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SmartMarket Report




Prefabrication
and Modularization:
Increasing Productivity in the Construction Industry

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              SmartMarket Report

              McGraw-Hill Construction                   Prefabrication and
                                                         Modularization:
              President
                                                         Increasing Productivity in
              Keith Fox                                  the Construction Industry
              Vice President, Product Development        SmartMarket Report                         About McGraw-Hill
              Kathryn E. Cassino                         Executive Editor                           Construction
                                                         Harvey M. Bernstein, F.ASCE, LEED AP       McGraw-Hill Construction
              McGraw-Hill Construction
                                                         Editorial Directors                        (MHC), part of The McGraw-Hill
              Research & Analytics/
              Industry Insights & Alliances              John Gudgel                                Companies, connects people,
                                                         Michele A. Russo, LEED AP                  projects and products across the
              Vice President, Industry
              Insights & Alliances                       Managing Editor                            design and construction industry,
              Harvey M. Bernstein, F.ASCE, LEED AP       Donna Laquidara-Carr, LEED AP              serving owners, architects,
              Senior Director, Research & Analytics      Director,
                                                                                                    engineers, general contractors,
              Burleigh Morton                            Design & Production                        subcontractors, building product
                                                         William Taylor                             manufacturers, suppliers, dealers,
              Director, Partnerships & Alliances
              John Gudgel                                Art Director/Production Manager            distributors, and adjacent markets.
                                                         Alison Lorenz                                 A reliable and trusted source
              Director, Green Content &
              Research Communications
                                                                                                    for more than a century, MHC
                                                         Contributing Art Directors
              Michele A. Russo, LEED AP                  Segal Savad Design                         has remained North America’s
                                                         Harry Segal, Principal/Creative Director   leading provider of construction
              Reproduction or dissemination              Alex Flannery, Designer                    project and product information,
              of any information contained               Editor
                                                                                                    plans and specifications, industry
              herein is granted only by contract         Enver Fitch, LEED Green Associate          news, market research, and
              or prior written permission from                                                      industry trends and forecasts. In
                                                         Contributor
              McGraw-Hill Construction.                                                             recent years, MHC has emerged
                                                         Bruce Buckley
                                                                                                    as an industry leader in the
              Copyright © 2011, McGraw-Hill              Research Project Manager
                                                                                                    critical areas of sustainability and
              Construction, ALL RIGHTS RESERVED          Dana Gilmore, MRA, PRC
                                                                                                    interoperability as well.
                                                         Research Analyst                              In print, online, and through
                                                         Mevhibe Barton
                                                                                                    events, MHC offers a variety of
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SMR0411_Masthead.indd 2                                                                                                                4/29/11 1:28:54 PM
SmartMarket Report
                                                                                                     Introduction

                                                                                                     P
                                                                                                                refabrication and modulariza-                           Last year, in the Green BIM SmartMarket
       Prefabrication and Modularization: Increasing Productivity in the Construction Industry




