EXCLUSIVE PURCHASER OPPORTUNITY

TURN-KEY, MODULAR CONSTRUCTION SYSTEM

Manufacturing Line Machinery &
Technology User License

Contents
Introduction 3
The UB System explained

Purchaser Opportunity

UB Production Technology & Process

Intellectual Property

Plant and equipment for sale

10

UB Projects

23

Design Guide

39

Floorplan Examples

40

Contact 41

Introduction

The Unitised Building (UB) System is a state-of-the-art modular construction technology that since
2008 has been used to construct internationally recognised building projects across Australia.
Established by world-renowned Architect Nonda Katsalidis (Eureka Tower, MoNA) and developed in
partnership with Australias most innovative builders, the Hickory Group, the UB System has been
used to produce over 1,200 modular units to date across residential, remote housing and hotel sector
projects.
Independent research* has proven the UB System to offer significant advantages in construction
speed, sustainability, cost, quality and safety including:
50% faster construction times
Up to 90% less construction waste
91% more recyclable materials
Up to 90% more thermally efficient buildings
Safer, higher quality work environment on the ground floor of a factory
Numerous cost advantages from financing and finding savings to reduced project consultant
and variation costs
An unprecedented opportunity exists to purchase a complete, custom-built UB plant and equipment
kit and technology user licence to produce patented Unitised Building modules in Australia and New
Zealand.
This system is capable of producing architecturally unique, high-quality accommodation projects
of up to 15 levels, and the UB brand is internationally recognised as a leading force in advanced
modular building technology and construction innovation.

*Research conducted in partnership with the University of Melbourne and Curtin University
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The UB System explained

The UB System works by breaking down (or unitising) construction projects into transportable
modules or units which are manufactured off-site at dedicated assembly factories. Each unit utilises
a proprietary steel frame and column design which forms a box-like structure onto which internal
linings, external faades, fixtures, fittings and services are attached and installed.
The completed unit effectively forms a self-supporting, three-dimensional building block that can be
affixed to other units to form a rigid structural frame on site.
The unique nature of the UB System ensures that the interconnecting support columns on every unit
are aligned with an exceptionally high degree of accuracy. This allows units to be safely and easily
stacked together to almost any height and for external faade elements to be fully incorporated offsite.
The UB System also provides significant architectural flexibility. Each units support columns are able
to be sized and positioned to meet a wide range of structural demands and design requirements.
Units can also be shaped to suit free-form designs, can be wedge-shaped or angled, assembled in
various configurations to suit the overall building design and varied in shape to create overhangs and
cantilevers.

The UB System off-site construction phase

Core steel components &

linings

Columns sized and placed according to

structural requirements

Factory completed unit with fixtures and fittings fully installed

While the manufacturing process is underway off-site, construction works at the project site can be
progressed in parallel. The nature of these on-site works will vary by project but typically involve the
construction of a buildings lift core, basement and ground level concrete sub-structures.
The UB System recognises that buildings have elements that lend themselves to being constructed
off-site, as well as those that do not. The system does not attempt to be an exclusively off-site
construction solution and only elements that suit prefabrication are manufactured in this manner. The
system gives primacy to design flexibility over standardisation and modularity. Moreover, the layout
(or unit mix) can be varied from floor-to-floor with little impact on structure or services. Once onsite works are finished, the manufactured units can be transported to site where they are lifted into
position and affixed to one another. Depending on the configuration of the site and factors such as
traffic access, 12 to 20 units can be installed per day per crane. This allows the assembly phase of a
typical sized medium rise apartment project to be completed in 810 days (assuming only one crane
is used).
Unlike alternative modular systems, the fabricated units are shipped with final building faades
attached. Further on-site works are therefore generally limited to finishing touches such as the
final fit-out of lobby areas and the connection of each units pre-installed plumbing, electrical and
exhaust services. This will typically take a few weeks of on-site post-assembly work.
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The UB System example of on-site assembly phase

Day 0

Day 1

Existing site conditions

Manufactured components
(Concrete components in place) begin to arrive on site
Day 3

