In the construction world, it is hard to keep promises as the way the construction industry operates. Silo thinking is widespread and there are many unknown unknowns resulting from on-site works. Also, time and budget overruns are very common… However, off-site construction largely eliminates the above problems. Through integrated design and manufacturing, OCCA can deliver projects on time and on budget. OCCA is one of those companies that can deliver off-site projects by utilizing different off-site construction techniques
East Broadway Residences
Project Description: 7 storey residential building with 10 apartment units.
Type of Offsite Construction: Volumetric Modular Offsite
Location: Lower East Manhattan, New York City.
Status: Under production
The building consists of 63 volumetric modules and site-built cellar and podium. OCCA Offsite designed and manufactured all volumetric modules:
- Completed %50 of Design Development stage,
- Assumed full responsibility over Construction Drawings phase,
- Collaborated with the Architect of Record (AoR), Engineer of Record (EoR) and Building Code Consultants for ensuring code compliant design and material selection,
- Coordinated structural, architectural, MEP design disciplines through Autodesk’s REVIT 3D design software,
- Prepared Bill of Materials (BOM) through submittals,
- Developed fully coordinated 3D manufacturing drawings per each module,
- Procured MEP materials & Rough-ins locally or internationally,
- Managed inbound and outbound logistics,
- Provided built-in fully finished kitchens, bathrooms, window frames, glazing and doors,
- Except vertical MEP shafts, installed 90 % of mechanical, electrical and plumbing items,
- Manufactured and design a core module that incorporates staircases and elevator shaft,
- Designed and manufactured lifting frames for loading and unloading operations at all phases of door-to-door delivery
MATAM Earthquake Research Center
Project Description: İTÜ MATAM Earthquake Research Center
Gross Building Area: 2.640 m²
OCCA’s scope: Architectural design, project management, façade panels manufacturing
Type of Offsite Construction: Hybrid Modular Offsite, prefabricated façade panels
Location: Istanbul, Turkey
Project Completion Time: The project was completed within a total construction period of 9 months, representing a reduction of at least 50% compared to conventional on-site construction methods. Moreover, it holds the distinction of being the first office building in Turkey to be delivered using this innovative approach.
In addition, the installation of the façade panels by OCCA was successfully completed in just 13 days, a timeframe that can be considered record-breaking.
The MATAM Earthquake Research Center was commissioned by Istanbul Technical University with the purpose of producing three-dimensional maps of active and/or previously unidentified fault lines in the Marmara Region through use of state-of-the-art technology and data. This will enable the continuous, up-to-date, and quantitative assessment of potential hazards and risks during an earthquake.
The Project is very pivotal for national safety, disaster preparedness, and long-term resilience and the data that will be generated will help local authorities and urban planners make well-informed decisions concerning urban regeneration projects as well as infrastructural projects.
İŞBANK (www.isbank.com.tr) one of the leading banks of Türkiye, motivated to get involved with the Project by the conviction that it could contribute to mitigating potential human and material losses during earthquakes in Marmara Region which as a region represents 45.47% of Türkiye’s Gross National Product.
The construction project was tendered by İŞBANK on a design-and-build basis, and the winning contractor was also required to implement all necessary measures in the design, manufacturing, and assembly processes to minimize the overall construction duration.
Throughout the design, manufacturing, and assembly phases, maximum coordination was ensured between the design and implementation teams, and the following measures were taken to enable the rapid construction of the building:
- The number of components in the structural steel fabrication was minimized through measures implemented during the design phase,
- Two-hour fire protection for all steel columns and beams was provided by factory coated intumescent paint,
- Ready to be installed OCCA Panels were fabricated at the factory concurrent with steel fabrication so that both fabrication would overlap,
- The installation of mechanical systems inside the building commenced immediately after the roof installation was completed, without waiting for the façade installation to be finished
Automotive Plant Offices
Project Description: Ford Motor Company Parts Manufacturing Facility with 500.000 sq. ft. covered area
Gross Building Area: 54900 m²
OCCA’s scope: Design, manufacture and installation of façade of office building, approximately 10.000.- sq. ft., that will serve the Manufacturing Facility
Type of Offsite Construction: Hybrid Modular Offsite, prefabricated façade panels
Location: Kocaeli, Turkey
Status: Completed
The façade consists of 49 prefabricated hybrid offsite panels, unusually large in size, reaching up to 41 feet in length, and panels have continuous thermal insulation and continuous air barrier.
The installation is completed within 15 working days, a record breaking speed.
The final layer of façade is coated with an intelligent paint that provides optimum resistance to weathering and protection against algae and fungi, in turn it keeps facades vibrant and beautiful under harsh climate conditions.
Saylak Primary School
Project Description : PwC TEV Saylak High School
Gross Building Area : 2.150 m²
OCCA’s scope : Architectural design, project management, design and manufacturing of OCCA façade panels
Type of Offsite Construction: Hybrid Modular Offsite, prefabricated façade panels
Location : Kırıkhan, Hatay, Turkey
Project Completion Time: From start to finish, the Project was completed in 6 months, unprecedented duration for a project especially compared to that of site built.
