The Prefab Revolution: How this re-emerging industry will lead to a more sustainable future for our planet, homes and economy Presented by: Johnny Hartsf i eld Barrett Eastwood Founder, Greenfab Project Manager, HyBrid EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
What we will cover....... Introduction A Brief History Prefab Types Prefab Benef i ts Modular Design Modular Construction EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
WHAT IS PREFAB? EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Introduction Henry Ford got it RIGHT! EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Introduction Not much has changed. EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
A BRIEF HISTORY EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
History of Prefab 1908 Sears Roebuck & Co. begins “houses by mail” program EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
History of Prefab 1929 Buckminster Fuller designs Dymaxion House EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
History of Prefab 1946 The war stimulates the market, Lustron Homes emerges EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
History of Prefab 1976 U.S. Dept. of Housing and Urban Development (HUD) EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
History of Prefab 2003 DWELL MAGAZINE Hosts Modular Design Competition EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
PREFAB TYPES EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Types of Prefab manufactured precut panelized (SIP) modular EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Types of Prefab The Manufactured Home (your grandma's DOUBLE-WIDE) ● built on non-removable steel frames ● built to the HUD Code ● sits on a permanent foundation ● a low cost alternative EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Types of Prefab The Pre Cut Home (your basic ERECTOR SET) ● pre cut materials in factory ● delivered to site ● do-it-yourself process EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Types of Prefab The Panelized Home (SIP's) ● highly precise and very strong ● requires a lot of site work ● entry step into prefab EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Types of Prefab The Modular Home (think LEGOS!) ● consists of larger units (mods) ● conforms to local codes ● craned into place EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
THE BENEFITS OF PREFAB EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Benef i ts of Prefab Construction TIME: Shorter Construction Timeframe Traditional site built construction: 9 – 12 months Site Foundation Framing Mechanical Insulation Finishing work Increased VOLUME Modular construction: 3 – 4 months Increased PROFIT Site Foundation Finishing work REDUCED Lending RISK Factory Construction HAPPY homeowners! EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Benef i ts of Prefab Construction COST: Eff i cient process = money saved ● Parallel processes save time/money ● Factory allows for bulk material purchase, economy of scale ● Can outcompete in areas where labor costs are higher EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Benef i ts of Prefab Construction HEALTH: Healthy Materials, Healthy People ● Materials stored and assembled in controlled environment ● Improved indoor air quality ● Safe work environment EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Benef i ts of Prefab Construction QUALITY: ● assembly line promotes highly skilled workers ● precise corners and angles with jigs ● quality control checks and automated equipment EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Benef i ts of Prefab Construction WASTE: ● 50-70% less waste ● Pre-ordering reduces material waste ● Many materials are optimized and recycled EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Benef i ts of Prefab Construction PLANET: ● Reducing construction carbon footprint ● Requires less energy to produce ● Save natural resources EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
IN DEPTH: THE MODULAR HOME EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
LET'S WATCH THIS IN ACTION! EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Media video content not available on pdf EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
MODULAR DESIGN EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Modular Design Begin Thinking MODULAR! ● Site conducive to craning ● Organization of services ● Minimize on-site connections ● Marriage line locations ● Module size 1. Longer boxes more eff i cient 2. Smaller boxes for specif i c situations EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Modular Design Building Information Modeling (BIM) ● Effective way to communicate design intent to factory ● Component based modeling ● Schedules created/updated throughout design ● Factory equipment runs from BIM coding EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
Modular Design It's important to understand the factory process ● Specify to factory preferred suppliers ● Understand limitations on detailing resulting from factory construction process 1. Wall joints – fully sheathed and dry-walled when walls come together 2. Rim Joists – electrical and plumbing often run in double wall ● Understand size and width constraints and design alternatives 1. Hinged roof 2. Divisible loads ● Construct In-Place or Moving Assembly Line EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
THE MODULAR CONSTRUCTION PROCESS Excavation / Foundation Utilities Factory Construction Ship Set Finishing EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process The Modular Construction Process Excavation / Excavation / Foundation Foundation Factory Construction Factory Construction Ship Ship Set Set Finishing Finishing Utilities Utilities EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities Construct In-Place ● Better suited for “one-off” designs ● Gateway into modular construction ● More eff i cient than on-site but less than assembly line process ● Can take up to two months EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities Moving Assembly Line ● Components move through stages ● Home starts construction once all materials are delivered ● Can handle large volume (10,000 s.f./week) ● Can take as little as one week EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities ● Size restrictions ● Transportation restrictions ● The most stress a home will endure ● Added bracing to prevent damage EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
The Modular Construction Process Excavation / Foundation Factory Construction Ship Set Finishing Utilities ● Specialized set crew ● Securing modules to foundation and each other ● Weather proof i ng marriage lines EcoBuilding 2010: Green Design and Construction Symposium October 24, 2010
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