25 units in place

First 8 units installed by days

end

Day 5

40 units in place
Day 8

64 units in place

End of Day 1

Day 7

56 units in place
Day 9

68 units in place

Completed Project

Purchaser Opportunity

A unique opportunity now presents itself to purchase a turn-key manufacturing kit including plant and
production license for this ground-breaking technology.
Currently located in Brooklyn, Victoria, the manufacturing kit includes the following plant and
equipment (further details for each item on page 10):
1. Twin Head Bridge Welder / Spot Welding Machine
2. Intermediate Conveyors and Floor Side Shift Station
3. Assembly Jig #1
4. Assembly Jig #2
5. Column Welding Cell
6. 20 tonne Monorail Crane
7. Spray Booth
8. Moving Fit Out Line
9. Travelling Single Phase Power Bus Bar
10. Transport Equipment
11. Lifting Equipment for Module Installation
12. Out-feed Cranes
Together with this operational equipment a production licence will be transferred to the Purchaser
at the time of sale which will enable the Purchaser to manufacture modules in Australia and New
Zealand. The details and limitations of this licence are to be determined.
This equipment is proven to deliver multi-unit residential and hotel projects up to 9 stories high (see
project details on page 21) and can be specified for projects up to 15 levels.

UB Production Technology &

Process
The UB production process incorporates five key elements or
steps:

1. Manufacture of unit floor and ceiling

panels
The factory operates a dedicated panel line which produces
customised wall, floor and ceiling panels for unit assembly.
The current line uses the fourth generation of the UB System
technology a semi-automated bridge and MIG welding line which
produces panels out of galvanised steel sheets and purlins. The
line was custom designed and built by UB.

2. Assembly JIG
The assembly JIG is a semi-automated piece of equipment which
holds and welds the various UB panels into a complete structural
units ready for fit-out. It also incorporates a sophisticated spatial
laser system which facilitates the accurate placement of the
column structures to the units. The assembly JIG was designed
and built by UB and is a dual-sided system providing for the
assembly of two steel structural units contemporaneously. The
assembly JIG is capable of producing a complete structural unit at
the rate of approximately two per shift.

3. Fit-out
Once a structural unit is welded together, it is transported to a
separate area of the factory to be fitted out. The fit-out sequence
takes the steel structural unit to the point of a completed
apartment which is essentially ready to move in once delivered
to site with fully painted walls, carpets, tiles and with kitchens,
bathrooms and other appliances installed (according to the clients
specifications). Importantly, the accuracy of the UB technology
permits all windows and faade elements to be affixed in-factory.
This allows UB to completely finish the outside of the building
as well as the inside. This is a key competitive advantage
which UB has over other modular systems. Fit out cycles at
the manufacturing facility are currently 16 days. This compares
favourably to a typical construction site sequence of more than
100 days, leaving aside potential weather delays.
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4. Transportation and cranage

UB has designed and manufactured special lifting apparati for
its structural units. These not only provide for free movement
within the factory but also allow for simple cranage using existing
stationary and mobile cranes and for easy levelling, placement and
installation. UB s current technology for lifting allows more than 20
lifts per crane per day.

5. Installation and testing of services

All services within each unit (e.g. power, plumbing, data and TV
cable, phones) are tested in factory prior to transport in order to
ensure quality control standards and identify/rectify any defects.
UB has developed IP around the location and placement of
services and the interface of these services to the main site. These
systems streamline the requirement for on-site works and permit
practical completion of the building to be reached in significantly
reduced timeframes and with limited on-site labour.

Intellectual Property
The proprietary technology underpinning the UB System was invented by Nonda Katsalidis.
The IP associated with the UB construction methodology is held by EKCO Patent and IP Holdings
Pty Ltd (EKCO Patent), a member of the Nonda Katsalidis controlled group of companies. The UB
System is patented both in Australia and internationally.
A technology user licence will be transferred to the Purchaser at the time of sale which will enable the
Purchaser to manufacture UB modules in Australia and New Zealand. The details and limitations of
this licence are to be determined.
TBC - The Purchaser will also be granted the rights to use the various trademarks associated with the
UB System.