                                                                                                                tion are construction processes                     Report (2010), we looked at the conver-
                                                                                                                that the industry has used for                      gence of the BIM and green trends and
                                                                                                                centuries. So why in 2011 is                        found that construction professionals who
                                                                                                     McGraw-Hill Construction conducting for-                       use BIM on green projects are more likely
                                                                                                     ward-thinking market research on what                          to do model-driven prefabrication than
                                                                                                     many consider to be old, well-established                      non-green BIM practitioners. These green
                                                                                                     methods used on construction projects?                         BIM practitioners saw model-driven prefab                 Harvey M. Bernstein
                                                                                                         Well, to paraphrase the song, everything                   as a way to design and construct greener                  F.ASCE, LEED AP
                                                                                                     old about prefab and modular is new again.                     buildings and have a greener site.                        Vice President
                                                                                                                                                                                                                              Industry Insights & Alliances
                                                                                                     This reemergence of prefab and modular                             Now, in this SmartMarket Report, we                   McGraw-Hill Construction
                                                                                                     as a “new” trend is tied to the rise of BIM                    take a new look at prefabrication and
                                                                                                     and green building, critical new trends                        modularization and their impact on a major
                                                                                                     identified by McGraw-Hill Construction and                     initiative within our industry—improving
                                                                                                     other industry leaders.                                        productivity. Through an Internet survey
                                                                                                         The emergence of building information                      of hundreds of AEC professionals, we
                                                                                                     modeling (BIM) is influencing design and                       gathered data on the impact of prefabri-
                                                                                                     construction processes and how project                         cation and modularization on key industry
                                                                                                     teams collaborate. In the Business Value                       productivity metrics including project
                                                                                                     of BIM SmartMarket Report (2009), we                           schedules, costs, safety, quality, eliminat-
                                                                                                     found that a key benefit of BIM is enabling                    ing waste and creating green buildings.
                                                                                                     the increased use of prefabrication and                        Some of the most significant productivity                 John E. Gudgel
                                                                                                                                                                                                                              Director,
                                                                                                     modularization, which in turn improves                         findings from prefabrication and modular-                 Partnerships & Alliances
                                                                                                     worksite productivity and overall project                      ization users include the following:                      McGraw-Hill Construction
                                                                                                     ROI. Contractors were especially excited,
                                                                                                                                                                    ■■66% report that project schedules are
                                                                                                     with 77% believing that BIM would allow
                                                                                                                                                                       decreased—35% by four weeks or more.
                                                                                                     them to use prefabrication on larger, more
                                                                                                     complex projects in the future.                                ■■65% report that project budgets are
                                                                                                         The phenomenal growth in green build-                         decreased—41% by 6% or more
                                                                                                     ing has also had an undeniable impact on
                                                                                                                                                                    ■■77% report that construction site waste
                                                                                                     the construction industry. Just last year, in
                                                                                                                                                                       is decreased—44% by 5% or more.
                                                                                                     Green Outlook 2011 we estimated that up
                                                                                                     to 35% of new nonresidential construction                      We would like to thank our premier part-
                                                                                                     is green, representing a $54 billion market                    ners including NIST, the Modular Building                 Donna Laquidara-Carr,
                                                                                                     opportunity that will grow to $120 billion or                  Institute, Island Companies, and Syntheon;                Ph.D., LEED AP
                                                                                                                                                                                                                              Manager, Green Research
                                                                                                     more by 2015.                                                  and our other corporate & association part-               and Communications
                                                                                                                                                                    ners for supporting this study.                           McGraw Hill Construction


                                                                                                     Harvey M. Bernstein, F.ASCE,           Professor with the University of         ability. He has over 17 years of     direction, analysis and content
                                                                                                     LEED AP, has been a leader in          Reading’s School of Construction         experience in technology project     to the SmartMarket Reports,
                                                                                                     the engineering and construc-          Management and Engineering in            management in the computer and       examining critical construction
                                                                                                     tion industry for over 30 years.       England. Bernstein has an M.B.A.         telecommunications industries.       trends including BIM and green
                                                                                                     Currently, he has lead responsibil-    from Loyola College, an M.S. in          John has an M.S. in eCommerce        building. Previously, with MHC’s
                                                                                                     ity for MHC’s market research          engineering from Princeton Uni-          from George Mason University,        Dodge division, she has nearly
                                                                                                     group as well as MHC’s thought         versity and a B.S. in civil engineer-    an M.S. in Telecommunications        twenty years of experience in the
                                                                                                     leadership initiatives in areas such   ing from the New Jersey Institute        from the University of Colorado      construction news industry. Since
                                                                                                     as green building, BIM, interop-       of Technology.                           and a B.S. in Geological Engineer-   2005, as Editorial Training and
                                                                                                     erability, innovation and global                                                ing from the Colorado School of      Policy Manager, she educated a
                                                                                                     construction markets. Previously,      John E. Gudgel is responsible for        Mines.                               team of over 250 reporters on key
                                                                                                     Bernstein served as the President      managing MHC’s relationships                                                  trends in the industry, including
                                                                                                     and CEO of the Civil Engineer-         with both national and regional          Donna Laquidara-Carr, Ph.D.,         public-private partnerships and
                                                                                                     ing Research Foundation. He            industry associations. He also pro-      LEED AP, has been Manager of         the evolution of project delivery
                                                                                                     currently serves as a member           duces and offers thought leader-         Green Research and Communica-        methods. Donna has a Ph.D. from
                                                                                                     of the Princeton University Civil      ship on construction technology,         tions at McGraw Hill Construc-       Tulane University, an M.A. from
                                                                                                     and Environmental Engineering          managing MHC’s SmartMarket               tion since December 2008. In that    Boston University and a B.A. from
                                                                                                     Advisory Council and as a visiting     Reports on BIM and Interoper-            capacity, she provides editorial     Middlebury College.




