.uk 020 7553 6410 [email protected]

Southern Housing Group

David Whitton Group Chief Architect, www.homegroup.org.uk 0191 285 0311 [email protected]
Home Group Ltd

Roger Courtney Consultant, innovation in www.ciria.org 020 7549 3300 [email protected]

construction/Mission
coordinator for CIRIA*

Tim Venables Tanaka Business School – www.imperial.ac.uk/tanaka/ 020 7594 6604 [email protected]
Imperial College London innovationstudies

Prof David Gann Tanaka Business School – www.imperial.ac.uk/tanaka/ 020 1594 6604 [email protected]
Imperial College London innovationstudies

* CIRIA Project Director: [email protected]

 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Appendix E
GLOSSARY

3D three dimensional
BDF Bundesverband Deutscher Fertigbau
oC degrees Celsius
CAD computer-aided design
CAM computer-aided manufacturing
CIRIA Construction Industry Research and Information Association (UK)
cm centimetre
DFV Deutscher Fertigbau Verband
DIY do-it-yourself
DTI Department of Trade and industry (UK)
GDF Gütegemeinschaft Deutscher Fertigbau
IT information technology
K kelvin
kg kilogram(me)
km kilometre
kWh kilowatt-hour
m metre
mm millimetre
MMC modern methods of construction
ODPM Office of the Deputy Prime Minister (UK)
OSB oriented strand board
OSM off-site manufacturing
QA quality assurance
R&D research and development
SIZ Stahl-Informations-Zentrum
SPRU Science and Technology Policy Research (University of Sussex, UK)
TRADA Timber Research and Development Association (UK)
UK United Kingdom
USA United States of America
v versus
W watt
WC water closet

71
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

Appendix F
LIST OF TABLES AND FIGURES

Tables

1.1 page 8 Position and viewpoint of mission participants

2.1 page 10 Usage of OSM by procurement route and built form
2.2 page 10 Usage of OSM by self-procurement route
4.1 page 28 Market shares of different types of block for ‘Massivbauweise’

Figures

1.1 page 7 Previous mission reports

2.1 page 9 Numbers and types of new homes completed in Germany, 1985-2004
2.2 page 10 Market share of various procurement routes in the UK
2.3 page 10 Market share of various procurement routes in Germany
3.1 page 15 Single occupancy house
3.2 page 15 Family home
3.3 page 17 Open living area
3.4 page 17 Use of roof volume
3.5 page 17 Balcony bathroom
3.6 page 18 Basement sauna
3.7 page 18 Basement playroom
3.8 page 18 Basement plant room
3.9 page 19 Chalet bungalow
3.10 page 19 Balcony under eaves
3.11 page 20 Solar shading
3.12 page 20 Double height spaces
3.13 page 21 Exposed structural elements
3.14 page 22 Section through house construction
3.15 page 22 The World of Living
3.16 page 23 Bathroom display area
3.17 page 23 Suppliers exhibiting at the World of Living
3.18 page 23 Show home at World of Living
3.19 page 23 Show home at World of Living
3.20 page 24 Show village house
3.21 page 24 Show village house
3.22 page 24 Map of Fellbach show village
3.23 page 25 Show village house
3.24 page 25 Show village house
3.25 page 25 Show village house under construction