Plant and equipment for sale

ITEM 1: Twin Head Bridge Welder/Spotwelding Machine

This machine is fully automated and was purpose built for the automated panel production of the
Unitised Building sheet steel panels. This system is capable of producing panels 4m to 16.5m in
length and 2.4m to 5.2m wide. Positional information, weld positions and weld data is all passed into
the PLC directly from CAD software through a CSV file. The system has a pallet magazine system
that holds all of the components to produce a panel and is automatically decanted from the pallet
to the welding table using a 2 axis automated pick and place with magnets and hooks for picking
the product. The completed panel is then carried away from the welder by a 16m long dual chain
conveyor that is also synchronised with the infeed drives. The system has been welding G350
galvanised material with thicknesses ranging from 1.8mm to 4mm thick and achieving spot weld
nugget sizes between 6mm and 10mm depending on the materials.
Below is a list and a brief description of hardware that is used in this system.
Allan Bradly L45E PLC with device net communication
Allan Bradly HMI screen
Samos Pro safety controller
6 sets of safety light curtains
4 safety gate switches
Roughly 28 motors and drives all SEW
Spot welding equipment is Obara including 2 Obara tip dressers
The infeed drive has a left and right gearbox drive with 3 clamping knurled rollers on each side;
both sides are synchronistic dual drive
4 servo driven spot weld heads capable of producing one weld every 3 seconds per head
Spot weld force of up to 900kg
Weld capacity 16,000ka

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ITEM 2: Intermediate Conveyors & Floor Side Shift Station

The Structure Panel Line has a number of conveyors

Accumulation conveyor 15m long directly after the bridge welder. This conveyor is dual chain
drive with a SEW motor gearbox and drive
The next conveyor is a 15m long dual chain drive lift conveyor with around 1.5m of lift. SEW
motor gearbox and drive with 2 hydraulic scissor lifts
In front of that we have a side shifting conveyor with 2 x 15m long dual chain drives. This
conveyor shifts of line from left to right allowing line works to be carried out on the floors. SEW
motor gearboxes and drives.
Off line behind the side shift conveyor is another 15m long twin chain drive conveyor for floor
accumulation and works

11

ITEM 3: Assembly Jig #1

The first assembly jig is where the floor, walls and roof come together. This jig also has a 15m long
chain driven conveyor (hydraulically driven) which sits on 6 hydraulic scissor lifts that allow the roof to
be lifted into place. The jig is adjustable in width from 2.4m to 5m wide, this is controlled by 4 SEW
servo driven encoded motors that are all synchronistic control back to the HMI screen. It has 4 tonne
hosts for lifting the walls from horizontal to vertical. Upper platform for access.
Allan Bradly L45E PLC with device net communication
Allan Bradly HMI screen
Allan Bradly safety relays
Hydraulic power pack
4 x 1 tonne Streets hoists
6 x hydraulic scissor lifts
15m hydraulic chain conveyors
SEW motor gearboxes and drives

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ITEM 4: Assembly Jig #2

The second assembly jig is where all on the accurate location is completed; IE columns are
located and welded off, facades brackets and faade frames are fitted, balustrades are fitted and
penetrations are installed.
Allan Bradly L45E PLC with device net communication
Allan Bradly HMI screen
Allan Bradly safety relays
6 x Hydraulic lift cylinders for lifting modules out of the locators
SEW motor gearboxes and drives

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ITEM 5: Column Welding Cell

Fully enclosed welding cell with safety gate switches.
Rotator jig with SEW motor and drive, Festo pneumatics. Adjustable to suit different length
columns
Allan Bradly PLC
Allan Bradly HMI Touch Screen
Kawasaki FA20N Mig welding Robot
OTC DPCP350 Amp Pulse welder
Bulk Pack Wire Feeder

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ITEM 6: 20 tonne Monorail Crane

Mono rail overhead crane with 2x10 tonne Donit hoists controlled by a single remote pendent
Runway has a 90 degree bend, first run is approx. 47.5m long and the second run is approx.
62m long.
Also running on this beam:
-- Type: Samsung Model: KGT-S(D)1000
-- Duty Rating: 1Am M4 (Heavy Duty Classification )
Height of lift : 6 metres available
Lift speeds : 5.8 & 2.9 metres per minute.
Traverse speeds : 20 & 5 metres per minute
Two sets of lifting spreaders for different width modules with twist lock attachments

15

ITEM 7: Spray Booth

The spray booth is large enough to hold a 16m long module and is used for the priming of the steel
structure. The booth has flexible transparent curtains on each end, mounted on the jib arm that
swings out of the way for the module to pass through via the monorail crane.
Spray booth specs:
-- Depth 1.2m
-- Width 13.2m
-- Height 4m
-- Air flow 6600L/PS or .5 cubic meters per second
2 sets of transparent curtains on swinging jib arms
Full side wall on one side
4 x fans, chimneys and caps through the roof