                                                                                                 	                                                 McGraw-Hill Construction         1  www.construction.com                            SmartMarket Reports



SMR0411_Letter-bio.indd 1                                                                                                                                                                                                                                     5/2/11 3:11:15 PM
SmartMarket Report
                                                                                                                                                                                        PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY


                                                                                                                                                                  TABLE OF

                                                                                                                                                                     CONTENTS
                                                                                                                                                                   4 Executive Summary
                                                                                                                                                                         4 Executive Summary
                                                                                                                                                                         6 Recommendations


                                                                                                                                                                   7 Data
                                                                                                                                                                    8 Market Activity and Opportunity
                                                                                                                                                                      8 Sectors with Opportunity for Prefabrication/Modularization
                                                                                                                                                                       10 Building Sectors with the Most Significant Future Opportunity for Prefabrication/Modularization
                                                                                                                                                                       12 Users of Prefabrication/Modularization
                                                                                                                                                                       13 Levels of Use of Prefabrication/Modularization: Today and in the Future for Current Users
                                                                                                                                                                       14 Future Activity by Current Non-Users of Prefabrication/Modularization
                                                                                                                                                                       14 Firm Size of Prefabrication/Modularization Users

                                                                                                                                                                   18 Productivity
                                                                                                                                                                      18 Impact on Project Schedule
                                                                                                                                                                       19 Impact on Project Budget
                                                                                                                                                                       20 Impact on Site Safety
      Photo courtesy of Liam Frederick (cover); Photo courtesy of Perkins  Wil (opposite page left); Photo courtesy of the Warrior Group (opposite page right)




                                                                                                                                                                       21 Impact on Purchase and Installation Costs for Materials
                                                                                                                                                                       22 Expected Impact on Project Schedule According to Prefabrication/Modularization Non-Users
                                                                                                                                                                       22 Impact on Project Budget According to Non-Users
                                                                                                                                                                       23 Impact on Reducing Onsite Resources According to Non-Users
                                                                                                                                                                       23 Impact on Improving Project Quality According to Non-Users

                                                                                                                                                                   29 Influence Factors
                                                                                                                                                                      29 Drivers for Use of Prefabrication and Modularization
                                                                                                                                                                       30 Factors Driving Future Use of Prefabrication/Modularization for Non-Users
                                                                                                                                                                       31 Non-Users’ Current Reasons for Not Using Prefabrication/Modularization on Projects
                                                                                                                                                                       32 Users’ Current Reasons for Not Using Prefabrication/Modularization on Some Projects

                                                                                                                                                                   33 Prefabricated and Modular Building Elements
                                                                                                                                                                      33 Influence of Job Site Conditions
                                                                                                                                                                       34 Most Commonly Used Prefabricated and Modular Building Elements

                                                                                                                                                                   39 Green Building
                                                                                                                                                                      39 Using Prefabrication/Modularization on Green Building Projects
                                                                                                                                                                       39 Construction Waste
                                                                                                                                                                       40 Materials

                                                                                                                                                                   41 Model-Driven (BIM) Prefabrication
                                                                                                                                                                      41 Usage
                                                                                                                                                                       42 Drivers




                                                                                                                                                                  SmartMarket Reports                 McGraw-Hill Construction  2  www.construction.com

