Image Credit: Precision Walls
A new report from the National Apartment Association indicates the U.S. must add 4.3 million apartments by 2035 to meet the anticipated housing demand. The lack of housing has presented opportunities for multifamily developers as a massive supply of homes is needed to fill this need.
A growing number of building professionals are embracing prefabrication as a means to speed construction without sacrificing quality. Using cold-formed steel (CFS) framing, contractors are building sustainable structures more efficiently, in less time and with lower costs.
Resurgence in Prefabrication
Prefabricated construction, a long-standing cost-effective alternative to traditional methods, is experiencing a resurgence in popularity. The concept has been around for decades.
“Much has evolved since those first panels,” says the website of SFIA member Precision Walls, a specialty subcontractor with nearly 50 years of experience installing light-gauge metal framing. “Technology, speed of construction, cladding choices, safety, and quality are among the current drivers pushing panelization.”
A Dodge Data & Analytics report shows that 25% of contractors are currently invested in prefabricated projects. This is expected to increase to 33% by 2024, the report says.
Robots + HighVolume CFS Manufacturers
Larry Williams, executive director of the Steel Framing Industry Association (SFIA), sees a future filled with construction technology and automation, which will facilitate positive change and help minimize the traditional downsides associated with the built environment.
“While site-built construction isn’t going away, I also believe that a majority of steel framing contractors will have off-site capabilities and facilities in the future,” Williams says. “And a fair number will have integrated BIM and other forms of virtual design and construction technologies into their operations.”
Cold-formed steel (CFS) leads the way as the preferred framing material for prefabricated structures for multiple reasons.
- Site Impact – Fewer onsite materials reduce congestion and injury potential while improving traffic flow
- Safety – Construction staff stand at floor level instead of working above their heads on ladders
- Improved Design – Virtual Design and Construction models all aspects of the building components. This enables innovation, improves quality, reduces errors and neutralizes escalation costs
- Speed to Market – Prefabricated building components advances supply chain deliverables and accelerates early revenue
- Cost Control – Prefabricated building process identifies cost commitments early on in the process thanks to proven predictability of outcomes. This increases the likelihood each project to meet budget
- Offset Worker Shortage – Prefabrication enables greater production offsite, reducing the need to increase labor
- Collaboration – Designers, contractors, trade partners and engineers all work together toward a unified goal and plan
Prebrication Requires 67% Less Energy
“Speed of delivery and quicker accessibility for carbon neutrality are two advantages of prefabricated construction,” says Emily Gallagher, Propmodo Former. “[It is] so alluring that real developers are finally beginning to see the sector’s appeal.”
Sustainability advantages are also making prefabricated structures look more attractive. According to C40 Cities, over 100 cities in the U.S. have pledged to accelerate net-zero emissions, and Los Angeles is taking that pledge to a new height with the unveiling of its Green New Deal that mandates that all new buildings be net-zero carbon by 2030.
Research from Arup reports that prefabricated construction requires up to 67% less energy than an equivalent traditionally built development.
To further reduce their carbon footprint and meet emission reduction goals, builders are building with steel framing. CFS meets the highest sustainability requirements set in all major green building standards and rating programs, including the Leadership in Energy and Environmental Design (LEED®) from the U.S. Green Building Council, the National Green Building Standard (ICC-700) for residential buildings, ASHRAE Standard 189.1 for commercial construction and the International Green Construction Code (IgCC).
The American Iron and Steel Institute reports:
- Steel framing contains a minimum of 25% recycled steel and is continually and completely recyclable — that is, “remade without any loss of quality”
- Most other construction products can only be down-cycled into lower-quality products
- While construction sites generate waste, steel framing minimizes site waste since steel can be recycled and, AISI says, “become tomorrow’s refrigerator, soup can or car door”
Steel is widely recognized as the most recycled material on the planet.
Steel: The Future of Prefabrication
As technology continues to advance, prefabrication will be increasingly integral in solving the demand for housing. Steel framing aims to remain at the forefront, offering sustainable solutions to build structures more efficiently, in less time and with lower costs.
3 Ways to Utilize Prefabrication
Precision Walls identified three areas where prefabrication can be utilized.
Kitting
Kitting in construction refers to the prefabrication of various components used on a jobsite, such as pre-cutting wallboard and framing members. This process becomes more advantageous in projects with repetitive conditions, leading to increased productivity. Pre-cut wallboard, for example, can be stocked at the project site without on-site pre-work, minimizing waste and disposal efforts. The controlled accuracy offsite reduces the need for re-work on the project, making kitting a simple and cost-effective form of prefabrication.
Load-Bearing Panels
Load-bearing panels can be installed 4-5 times faster than conventional stick framing. Quality control is crucial, given that the framing supports the structure. Precision Walls employs various tools for increased productivity and quality, including air-assisted fabrication tables, a modified forklift for moving large panels, and transportation using a tractor and 48’ trailer that can be used to shuttle panels to the jobsite.
Architectural Panels
Architectural panels are gaining prominence in design and architectural communities. These panels showcase new cladding and finish systems with diverse substrates, surpassing traditional EIFS panel systems. Sto Panels has collaborated with cladding and window manufacturers to guarantee different product assemblies, resulting in lower installed costs compared to onsite installations. Building owners and architects are showing significant interest in these cost-effective panels. Early involvement in the design process is crucial due to different attachment points, and BIM modeling is essential.
Read the Full Article from Precision Walls
Additional Resources
- SFIA’s Larry Williams Shares Insights on the Future of Construction and Technology on “Build It Better” Podcast
- Builders Embrace Steel Framing for Offsite Construction
- CFS Prefab 101: Engage the Contractor/Manufacturer Early in the Project