Gensler Australia

Ken McBryde

An award-winning architect, Ken McBryde is an industry thought leader in modern methods of construction, with extensive expertise in designing complex, large-scale global projects. Ken is widely respected in the industry for his record of delivering beautiful, efficient, passively environmentally designed buildings, mixed-use and commercial projects. With more than 30 years of experience, Ken’s combination of international and domestic work includes a diversity of multi-residential (including build-to-rent), commercial, educational and cultural projects. His expertise lies in a rare combination of international architectural design pedigree and a high level of understanding of modern construction methods (MMC) and Design for Manufacture, Assembly & Disassembly (DFMAD).

Innovative Design to Meet Housing Demands

The world’s population is multiplying and cities around the world are experiencing a global housing crisis. At the same time, climate-related crises are causing widespread impacts, from property damage to biodiversity loss to climate migration.

We cannot solve the world’s accelerating housing shortages and respond to the climate crisis with the inherent inefficiencies in conventional construction methods. The world’s needs are changing fast and buildings are becoming superseded at increasing rates. As buildings become larger and more complex, we must find new ways to build while also extending the life of existing structures. We need a paradigm shift.

Designing for Manufacturing, Assembly and Disassembly (DFMAD) is an innovative solution to meet the demands of a growing population while creating a more sustainable, efficient built environment.

“To solve two of the world’s two significant challenges, namely reducing our impact on the planet and our burgeoning populations’ accommodation requirements, we must adopt Design for Manufacturing, Assembly & Disassembly (DFMAD),” says Ken McBryde, Design Director of Architecture, Gensler Australia

Designing for Manufacturing, Assembly and Disassembly (DFMAD)

DFMAD optimizes manufacturing and assembly processes. It involves resolving construction systems, modules, panel sizes, cranage, service integration, structural connections and architectural junctions for easy assembly and disassembly.

This methodology relies on a collaborative multidisciplinary design approach and benefits from early selection of manufacturing partners or designing for industry capabilities. Using data-driven BIM (Building Information Modelling), DFMAD considers manufacturing capabilities, materials, tolerancesand buildability to virtually build the structure early in the process. By finalizing the design early and manufacturing as many components off-site as possible before onsite assembly, this minimizes waste, improves efficiency and streamlines the construction process.

DFMAD is a crucial way to leverage design to address housing shortages and climate crises. Conventional construction methods are inefficient and we must respond to these global challenges through new, innovative methods.

Five Trends Limiting Conventional Architectural Practices

1. Size and Complexity: Architecture and design projects are becoming larger and more complex, requiring seamless, collaborative design approaches that break down traditional silos. Diverse expertise, informed by data-driven design decisions, is essential.

2. Get Our Hands Dirty: Downward pressure on fees has led to less experienced designers and alternative procurement processes like Design & Construct (D&C) and early contractor involvement (ECI), resulting in a lack of site experience for architects.

3. Disassembly: Buildings are becoming obsolete faster, making disassembly and reuse essential for circular economics. Efficient structural connections and joints are crucial for disassembly and reducing embodied carbon.

4. Supply Chain: Material and component delivery affects construction timeframes and feasibility. Post-pandemic conditions and geopolitical uncertainties have exacerbated these issues.

5. Value Engineering: Elaborate designs with limited understanding of buildability necessitate value engineering to deliver projects on time and on budget. Separate processes can threaten designers if the design purpose is not well articulated.

Positive By-Products of DFMAD

1. A More Equitable, Inclusive Process: Off-site manufacturing improves gender balance and childcare organization due to consistent work locations and times. The clean, mechanized workplace also reduces physical demands.

2. Less Disruption: Conventional construction sites are disruptive. DFMAD reduces site-based construction, focusing on handling and assembling pre-assembled components.

3. Reduced Risk of Exposure: Fewer builders on site and distributed teams in manufacturing facilities lower disease transmission risks, especially in remote communities.

Barriers to Broader Adoption

Moving forward, the industry needs to find a way to reduce the barriers to the broader adoption of modern methods of construction. We see these barriers fall into three main categories:

1. Risk Management: Risk management must be better understood through collective partnership agreements.

2. Consistent Supply Pipelines: More consistent pipelines are needed for off-site construction components to offset manufacturing facility overheads. Government authorities can help support this.

3. Procurement Policies: Procurement policies need to be adjusted to allow for innovation rather than conventional tendering.

Outcomes for the Development Industry

DFMAD and diverse multidisciplinary minds enable faster, safer and higher-standard project delivery. Understanding building assembly advanced digital design and parametric tools are essential. DFMAD integrates manufacturer components into shared digital models, offering practical solutions for carbon reduction and accommodation needs.

Ken McBryde is the Design Director of Architecture at Gensler and Adjunct Professor of Architecture at The University of Sydney. This article has been prepared independently from the University of Sydney.