16

ITEM 8: Moving fit out line

There are 2 moving fit out lines, once the module leaves the structure line it is then placed onto 2 sets
of skates that are adjustable to suit the module width. The line is then indexed forward by 2 x 6m
stroke hydraulic cylinders on each line, each controlled by a HMI screen. Each of the cylinders have
liner transducers to monitor the position of the modules. They also have synchronistic control to keep
the cylinders travelling at the same speed and spacers to create gaps between modules for cladding.
This line also has 600mm walkways that can be placed between modules.
Allan Bradly L45E PLC with device net communication
Allan Bradly HMI screen
Samos Pro safety controller
Hydraulic power pack with fine adjustable valves
120 Skates or 60 sets.
Walkway platforms.

17

ITEM 9: Travelling single phase power bus bar

The travelling bus bar power is a 15amp RCD protected power point that can be attached to each
module at the start of the line and will travel along with the module until it reaches the end of the line.
Once it has reached the end of the line the overhead track transfers to a return track and the power
point can be returned to the start of the process to be attached to another module. There is enough
points to be attached to each of the modules on each of the fit out lines. This is a great system for
overcoming the OHS issues of having power leads sprawled across the ground.

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ITEM 10: Transport Equipment

The UB system is transportable via road or sea and comes with all necessary transport equipment
including twist lock spreaders to fit onto the drop deck extendable 75 beams that the modules sit on.
Shipping & transport equipment includes:
Starter base plates for the bottom of the hull
Module tie plates for stacking 4 modules high
Lashing points
Crane lifting boxes for all of the above items

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20

ITEM 11: Lifting Equipment For Module Installation

The system also comes with the lifting frames/ jigs for installing the modules on site. The lifting jigs
are adjustable and connect to either the top of the columns by a twist lock or by use of a panel clutch
attached to a lifting point on the bottom ring beam of the module.

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ITEM 12: Out-Feed Cranes

Out feed cranes (20 tonne total)
2 x 7 meter span beams (10 tonne each with 2x5 tonne hooks on each beam)
Runway lengths 72 meters
Cranes are controlled by a Flex remote pendent with the ability to control each beam
separately (1 hook or 2 hooks together or all 4 hooks at the same time)

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UB Projects
UB successfully constructed and delivered its first building project in June 2010 a 9-storey
apartment complex in Russell Place, Melbourne CBD known as Little Hero. Acting as subcontractor to Hickory, UB was responsible for the manufacture of all 63 apartments in the complex,
which comprised a mix of one- and two-bedroom apartments and several duplex penthouses.
Utilising the UB System for all residences (which required the manufacture and fit-out of 75 individual
UB units), UB was able to deliver this project on time and on budget whilst facilitating an estimated
4050% reduction in the overall duration of the projects construction timeline.

UB1 Little Hero Project in Melbourne CBD

Original Concept Design (left) & Completed Building(right)

On the back of the success of the Little Hero project, UB was awarded contracts for an additional
three buildings in Victoria during the same year, representing 630 units (355 apartments) and
revenues of over $46 million.
The largest of these projects was The Nicholson, a 199-apartment building in Coburg, developed
by VicUrban. The Nicholson is a significant milestone in UBs early history a complex building with
multiple structural elements, detailed and innovative faades and numerous complexities in roof
detail. Significantly, this building was designed completely without regard to the UB System a
testament to the flexibility of the system to interpret and reflect ultimate architectural design.
Following the successful delivery of the first 4 residential Melbourne metropolitan projects, UB was
awarded a 240 room hotel project in Port Hedland, WA. The hotel was manufactured in 2012,
however not delivered to WA as intended due to the developer falling into financial difficulty. The
project was repurposed by UB and utilised by Asian Pacific Group as a 128 room Art Series hotel in
Bendigo, adjacent to an extensive new hospital project.
UB has also been used to construct the 3:East apartment project in Richmond, comprising 57
apartments, the One9 development in Moonee Ponds Victoria, a 9 level building erected in site in 5
days, and several other projects in Perth, Port Hedland and Karratha, WA.