SMR0411_ToC.indd 2                                                                                                                                                                                                                                                                4/29/11 3:33:48 PM
Front cover:
                                                                                                     The Summit at Queens College
                                                                                                     Student Residence Hall, Queens, NY

                                                                                                     From left to right:
                                                                                                     Texas Health Harris Methodist
                                                                                                     Alliance Hospital, Fort Worth, Texas;
                                                                                                     Fort Sam Houston Medical Education
                                                                                                     and Training Complex Barracks,
                                                                                                     San Antonio, Texas
       CONTENTS




                  46 Contractors
                     46 Usage
                     47 Productivity
                     48 Drivers

                  49 Architects and Engineers
                     49 Usage
                     50 Drivers and Productivity


                  43 Data Sidebar: Drivers Behind Owner Adoption of
                     Prefabrication and Modularization
                  Sidebars
                      9 Brief History of Prefabrication/Modularization
                      25 Lean Construction


                  Thought Leader Interviews
                      15 J. Doug Pruitt, Chairman and CEO, Sundt Construction
                      24 Gregory Howell, Cofounder and Managing Director, Lean Construction Institute


                  Case Studies
                      16 Speeding Delivery to Meet a Military Mission:
                         Fort Sam Houston Medical Education and Training Complex Barracks, San Antonio, Texas
                      26 Pushing the Envelope in Prefabrication: Texas Health Harris Methodist Alliance Hospital, Fort Worth, Texas
                      36 Innovation in Prefabrication to Achieve a Tight Schedule and Green Results:
                         The Summit at Queens College Student Residence Hall, Queens, New York


                  51 Glossary
                  52 Methodology
                  53 Resources


                                                   McGraw-Hill Construction    3
                                                                                  www.construction.com                  SmartMarket Reports



SMR0411_ToC.indd 3                                                                                                                           4/29/11 3:33:56 PM
Executive Summary
                                                                                                 Everything Old Has Become New Again!

                                                                                                 Building information modeling (BIM), modern manufacturing
       PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY




                                                                                                 methods, sustainability goals and recognized productivity
                                                                                                 gains rejuvenate centuries old-construction processes.
                                                                                                 Prefabrication and modular construction are processes that have been used by generations of
                                                                                                 construction professionals. Over the past century, these processes have developed a stigma of
                                                                                                 “cheapness” and “poor quality.” However, through modern technology, that image has changed.
                                                                                                 Now it’s a key component of the drive to improve construction industry productivity.



                                                                                                 Adoption and Usage                                                Percentage of Prefabrication/
                                                                                                 Prefabrication and modular building processes are                 Modularization Users Today (2011)
                                                                                                 not new activities—63% of those that are using these              Source: McGraw-Hill Construction, 2011

                                                                                                 processes have been doing so for five years or more.                   User              Non-User
                                                                                                 Given that prefabrication/modular construction has
                                                                                                 been around for many years, it is not unexpected that             Contractor
                                                                                                 85% of industry players today are using these processes                                                                    84%
                                                                                                 on some projects—including 90% of engineers, 84% of                            16%
                                                                                                 contractors and 76% of architects.
                                                                                                                                                                   Engineer
                                                                                                     By 2013, nearly all players (98%) expect to be doing
                                                                                                                                                                                                                                90%
                                                                                                 some prefabrication/modularization on some projects.
                                                                                                                                                                            10%
                                                                                                 Among users, usage today is fairly low. Only about a
                                                                                                 third of users (37%) have been using it at a high or very         Architect
                                                                                                 high level (more than 50% of projects). Over the next                                                                    76%
                                                                                                 two years, usage on projects is expected to moderately                                24%
                                                                                                 grow, with high or very high usage reaching 45% by 2013.
                                                                                                 Among all players surveyed, the highest level of current          Current Drivers to Use of
                                                                                                 and future usage is among fabricators, mechanical                 Prefabrication/Modularization
                                                                                                 contractors and design-builders.                                  (By Player)
                                                                                                     Among all players, the primary reason they are                Source: McGraw-Hill Construction, 2011
                                                                                                 not using prefabrication and modularization on some
                                                                                                                                                                      Contractor              Engineer        Architect
                                                                                                 or all of their projects is that the architect did not design
                                                                                                 it into their projects. Owner resistance was the primary          Improve Productivity
                                                                                                 reason given by architect users (39%) and non-users                                                                            92%
                                                                                                 (54%) for not including prefabrication and modularization                                                          70%
                                                                                                 into their designs.                                                                                               68%

