Case Study: Hickory Building Systems' Holiday Inn Express Project

This report provides a comprehensive case study of the Holiday Inn Express Project, constructed by Hickory Building Systems using prefabrication methods. The project, featuring 245 hotel rooms, offices, parking, and retail space, highlights the benefits of prefabrication in terms of speed, sustainability, and safety. The report details the characteristics of Hickory Building Systems, the project's description, and the prefabrication process, including the use of steel structures, sync bathroom pods, and a proprietary façade system. It examines the problems encountered, such as sophisticated connections and structural limitations, while also emphasizing the innovations implemented, like the proprietary façade system for ventilation and energy efficiency, and sync bathroom pods to reduce defects and construction time. The outcome section discusses the positive impacts of these innovations, including reduced waste, improved quality, and cost-effectiveness. Finally, the report suggests potential improvements for the sync bathroom pods, such as integrating them into prefabricated bathrooms for enhanced buildability and efficiency.

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HOLIDAY INN EXPRESS PROJECT
By Name
Course
Instructor
Institution
Location
Date

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EXECUTIVE SUMMARY
Hickory Building Systems is a family-owned company to one of the preeminent construction
groups in Australia and has steadily evolved since 1991. Holiday Inn Express Project is the
prefabrication project that was constructed by the Hickory Building Systems with 245 hotel
rooms and also provides 3 levels of offices, 3 levels of above ground parking, and ground floor
retail. Prefabrication construction method allows Hickory Building Systems to deliver hotel
project more sustainable, faster, and safer. The two major innovations incorporated during the
construction of the Holiday Inn Express Project were Sync bathroom pods and proprietary façade
system which be improved through incorporating these bathroom pods in a pre-fabricated
bathroom which will ensure high buildability and better quality of bath pods.

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Table of Contents
EXECUTIVE SUMMARY.................................................................................................................................2
INTRODUCTION...........................................................................................................................................3
1.1 Characteristics...................................................................................................................................4
1.2 Project Description............................................................................................................................4
1.3 Prefabrication Construction Process of Holiday Inn Express Project.................................................5
2.0 PROBLEMS.............................................................................................................................................6
2.1 Sophisticated Connection..................................................................................................................6
2.2 Prefab Limitations..............................................................................................................................7
2.3 Structural Issues................................................................................................................................7
3.0 INNOVATIONS........................................................................................................................................8
3.1 Proprietary façade system.................................................................................................................8
3.2 Sync bathroom pods..........................................................................................................................9
4.0 OUTCOME..............................................................................................................................................9
5.0 POSSIBLE IMPROVEMENT ON INNOVATION........................................................................................11
6.0 CONCLUSION.......................................................................................................................................12
7.0 ACKNOWLEDGMENT...........................................................................................................................12
8.0 BIBLIOGRAPHY.....................................................................................................................................13

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INTRODUCTION
This research paper is about a case study of Holiday Inn Express Project that was consulted,
designed, manufactured, and installed by Hickory Building Systems. This case study majorly
focuses on the characteristic of Hickory Building Systems, Holiday Inn Express Project
description, problems encountered by the construction company, various innovations
implemented in the project, the benefits realized by the innovations, and the possible
improvements that can be made on the innovations. Holiday Inn Express Project was one of the
modern construction projects constructed by the Hickory Building Systems through the process
of prefabrication. Prefabrication process involves the manufacture of building units in the
company through fabrication or assembling, then transportation of the units to the site, and the
assembly of the units to form the complete project.
1.1 Characteristics
Hickory Building Systems is a family-owned company to one of the preeminent construction
groups in Australia and has steadily evolved since 1991. This construction company has gained
reputations as a dynamic and innovative company that has grown into a nationwide group of
crane logistics specialists, fit out, manufacturing, facades, structures, and construction. Hickory,
as an integrated construction with employees over 550, provides clients with best for projects by
partnering with suppliers, subcontractors, and clients to ensure the most efficient and effective
solution to attain the objectives. Prefabrication construction method allows Hickory to deliver
the project more sustainable, faster, and safer (Anon., 2019).
Less labour and time is normally used during the process of prefabrication compared to the
traditional in-situ method. Majority of the work performed in a controlled company environment
improves safety by minimizing work at heights, reduces downtime because of inclement
weather, and improves quality. Site logistics are also improved since most of the construction