Façade installation took just 18 days to finish, another record time.
As a result of the February 6, 2023 Earthquake, Kırıkhan district in Hatay was among the most severely affected settlements. The district center was almost completely destroyed, and many educational institutions became unusable, making the rapid construction of new school buildings a necessity.
TEV (www.tev.org.tr) and PwC(www.pwc.com.tr), Turkish branch of one of the leading global consultancy company, initiated efforts to construct a new high school building in Kırıkhan as a donation to Ministry of Education of Türkiye.
In the aftermath of the Earthquake, the near-total destruction of Kırıkhan’s infrastructure posed substantial challenges to the construction process, requiring comprehensive planning and adaptive solutions.
Through OCCA’s use of off-site construction techniques in the design, manufacturing, and assembly processes, Kırıkhan High School was completed in a record time of just six months.
The key factors that enabled the rapid construction of the building are as follows:
- The building structure was designed using structural steel, thereby minimizing the assembly time of the main structure.
- The façade was designed with OCCA Panels, and their production was initiated simultaneously with the structural steel works.
- Roof skylights, staircases, railings, and similar building elements were manufactured in the factory and delivered to the site ready for installation, significantly reducing on-site works.
- Thanks to the 3D design software utilized by OCCA, all potential coordination issues on site were identified and resolved in advance.
Çakı Primary School
Project Description: PwC TEV Çakı Primary School
Gross Building Area: 490 m²
OCCA’s scope: Architectural design and coordination, project management, design and manufacturing of façade panels
Type of Offsite Construction: Hybrid Modular Offsite, prefabricated façade panels
Location: Yayladağı, Hatay, Turkey
Project Completion Time: The project was constructed in just 4 months, which can be considered a record time.
Façade installation is completed in 7 days, again a record time for façade installations especially as compared to site built façades.
Çakı Primary School was donated by the Turkish Education Foundation(www.tev.org.tr) and Price Waterhouse Coopers (www.pwc.com.tr), Turkish branch of one of the leading global consultancy company, to Ministry of Education of Türkiye.
Yayladağı is a district of Hatay Province and is the geographically southernmost district of Türkiye that has a border with Syria. Çakı is a small village of Yayladağı, remotely located on the hills of Samandağı Mountain.
The Project posed many challenges in terms of logistics and construction such as the narrow road conditions that made it unfeasible to deliver construction materials by trailers or to perform concrete pouring using a mixer truck.
Under the Design & Build framework, OCCA incorporated these challenges into its work from day one, shaping both the design and the execution accordingly.
The Project was completed in record time of 4 months from start to finish due to utilization of offsite construction techniques such as use of three-dimensional design software programs as well as prefabrication of façade panels in the factory and prefabricated steel structure. By doing so the project duration was minimized, site works were eliminated, site safety was improved and superior building finish was achieved.
Kırıkhan Student Accommodation
Project Description: Kırıkhan Student Accommodation
Gross Building Area: 3000 m²
OCCA’s scope: Architectural design, project management, façade panels manufacturing
Type of Offsite Construction: Hybrid Modular Offsite, prefabricated façade panels
Location: Kırıkhan, Hatay, Turkey
Status: Completed
Following the devastating earthquake on February 6, 2023, Kırıkhan in Hatay faced widespread destruction, with much of its infrastructure and educational facilities rendered inoperative. The scale of the damage made it imperative to plan carefully and implement adaptive construction strategies to quickly provide new, functional student accommodation buildings for the community.
Kırıkhan Student Accommodation project showcases OCCA’s expertise in hybrid modular offsite construction. Covering 3,000 m², the project combines modern architectural design with prefabricated façade panels, allowing for efficient construction and high-quality results. OCCA handled the full design, project management, and panel manufacturing, delivering a functional, durable, and visually appealing student housing facility.
Grand Street Residences
Project Description: 6 storey residential building with 12 apartment units
Type of Offsite Construction: Hybrid Offsite, including superstructure, bathroom pods and façade panels.
Location: Lower East Manhattan, New York City.
Status: Design phase
Building is manufactured and designed as three main components; super structure, bathroom pods and facade panels:
- Designed and prepared all of the on-site construction and off-site manufacturing documents,
- Managed all material procurements including both off-site and on-site installed materials,
- Ensured fully code compliant design and manufacturing through close collaboration with EoR and AoR,
- Procured materials after getting approvals through RFis and submittals,
- Coordinated design teams,
- Prepared Bill of Materials (BOM)
- Developed fully coordinated 3D manufacturing drawings for bathroom pods and façade panels,
- Assumed full responsibility over inbound and outbound logistics of Hybrid Construction components including bathroom pods, façade panels and steel structure,
- Prepared project budget and project timeline,
- Supervised on-site installation of building components, procurement of on-site materials and supervised subcontractors at site.