                                                                                                 BUILDING SECTORS AND AREAS OF USAGE                               Competitive Advantage
                                                                                                 Adopters are using prefabrication/modular building                                                                         85%
                                                                                                 processes on a wide variety of commercial building proj-                                                     60%
                                                                                                 ects. In particular, respondents today are using it on                                                     52%
                                                                                                 healthcare facilities (49%), college buildings and dormi-
                                                                                                                                                                   Generates Greater ROI
                                                                                                 tories (42%) and manufacturing buildings (42%). These
                                                                                                                                                                                                                     70%
                                                                                                 respondents see the most future opportunity in health-
                                                                                                                                                                                                    43%
                                                                                                 care facilities (14%), hotels and motels (11%), commercial
                                                                                                                                                                                                   40%
                                                                                                 warehouses (11%) and other building types (10%) that
                                                                                                 included data centers, prisons, power plants and oil refin-       Owner/Client Demand
                                                                                                 eries. These opportunities do vary by player type.                                        31%
                                                                                                                                                                                                            51%
                                                                                                                                                                                               35%


                                                                                                 SmartMarket Reports                  McGraw-Hill Construction   4  www.construction.com

SMR0411_ExecSum.indd 4                                                                                                                                                                                                                4/29/11 1:22:26 PM
Executive Summary             CONTINUED




                                                                                                                                                                                 Level of Decrease in Project
                                                                                                                                                                      40%
                                                                                                    Within a building, prefabrication and modular                                Schedule Due to Prefabrication/
       PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY




                                                                                                 construction are used in a variety of areas but most                            Modularization
                                                                                                 often in the building superstructure (27%), mechanical,                         Source: McGraw-Hill Construction, 2011                35%
                                                                                                                                                                      30%
                                                                                                 electrical and plumbing (MEP) systems (21%) and exterior
                                                                                                 walls (20%).
                                                                                                    When deciding whether or not to use prefabrication
                                                                                                 or modularization, the most important factor is the                  20%
                                                                                                 job site accessibility (58%) followed closely by the
                                                                                                 number of building stories (53%) and the type of building
                                                                                                                                                                      10%
                                                                                                                                                                                                      14%
                                                                                                 exterior (52%).
                                                                                                                                                                                                                           10%
                                                                                                                                                                                   7%
                                                                                                 USAGE DRIVERS
                                                                                                 The most important driver to current usage of prefab-                0%
                                                                                                 rication and modularization is its ability to improve                           1 Week             2 Weeks               3 Weeks     4 Weeks
                                                                                                 productivity (82%). This is particularly important to                                                                                or More
                                                                                                 contractors (92%). All players also see these processes as
                                                                                                 making them more competitive in the marketplace (75%).                       Level of Decrease in Project Budget
                                                                                                                                                                              Due to Prefabrication/Modularization
                                                                                                                                                                      30%
                                                                                                 Productivity Improvements—                                                   Source: McGraw-Hill Construction, 2011

                                                                                                 Primary Future Driver
                                                                                                 Architects, engineers and contractors are also very
                                                                                                 closely aligned in the belief that the primary drivers to                       24%
                                                                                                                                                                      20%
                                                                                                 future usage will be the improvements that prefabrication
                                                                                                 and modularization can provide to elements of productiv-                                            19%
                                                                                                                                                                                                                          17%
                                                                                                 ity including project schedule, cost, safety and quality.