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materials are delivered to the fabrication point, hence resulting in less onsite storage requirement,
improved vertical movement, and better trade coordination on site. Hickory Building Systems is
involved in numerous projects majorly residential, commercial, high-rise, sync modular
bathrooms, fit out and refurb (Anon., 2019).
1.2 Project Description
Holiday Inn Express Project is the prefabrication project that was constructed by the Hickory
Building Systems and is expected to be the tallest hotel on Australia to use fast-track
construction of Hickory Building Systems. This hotel project has 245 hotel rooms and also
provides 3 levels of offices, 3 levels of above ground parking, and ground floor retail. The initial
8 levels of the project used in-situ and conventional construction method and level 8 to 22 were
constructed using Hickory Building Systems which was attained through sync bathroom pods,
proprietary façade system and structural prefabrication (Anon., 2019).
Figure 1: Holiday Inn Express Project (Anon., 2019)
Steel was used in prefabrication purposes since steel is a flexible material which can be formed
into numerous shapes such as building beams and columns. The prefabricated steel members

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come in different sections and sizes. Prefabricated steel structures were then assembled easily
using welding methods or bolts after being delivered to the construction site (Yun, et al., 2013).
Since they are being manufactured from the company, metal panels system were erected quickly
onsite hence saving money and time. Steel cladding is a prefabricated material for finishing
which comes in numerous colours, surfaces, and sizes (Zhong, 2013).
1.3 Prefabrication Construction Process of Holiday Inn Express Project
The prefabrication system was used for faster production of design and the method is also
economical. Prefabrication steel which was manufactured by the Hickory Building Systems in
the factory before being distributed to the construction site. These panels were manufactured
from various thickness of two layers depending on the framing. The prefabricated modules came
with fixtures, interior finishes, and mechanical system after being built in the factory and then
delivered to the construction site (Zou, et al., 2014). These modular units were designed and built
using standardized dimension and system which made it easy for mass production. Since the
modules were pre-made, there were difficult to change or modify the design.
Figure 2: Assembly process of prefabricated structures (Zhao, 2014)

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With steel modular units, the roof and wall frames were constructed using track and stud
connection method, whereby sections are combined together by the use of rivets, self-drill
fasteners, bolts, and tap fasteners. The roofing of the Holiday Inn Express Project was made from
prefabricated steel, however, those steel required onsite installation. The workers connected the
steels by the use of bolts and then installed roof tiles (Wang, 2014).
2.0 THE PROBLEMS
2.1 Sophisticated Connection
The behaviour of connections determines the performance of prefabricated steel structures.
During the assembly of prefabricated steel structures in the Holiday Inn Express Project, the
connections between the prefabricated steel structures were very complicated due to intense
workforce and supervisions required. Well trained and skilled labours were required to ensure a
proper connection is realized during the erection stage resulting into additional cost. The
structural behaviour of module assembly is complex due to the effect of the tolerances in the
installation procedure, the manner in which forces are transferred to the stabilization elements
like core walls and vertical bracing, and also the numerous interconnections between the
prefabricated modules (Amtered & Ezanee, 2015).
2.2 Prefab Limitations
There were some structures of the projects such as floor plans that can be customized, however,
there are numerous limitations that are inherent to the transportation and manufacturing
processes. The individual pieces of prefabricated steel structures were limited in width to 16 to
14 feet. Majority of prefabricated steel structures are limited to two stories due to the restrictions
in transportation. These dimensions and sizes restricted the designs of an open floor plan and
wide rooms. The logistics in transportation of prefabricated steel also posed series problems
during the construction of the project. There was a need for adhering to the transportation

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regulations for weight and size loads, and escort vehicles and special permits were required
during the transportation of oversize modules (Amtered & Ezanee, 2015).
2.3 Structural Issues
The major structural issues that were faced during the construction of the Holiday Inn Express
Project was the restricted changes in the design plans during the construction process. It was not
possible to make any changes in the initial design since the structures were already prefabricated
hence reduced the flexibility of the building design. There was also a problem faced by Hickory
Building Systems in finding an economical and reliable method of joining prefabricated steel
structures (Zou & Zhou, 2011).
3.0 INNOVATIONS
3.1 Proprietary façade system
Façade is used to refer more specifically to external faces of the structure that have a specific
architectural emphasis like the main building entrance, decoration, and design. The proprietary
façade system of the Holiday Inn Express Project was one of the major innovations made by the
Hickory Building Systems during the construction of the project. The façade of the project acts
as a significant aspect of the design standpoint from the design perspective. The façade is also a
significant part of the project since it increases the energy efficiency of the building. The
proprietary façade system of Holiday Inn Express Project was suspended from the concrete floor
slab and also have a fire-resistance rating (Vatin, et al., 2015)

