HOUSING MARCH 201770

Sustainable Design

Innovation and learning has always

been at the heart of this Melbourne-

based prefab construction company.

Annie Reid reports.

a prefab

When ArchiBlox managing director Bill McCorkell’s father built one of the first houses in Melbourne with

solar hot water panels on the roof, and was also one of the first employees of iconic Merchant Builders Pty Ltd, it wasn’t a stretch that Bill would develop a passion for sustainability from a young age.

‘I have always said there is a need for sustainable buildings because they lead to healthy living,’ he says. ‘It makes a big difference.’

And that’s exactly what happened. After spending a childhood on building sites and an early career in design and architecture, Bill decided to forge his own path of innovation and building sustainably. Seven years ago he established ArchiBlox in Melbourne, a prefabrication and modular construction company.

ArchiBlox’s difference is that it is essentially architect-driven and design-oriented. ‘I’m an architect as well as a builder, and I bring the two skills together to achieve a pleasing outcome for all parties,’ Bill says.

Specialising in modular building, the business creates prefabricated homes and buildings, from concept and design through to manufacture and installation, in just 12–28 weeks.

Designing big rather than building big, ArchiBlox’s philosophy is about creating spaces that can be used for more than one purpose, and for future generations to enjoy. Its designs range from sustainable granny flats and carbon positive houses to fully flexible, custom dream projects, and extend to innovative commercial projects.

The company’s approach is to continually innovate with every aspect of the business. For example, Bill is constantly refining and redefining ArchiBlox’s sales procedure and communication systems, using the agile methodology of project management. A vital part of this is ensuring that the project specifications and communications are accurate, along with simple documentation.

‘Documentation becomes a bible of the business,’ he says. Without it, he says, poor communication occurs and customer disillusionment results. Therefore, the team works hard to create a streamlined customer process right from the start, with the opportunity for change as the project is underway.

The improvement process involves looking outside the business as well.

futureTwelve months ago, Bill began ‘score cards’ where colleagues and stakeholders, who work both internally and externally, score different parts of the business. Bill monitors the feedback and makes changes to reflect what has been relayed back to them.

‘It’s about being able to control and influence the client on their journey as much as we can,’ he says.

Of course, prefab is nothing new. It’s been around since the gold rush in the 1850s, and has been adopted by many countries, including Japan, one of the world’s leading markets, where prefab costs 20 per cent more than traditional building.

According to Bill, all builders use prefab: ‘I think inherently every building uses a form of prefab, but each builder uses different levels,’ he says.

Bill and his team are always looking at research and development in prefab; it’s one of his favourite aspects of working in the industry. And as the technology advances, there are more prefab players entering the market, each offering a different model and methodology.

Bill notes that the competition has been positive for the industry. Not only does the sustainability message continue to reach new audiences, but the increased exposure also means typically less time educating clients on the benefits of prefab over traditional construction methods.

‘The biggest change in prefab is that it’s become cooler,’ he laughs. ‘People are engaging with it a bit more, and perceiving it to be different to the more common way of building.’

Bill also believes prefab has a great future in Australia as this awareness continues to grow, but says the innovation must continue.

‘The biggest change in prefab is

that it’s become cooler…people

are engaging with it more’

HOUSING MARCH 2017 71

‘We are always innovating in the business. We’ve changed the way we manufacture five times in seven years.’

Along the way, Bill has come to recognise the value of staying connected through industry memberships, such as HIA. He has been a member since he started his business, and regularly seeks HIA’s help with legal issues, contracts and other resources. ‘It’s a really good sounding board and allows us to make better and more strategic decisions,’ Bill says. ‘It’s invaluable.’

The business has grown today to a full time staff of about 40, with a range of contractors and subcontractors. A recent decision to relocate its prefabrication premises from Gippsland to Laverton, in Melbourne’s west, has helped to improve business productivity.

And while the design headquarters remains in Richmond, the new prefab base has shortened the travel time between the two offices significantly to just 17 minutes, which has enabled Bill to streamline various departments more efficiently. ‘The tyranny of distance was too much,’ he says. ‘Now, both offices have more synergy and interaction.’

Although ArchiBlox is better known for its residential focus and custom designs, the business has its sights firmly set on the future and is expanding to offer commercial work.

Currently, the ArchiBlox team is working on an early learning childhood centre in Melbourne and a sustainable education hub, as well as resort accommodation on King Island, Tasmania. Last year, they designed and constructed a retail pop-up space tenanted by luxury ice-cream brand, Häagen-Dazs, in Melbourne’s Federation Square.

‘As awareness increases, there is market demand and we see a lot of opportunities for growth,’ Bill says.

Left: ArchiBlox managing director Bill McCorkell.

Green all over

Melbourne-based prefabrication and modular construction company, ArchiBlox, led by managing director Bill McCorkell, creates a rich variety of sustainable projects around Australia, including beach or rural houses, extensions and custom homes.

ArchiBlox’s Avalon House in NSW offers something a little different – it’s a standard prefab house project but with a lush green roof that extends the full length of the dwelling. Tying in the natural landscape seamlessly with the built form, the roof is aesthetically pleasing but also hardworking, minimising solar penetration and rainwater run-off.

The exterior features windows facing north to maximise the sun, as well as other orientations, such as east-west cross ventilation to eliminate the use of airconditioning. It also offers metallic panels that help to seal and protect the home from the ocean winds.

Inside, the house has a small footprint of 106 square metres containing two bedrooms with walk-in robes, one bathroom including a sunken bathtub, open plan kitchen, dining and living, plus a storeroom. The project uses locally-sourced wood milled from sustainable forests and other materials, including low-VOC paints and natural oils.

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