72
 MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

4.1 page 29 Typical German timber frame wall build-up

4.2 page 30 Gasket sealant on joint
4.3 page 30 Floor construction detail
4.4 page 31 Baufritz demonstration house
4.5 page 31 Wall panel during construction
4.6 page 32 Model of Baufritz wall construction
4.7 page 33 Baufritz demonstration house
4.8 page 34 The ExNorm factory, frame assembly
4.9 page 34 The ExNorm factory, timber preparation
4.10 page 36 Option house
4.11 page 36 Frame assembly
4.12 page 36 Frame assembly
4.13 page 36 Option house module layouts
4.14 page 37 Option house interior
4.15 page 37 Raw material at factory
4.16 page 38 Carl Platz demonstration homes
4.17 page 38 Interior of a Carl Platz house
4.18 page 38 Insulated sanitary ware being fitted
4.19 page 39 Wall panels ready for first coat of render
4.20 page 39 Elk factory in Ireland
4.21 page 39 Interior of Elk factory
4.22 page 40 Wall panel assembly
4.23 page 40 External finishing of wall panel
4.24 page 41 Elk apartments in Ireland
4.25 page 41 Elk houses in Ireland
4.26 page 41 Elk house in Ireland
4.27 page 43 Floating demonstration facility
4.28 page 44 Machine laid reinforcement
4.29 page 44 Concrete panels being moved in factory
4.30 page 44 Cured panel being inserted into second skin
4.31 page 45 Model of basement
4.32 page 45 Insulated basement panels
4.33 page 46 Reinforcement cages being lifted into position
4.34 page 46 Aerated concrete curing
4.35 page 46 Bar coded panels
4.36 page 47 Panels ready for delivery
4.37 page 47 Hebel Haus’ Passiv Haus
4.38 page 47 Clay bricks designed for casting into concrete
4.39 page 48 Cast wall panel
4.40 page 48 Insulated wall panel
4.41 page 49 ICON house sizes
4.42 page 50 ICON house

73
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

5.1 page 51 Purholz wall panels

5.2 page 51 Vertically stacked wall panels
5.3 page 52 Finished wall build-up
5.4 page 53 Bay window assembly
5.5 page 54 Pre-finished panel ready for assembly
5.6 page 54 Timescales for erection/fit-out of a 230-m2 property
5.7 page 55 Panel taped and jointed in factory
5.8 page 55 Toilet panel ready for installation
A.1 page 66 Mission participants at Hebel Haus

All images are copyright T Venables except figures 4.20 to 4.26 which are courtesy of
Elk House Ireland Co Ltd.

74
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

75
MODERN METHODS OF CONSTRUCTION IN GERMANY – PLAYING THE OFF-SITE RULE

76
The DTI’s Global Watch Service provides support dedicated
to helping UK businesses improve their competitiveness
by identifying and accessing innovative technologies and
practices from overseas.
Global Watch Information Global Watch Missions – enabling teams of
Global Watch Online – a unique internet- UK experts to investigate innovation and its
enabled service delivering immediate and implementation at first hand. The technology
innovative support to UK companies in the focused missions allow UK sectors and
form of fast-breaking worldwide business and individual organisations to gain international
technology information. The website provides insights to guide their own strategies for
unique coverage of DTI, European and success.
international research plus business Contact: [email protected]
initiatives, collaborative programmes and
funding sources. Global Watch Secondments – helping small
Visit: www.globalwatchonline.com and medium sized companies to send
employees abroad or receive key people from
Global Watch magazine – the website's sister another country. Secondments are an
publication, featuring innovation in action. effective way of acquiring the knowledge,
Distributed free to over 16,000 UK skills, technology and connections essential
organisations, this monthly magazine features to developing a business strategically.
the latest technology developments and Contact:
practices gleaned from Global Watch Service [email protected]
activities around the world now being put into
practice for profit by British businesses. Global Watch Technology Partnering –
Contact: providing free, flexible and direct assistance
[email protected] from international technology specialists to
raise awareness of, and provide access to,
UKWatch magazine – a quarterly magazine, technology and collaborative opportunities
published jointly by science and technology overseas. Delivered to UK companies by a
groups of the UK Government. Highlighting network of 16 International Technology
UK innovation and promoting inward Promoters, with some 6,000 current
investment opportunities into the UK, the contacts, providing support ranging from
publication is available free of charge to UK information and referrals to more in-depth
and overseas subscribers. assistance with licensing arrangements and
Contact: [email protected] technology transfer.
Contact: [email protected]

For further information on the Global Watch

Service please visit
www.globalwatchonline.com
Printed in the UK on recycled paper with 75% de-inked post-consumer waste content
First published in September 2004 by Pera Innovation Limited on behalf of the
Department of Trade and Industry
© Crown copyright 2004
URN 04/1430