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Figure 2: Proprietary façade system (Anon., 2019)
The proprietary façade system was designed in the building for the purposes of ventilation, heat
control, and sun control.
3.2 Sync bathroom pods
The Sync bathroom pods are also one of the innovations made by the Hickory Building Systems
during the construction of Holiday Inn Express Project. These Sync bathroom pods are built in
the factory setting and provide fewer defects. This offsite method of construction enables the
Sync bathroom pods manufacturers to implement and research functional and aesthetic
functional innovations to improve the quality of bathroom pods. The use of Sync bathroom pods
reduced the cost of construction by eliminating the bathroom defects, improving quality, and
reducing construction time (Anon., 2019). https://www.hickory.com.au/what-we-do/our-
systems/sync-bathrooms

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Figure 3: Sync bathroom pods (Anon., 2019)
In traditional building construction, numerous trades need to be organized to attain the required
bathroom design. This requires a high level of management and supervision on site to make sure
that quality and supervision is correct from carpenters, glaziers, decorators, sealant applicators,
floor layers, tilers, electricians, and plumbers (Anon., 2019).
4.0 OUTCOME
The application of Sync bathroom pods during the construction of Holiday Inn Express Project
reduced the level of issues related to waste and improving the quality of result in better
performance and less snagging. As architects and construction managers become more
comfortable with prefabrication as well as its application areas, the Sync bathroom pods have
become more effective at delivering more profitable outcome and higher quality compared to
conventional onsite buildings. The Sync bathroom pods innovation also resulted in less wasteful
compared to conventional forms of construction since the waste materials in this methods was
about 1.5% compared to the traditional construction wastes which are about 7% (Drean, et al.,
2018).
Sync bathroom pods cost the same as site-built bathrooms on the basis of direct cost. This alone
is an important value since Sync bathroom pods are designed to a much higher quality level

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which cannot be attained in the on-site bathroom pods. The operation of the factory also about
250% more efficient compared to the same activities performed on-site (Anon., 2019).
The installation of proprietary façade system also resulted in numerous positive impacts to the
Holiday Inn Express Project. The proprietary façade system helps in reducing the energy
consumption of the hotel by offering better airflow and improving natural lighting hence making
this structure clad the building easy and functional on the eye. This structure also helps in
reducing the energy bills significantly by reducing solar gains which in turn minimizes the
cooling loads of the structure which definitely result in low energy bills (Cardoso & Jalali,
2014).
Unfortunately, the construction of proprietary façade system accounted for approximately 21%
of the entire project construction cost. The design of proprietary façade system also defines the
feel and sets expectations of the entire structure by displaying the values about transparency and
trust of the hotel. The structure also protects the occupants of the hotel from rain and wind and
extremes humidity and temperature. The help in resisting corrosion, weathering, and
temperature. This proprietary façade system also essentially acts as the external skin of the
structure and is attained through mechanized windows, cavity skins, and design aspects (Deniz &
Dogan, 2014).
5.0 POSSIBLE IMPROVEMENT ON INNOVATION
One of the ways in which the Sync bathroom pods can be improved is through incorporating
these bathroom pods in a pre-fabricated bathrooms which will ensure high buildability, better
quality of bath pods, reduced network, improved productivity of labour on site, low wastage of
materials, and higher quality finishes (Bin & Duan, 2014).

