DMOC – Distributed Manufacturing for Offsite Construction

Unlocking Off-site Construction at Scale…

The DMOC project set out to revolutionise the way high-performance buildings are manufactured. At its core was the ambition to bring automation, flexibility and digital integration into off-site construction. Working closely with aLL Design, HAL Robotics and ourselves (as MEP/energy and service-integration consultants), we helped deliver a solution that connects intelligent design, manufacturing orchestration and supply-chain robustness.

Digital Thread from BIM to Factory Floor…

We helped embed process-capability data within the Building Information Model (BIM) to enable automatic dispatching of manufacturing tasks to the optimal facility. A hybrid-cloud “orchestrator” dynamically allocates work, monitors production cells, reallocates tasks in fault scenarios and ensures just-in-time delivery across multiple sites. In our role, we analysed how these digital workflows impact services-integration, plant layout, distribution logistics and energy-performance assurance in modular construction.

Driving Efficiency & Quality in Modular Production…

With automation and machine-toolpath generation coming directly from BIM, the barrier to entry for automated manufacturing is substantially lowered. The result is greater machine utilisation, quicker throughput, fewer manual interventions and tighter tolerances — all key to high-quality off-site modules. The project aimed for up to a 40% productivity uplift across construction processes. GtR By coordinating the MEP and energy-analysis workstreams with these advanced manufacturing flows, we ensured that services integration did not become a bottleneck in the smart factory–to-site chain.

Sustainability & Performance Built In…

A robust services strategy is only as good as its delivery. By aligning our MEP design with this new manufacturing paradigm, we were able to anticipate distribution routing within factory-built modules, optimise energy systems accordingly, and validate performance within the digital-manufacturing environment. The outcome: modules that arrive on-site with services pre-integrated, factory-tested, and ready for rapid assembly — reducing on-site labour, waste, and defects.

Collaboration That Made It Possible…

This was a multi-disciplinary, multi-organisational collaboration. HAL Robotics brought their expertise in machine-integration, simulation and edge-computing. aLL Design led the DfMA (Design for Manufacture and Assembly) principles and modular-housing platforms. We brought the critical services-design and energy-modelling capability to ensure that these modules wouldn’t just be built—they would perform. Together, the consortium demonstrated a credible path for scalable, high-quality off-site construction in the UK.

Outcomes & What’s Next…

The project closed in March 2022, delivering a proof-of-concept that manufacturing cells can be orchestrated intelligently at scale, and that design, manufacturing and services can be deeply integrated from the very start. GtR The knock-on benefits for a future where homes and buildings are healthier, faster to construct and more energy-efficient are compelling. For us, the project validated how early alignment of MEP, digital manufacturing and architectural ambition can unlock superior built outcomes.