ISSUE THREE: THE MONTHLY JOURNAL OF ARCHITRAM PLUS, A MEMBER OF NARDI ASSOCIATES HOLDINGS
The challenges confronted by the design and building industries to address the growing demand for available and affordable construction solutions, mostly impacted by finding creative responses to the housing crisis, have triggered the search for innovative technologies. Construction prefabrication has been considered for a long period as one of the possible answers to those challenges. Prefabrication refers to the practice of manufacturing building components or modules off-site in a controlled environment and then transporting them to the construction site for assembly., aiming to improve construction efficiency, reduce costs, enhance quality control and eventually increasing its sustainability by taking advantage of a controlled manufacturing environment. But regardless of the benefits that those systems may contribute to the building environment, they should be evaluated in their own set of pros and cons, as follows:
Pros:
Efficiency: Prefabrication can significantly reduce construction time since multiple components are created simultaneously, allowing for faster assembly on-site
Cost Saving: Streamlined processes and reduced on-site labor can lead to cost savings in terms of construction time and workforce.
Quality Control: Manufacturing components in a controlled environment enhances quality control, ensuring consistency and precision in production.
Safety: Fewer workers are exposed to on-site hazards, contributing to a safer construction environment.
Environmental Impact : Reduced on-site time and waste, along with potential use of sustainable materials , can lower a negative environmental impact.
Cons:
Initial Investment: Setting up a prefabrication facility requires a significant initial investment, which can be a barrier for smaller construction projects.
Transportation Costs: Transporting prefabricated components to the construction site can carry a significant cost, particularly for large or heavy items.
Limited Customization: Prefabrication may limit design flexibility since components are produced based on standardized models, making customization more challenging.
Site Dependency: Prefabrication may not be suitable for every construction project, especially those in remote locations where transportation of components is challenging.
Perception, Traditions and Negative Social Impact: Some stakeholders may resist the shift to prefabrication due to traditional construction practices or concerns about the perceived quality of pre-made components. By reducing labor, it could be understood as increasing unemployment.
Process shown: installing a pre-fabricated room
Striking a Balance: Prefabricated Bathrooms in Architecture
One significant and transformative aspect of this trend is the incorporation of prefabricated bathrooms. California, in particular, has emerged as a hotspot for innovation in the hospitality sector, with teams like davisREED Construction www.davisreedinc.com leading the charge in embracing modular construction techniques. One notable player in this arena is SurePods, www.surepods.com the foremost provider of prefabricated bathrooms in North America. Leveraging Building Information Modeling (BIM) and lean manufacturing technology, SurePods collaborates with construction teams from design to installation, delivering custom, ready-to-install bathroom pods for diverse projects, from hotels to multi-unit residential developments. davisREED Construction stands out as a trailblazer, slated to implement SurePods in upcoming projects such as the Hilton Garden Inn in San Marcos and an AC Hotel by Marriott in San Diego. The adoption of prefabricated bathrooms is not just a choice; it is a strategic move that aligns with the pressing needs of the construction industry, offering numerous benefits that range from efficiency to customer satisfaction.
What is the installation process like?
Step 1: Pods are loaded into the center of each room fully wrapped and elevated until the building is dry
Step 2: 3D Revit models and full-size templates are used to coordinate the floor penetrations
Step 3: Fire-rated walls and waste stacks are pre-installed before pods are set into position
Step 4: Thin set is troweled on the whole area of where the pod will sit
Step 5: Pod is unwrapped and inspected before being pushed into final position
Step 6: Pod water supply manifolds and electrical whips are connected
Step 7: Toilet, shower and lavatory drainage connections are completed and tested
Step 8: Pod is framed in and drywall is hung on exposed pod walls to finish guestroom corner
Step 9: Specially beveled pod entry door threshold is fit and installed SurePods are wrapped, sealed with weatherproofing and elevated on a pallet to withstand the elements that surround them before dry in.
PREFAB FACADES: Another example of a great prefabrication brand is Spek (spek-ocs.com), an extension of the KHS&S brand. Amongst some of SpeK’s prefabricate manufactured volumetric units, besides components such as bathrooms, kitchens, are exterior façades. Facades panels are installed over traditional structural systems in order to create space closures
FACADES Cont. Typical steps include: Establishing LFD (Level of Framing Detail) for 3D Models Evaluating Panel Breaks Developing Embed Drawings Creating Sections and Connection Details Incorporating Finish Details How are these panels built? We leverage our in-house Construction Design Department to create shop drawings and machine output data. All metal studs are created in-house on our roll-forming machines, virtually eliminating waste and ensuring consistency and precise dimensions. So, what’s the advantage? Panels can be taken out to sheathing, or all the way to full finish with waterproofing and glazing installed. Off-site or near-site construction saves space and allows for the time benefit included with prefabrication. Quality and safety increase in a stable manufacturing-style environment, and panels can be finished and approved at point of fabrication prior to install.
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