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Figure 4: Pre-fabricated bathroom with Sync bathroom pods
The bathroom is an indispensable section of the building and the traditional method of bathroom
construction on site entails numerous labour intensive building trades such as accessories
installation, electrical works, sanitary, plumbing, finishes, waterproofing, and blockwork. The
prefabrication of bathrooms and Sync bathroom pods proved to be labour intensive. The
prefabricated bathroom unit refers to a bathroom unit preassembled off-site complete with
bathroom cabinets, Sync bathroom pods, ceiling, conduits, concealed pipes, sanitary wares, and
finishes (Deniz & Dogan, 2014).
6.0 CONCLUSION
This case study of Holiday Inn Express Project that was consulted, designed, manufactured, and
installed by Hickory Building Systems majorly focuses on the characteristic of Hickory Building
Systems, Holiday Inn Express Project description, problems encountered by the construction
company, various innovations implemented in the project, the benefits, and the possible
improvements that can be made on the innovations. This hotel project has 245 hotel rooms and
also provides 3 levels of offices, 3 levels of above ground parking, and ground floor retail.
Holiday Inn Express Project was one of the modern construction projects constructed by the

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Hickory Building Systems through prefabrication process. Prefabrication construction method
allows Hickory to deliver the project more sustainable, faster, and safer. The major innovations
incorporated during the construction of this hotel were Sync bathroom pods and proprietary
façade system.
7.0 ACKNOWLEDGMENT
I wish to take this opportunity to thank Holiday Inn Express for their newsletters and online
supports which assist in information gathering especially information relating to the various
sections of the hotel and materials used in its construction. I would also wish to thank Shan
Kumar, Chief Engineer Hickory Building Systems for a brief description of the company as well
as information relating to the construction of Holiday Inn Express project.
8.0 BIBLIOGRAPHY

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Amtered, K. & Ezanee, F., 2015. Motivations and Limitations of Prefabricated Building: An Overview.
s.l.:Applied Mechanics and Materials. Vol 802. pp. 668-675.
Anon., 2019. Architectureanddesign.com.au. s.l.:Architectureanddesign.com.au.
Anon., 2019. Hickory Building Systems > Hickory Group. s.l.:Hickory.com.au.
https://www.hickory.com.au/what-we-do/our-systems/hickory-building-systems
Anon., 2019. Hickory Group. s.l.:Hickory.com.au. https://www.hickory.com.au/
Anon., 2019. Sync Bathrooms > Hickory Group. s.l.:Hickory.com.au.
https://www.architectureanddesign.com.au/getmedia/bc7dfeae-10bd-4ce1-828c-c16f9d0bb20a/Sync-
Bathroom-Pod-Technology.aspx
Bin, S. & Duan, L., 2014. The Development of Prefabricated Concrete Structures. s.l.:Applied Mechanics
and Materials. Vol 680. pp. 81-84.
Cardoso, C. & Jalali, S., 2014. Thermal Performance Characterization of a Modular System for Facade.
s.l.:Key Engineering Materials. Vol 634. pp. 62-71.
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Architecture and Civil Engineering. Vol 8.
Drean, V., Schillinger, R. & Auguin, G., 2018. Assessment of an insulating air layer model of façade
external system: contribution to fire simulation of facade performance fire test. s.l.:Journal of Physics:
Conference Series. Vol 1107. pp. 420.
Vatin, N., Nemova, D. & Marinenko, D., 2015. Characteristic and Application of Facade System
‘Polialpan’. s.l.:Applied Mechanics and Materials. Vol 725. pp. 80-86.
Wang, J., 2014. Based on RFID Prefabricated Building Component Design and Monitoring System
Research. s.l.:Advanced Materials Research. Vol 983. pp. 359-362.
Yun, W., Chen, D., Yang, X. & Chen, S., 2013. Finite Element Analysis about Temporary Bracing of
Prefabricated Column of Prefabricated Structure. s.l.:Applied Mechanics and Materials. Vol 275. pp. 275-
277.
Zhao, H., 2014. Features and Construction of Prefabricated Buildings. s.l.:Applied Mechanics and
Materials. Vol 580. pp. 2262-2265.
Zhong, X., 2013. Prefabricated Buildings Selective Disassembly Strategy. s.l.:Advanced Materials
Research. Vol 639. pp. 1265-1268.
Zou, L. & Zhou, X., 2011. Study on Bearing Capacity Assessment of Prefabricated RC Slab Bridges.
s.l.:Advanced Materials Research. Vol 253. pp. 1750-1754.
Zou, Y., Lin, H. & Qiang, W., 2014. Analysis on Self-Centering Capacity of Prefabricated Frame Joints.
s.l.:Applied Mechanics and Materials. Vol 580. pp. 1471-1476.

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