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UB1 Little Hero Project

Off-site Manufacture

24

UB1 Little Hero Project

Delivery to Russell Place

25

UB1 Little Hero Project

Assembly at Russell Place

26

UB1 Little Hero Project

Project Completion

27

watch project video

The Nicholson - East Coburg

A Design Inc. creation, in
conjunction with Places
Victoria, The Nicholson
contains 110 privately
owned apartments,
58 National Building
Housing Initiative social
housing apartments
and 31 affordable rental
apartments
Average 6 star energy
efficient apartments
all feature a number of
sustainable innovations.
Winner of the Urban
Design Institute of
Australia Award for
Excellence

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Pegasus Apartments Mitcham

Suburban multi-residential
project in Mitcham, 20
minutes from Melbourne
CBD
D
esigned by Nonda
Katsalidis
5
0 apartments across
two integrated buildings

29

Centvm - Preston

D
esigned by BBP
Architects, Centvm is a
Bensons Group project
comprising a total of
109 apartments
Comprises 3 five storey
high buildings made up of
219 UB modules
Meets a minimum BCA
5-star standard rating for
energy and efficiency

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watch project video

3:East - Richmond
5
7 apartments (comprising
63 UB modules) installed
on site in just 11 days
U
sing UBs parallel track
building technology
dramatically reduced
disruption to the local
community during
construction in this busy
inner city suburb

31

UB Onsite (3:East)

32

Port View Port Hedland WA

L
ocated in Port Hedland
overlooking the Indian
Ocean, Port View
apartments offers 21 one
bedroom apartments
F
ully finished in UBs
Melbourne factory and
transported across the
country to WA
F
irst project in Western
Australia to use the UB
system

33

watch project video

The Schaller Studio - Bendigo

1
28 room Art Series Hotel
in regional Victoria erected
in just 6 days.
66 modular units used
4 level project comprising
in-situ ground floor lobby
and restaurant and 3
levels of modular hotel
rooms.

34

watch project video

One9 - Moonee Ponds

9
level building installed in
just 5 days
Project featured on
numerous international
design blogs and journals.
Comprises 34 modern
one and two bedroom
apartments fitted with
timber floors and bolt-on
balconies.

35

UB Onsite (One9)

36

Concorde South - South Hedland WA

6 level apartment building
in regional WA featuring
1, 2 and 3 bedroom
apartments.
108 UB modules
complexed across 77
apartments.
All modules installed on
site in just 8 and a half
days.

37

watch project video

Adara Apartments - Success WA

Department of Housing
project featuring 77
apartments over 6 levels.
Comprises 96 modules
manufactured in
Melbourne and delivered
by road to WA.
Includes apartments
offered under the National
Rental Affordability
Scheme and the WA
Shared Equity Scheme.

38

Design Guide
Whilst some maximum spacial paramenters apply, the UB system does not have fixed module sizes
or layouts, and is suitable for a range of low to medium-rise projects including:
Apartments
Hotels
Remote mining & resource villages
Student accommodation
Aged care accommodation
Healthcare projects
Having delivered 16 separate projects and documented design typolgies and detailed schemes for
dozens more, a part of this sale will include the provision of a detailed design guide containing sample
module layouts, floorplates and parametric models.

UB System Spatial Parameters

ITEM

VALUE

Maximum Overall Unit Length (including faade)

16.4 m

Maximum Unit Width (including faade)

5.45 m

Maximum Unit Square Meterage (gross)

74.0 m2

Minimum Unit Width (column centre to column centre)

3.0 m

Maximum unit height for transportation

(from bottom of column plate to absolute top of unit)

3500 mm

Typical bulkhead/low ceiling height (SFL to underside of lining)

2400 mm

Maximum area of openings in side wall panel

max 45% of wall length

Max single opening in wall with no additional structure

3m (Subject to engineering
check)

Unit weight
Average unit/no side wall/no roof per m2

280kg/m2

Roof structure and deck

+ 1 tonne per unit

Side wall cladding

+1 tonner per unit

39

Floorplan Examples
APARTMENT

REMOTE ACCOMMODATION

HOTEL

40

Contact
To enquire about this exclusive opportunity,
contact Todd Chadwick, Production Manager.
M: +61 407 597 633
E: t.chadwick@hickory.com.au

Hickory Group

101 Cremorne St
Richmond VIC 3121
T: +61 3 9429 7411
F: +61 3 9428 7376

hickory.com.au

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