From Volume 2 Issue 1 of Connected.
Terms like ‘prefabrication’ and ‘modular’ have recently been gaining popularity in the construction industry. These terms can often be heard in the same sentence, but what do they mean? Milwaukee Tool writes, “The distinction lies in singular components vs. whole modules, ‘flat’ pieces vs. Complete enclosures.” Both methods build components offsite which are then delivered onsite for installation — but there are key differences. Prefabricated parts are singular components, or flat pieces, while modular items are entire complete enclosures, or closed spaces. An example of prefabricated construction would be a wall panel, while modular construction would be an entire room.
Prefabrication has been around for centuries and first became available in the United States in the late 1830s. Autodesk reports that during this time, the Gold Rush was sweeping the nation and settlers needed homes quickly. These revolutionary, prefabricated homes, or ‘kit houses’, were quickly completed and shipped by railroad to settlers. Prefabricated homes continued to advance and by 1908, companies like Sears had more than 370 ready-to assemble kit house designs that were sold through mail order, according to National Parks Services. In the 1940s and 50s, Kirby Risk Electric Company worked directly with National Homes to supply the electrical needs for thousands of houses and assembled approximately 200 electrical packages a week.
By the 1960s, a large wave of modular homes and buildings were being produced. With a significant increase in the need for housing, modular construction had taken the world by storm. Homes, offices, schools and more were being built with two main modular construction types. Blackridge Research describes these construction types as Permanent Modular Construction (PMC) and Relocatable Building (RB). PMC can standalone, be added on to an existing building or integrated into a project as a turnkey solution. RB is a quick, temporary solution that can be moved to multiple locations when extra space is needed.
HOUSING MARKETING IMPACT
Prefabrication and modular construction methods have been used for decades and are now being heavily utilized in building methods. These techniques have become more vital than ever when dealing with today’s housing market. There are stark differences when comparing the housing market from the 1960s to now. In the past, home builders were able to keep up with demands — even as numbers of houses built increased by 76%, reports Los Angeles Times.
The housing market has been a continuous issue for the past two years and only threatens to continue. With fewer homes available for purchase and too many buyers willing to pay well over the asking price — home prices have skyrocketed. This housing shortage leaves potential home buyers across the U.S. with very few options. To combat this issue, many companies are turning to modular or prefabricated homes and buildings to keep up with demand.
PREFABRICATION SOLUTIONS
The shortage of skilled workers has posed many challenges in the construction industry, especially with project schedules. To meet these tight deadlines, contractors have been turning to companies like Eaton for innovative solutions. Eaton’s Crouse-Hinds & B-Line Division has a line of prefabricated products specifically made to increase electrician efficiency and installation speed on the jobsite. In commercial buildings with repetitive layouts such as hotels or hospital rooms, these prefabricated solutions are highly effective. “Data shows at least eight minutes saved by rough-in crews per installed assembly on a typical hotel over traditional ‘stick-build’ wiring methods for greatly improved job site efficiency,” reports Eaton.
Electrical construction company Gaylor Electric has been utilizing fabrication methods to increase their project efficiency and employee safety. Wayne Manwaring, Gaylor Electric’s Vice President of Engineering and Innovation comments, “Over the years, I have seen first-hand how technology has transformed the industry. The innovations we employ today have improved the practicality, safety and productivity of electrical construction. Our methods reduce work time and eliminate jobsite safety hazards — that alone is groundbreaking for an industry like ours.”
Compared to traditional building methods, prefabrication and modular construction saves time, is environmentally friendly, provides increased safety for workers and is more cost effective.
Saves Time
“Modular building projects can be completed 30% to 50% quicker than traditional construction,” Fortune Business Insider reports. Prefabrication can also reduce project completion time up to a third while increasing schedule certainty to nearly 90%, according to Dodge Data & Analytics.
Environmentally Friendly
Prefabricated or modular homes and buildings are more ecofriendly compared to the traditional method of building. Prefabrication and modular construction methods rely heavily on materials that have been recycled or are sustainable. According to C.D. Smith Construction, “Prefabrication provides precise measurements, preventing material waste. Furthermore, unused raw materials can be recycled into other prefabricated materials.” Prefabrication and modular techniques also can greatly reduce emissions and energy consumption. BigRentz writes, “Modular construction can reduce total deliveries to building sites by 90%, greatly reducing emissions… energy usage is optimized using machine learning to create an environmentally sound building process, and shorter construction times result in lower on-site energy expenditures.”
Worker Safety
According to Dodge Data & Analytics, 86% of survey respondents cited an overall safety increase by utilizing prefabrication or modular construction methods. By building in a controlled environment, the chance of workers getting hurt while on the job is drastically reduced. “Not only is there a reduced risk of slips, trips and falls — particularly as work at height is reduced — but there is also a reduction in onsite activity, thus ensuring health and safety always remains a top priority from start to finish,” writes PBC Today.
Cost Effective
Prefabrication and modular building methods can lead to nearly 10% in savings on overall construction costs, reports Dodge Data & Analytics. These savings are possible due to a decrease in labor needed, less material waste, quicker building times and projects remaining on schedule. Compared to traditional builds, these building methods are more cost-effective and far more energy efficient — leading to more savings on utilities and maintenance.
>Read Volume 2 Issue 1 of Connected magazine.