                                                                                                 IMPROVED PROJECT SCHEDULES                                           10%
                                                                                                 A key metric of productivity is the project schedule. 66%
                                                                                                 of user respondents indicated that prefabrication/modu-
                                                                                                 larization processes have a positive impact on project                                                                                 5%
                                                                                                 schedules, with 35% of those respondents indicating that             0%
                                                                                                 it can reduce the project schedule by four weeks or more.                    Decreased           Decreased            Decreased Decreased
                                                                                                                                                                               1%–5%               6%–10%              11%–20% More Than 20%
                                                                                                 REDUCED COST AND BUDGETS
                                                                                                 Another key productivity metric is project cost
                                                                                                 as measured by the project budget. 65% of user                       GREEN BUILDING AND WASTE REDUCTION
                                                                                                 respondents indicated that the use of prefabrication/                Green was not a major driver to prefabrication and modu-
                                                                                                 modularization had a positive impact on project budgets,             larization adoption. However, when asked about elements
                                                                                                 with 41% indicating that it reduced project budgets by               of green, including site waste and amount of materials
                                                                                                 6% or more.                                                          used, a different story emerges. 76% of respondents indi-
                                                                                                                                                                      cate that prefabrication/modular construction reduces
                                                                                                 SITE SAFETY                                                          site waste—with 44% indicating that it reduced site waste
                                                                                                 More respondents (34%) believe that prefabrication and               by 5% or more. In addition, 62% of respondents believe
                                                                                                 modularization can improve site safety versus those                  that these processes reduce the amount of materials
                                                                                                 who think the practices reduce safety (10%). Most users              used—with 27% indicating prefabrication/modularization
                                                                                                 believe that these processes are safety neutral (56%).               reduced materials used by 5% or more.




                                                                                                                                      McGraw-Hill Construction    5
                                                                                                                                                                     www.construction.com                                           SmartMarket Reports



SMR0411_ExecSum.indd 5                                                                                                                                                                                                                                4/29/11 1:22:27 PM
Recommendations
                                                                                                 The research findings have varying
                                                                                                 implications for different industry players.

                                                                                                 Owners:                             Reduce project                 design and construction,         help achieve green objec-
       PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY




                                                                                                 Consider using                      schedules—sometimes            engineers should evaluate        tives should be promoted
                                                                                                 prefabrication and                  by a month or more.            the quality and availability     and emphasized in bids.
                                                                                                 modularization                      Decrease purchase and          of prefabricated/modular
                                                                                                 processes on your                   installation costs of          products and be the              Specialty
                                                                                                 projects. This is not your          materials—ultimately           catalyst for their use.          Contractors:
                                                                                                 grandpa’s prefab! With the          decreasing the project            Many engineering firms        Adopt for competitive
                                                                                                 precision bestowed by BIM           budget.                        today are already using pre-     reasons. For some con-
                                                                                                 and the quality provided            Increase construction          fabricated /modular ele-         struction specialty trades,
                                                                                                 by modern materials and             site safety—resulting          ments for the building           such as mechanical and
                                                                                                 manufacturing facilities,           in fewer accidents and         superstructure, exterior         electrical contracting, pre-
                                                                                                 prefabrication and modular          lower insurance costs.         walls, roof and floor, and       fabrication/modularization
                                                                                                 construction offer the              Eliminate significant          they view their use as a way     has become an integral part
                                                                                                 opportunity to obtain               amounts of construction        to differentiate themselves      of their business. With the
                                                                                                 significant productivity            site waste, making the         from their competition.          inherent efficiencies and
                                                                                                 gains on your projects.             project greener.                                                productivity gains and cur-
                                                                                                 Owner demand is the                 Allow the specification        General                          rent projections showing
                                                                                                 primary driver for architects       and installation of            Contractors and                  increased usage on proj-
                                                                                                 to include prefabrication /         better quality and more        Construction                     ects, specialty contractors
                                                                                                 modular construction into           sustainable building           Managers:                        need to acquire experience
                                                                                                 their project design.               materials.                     Build prefabrication/            with prefabricated/mod-
                                                                                                                                                                    modular efficiencies             ular processes in order to
                                                                                                 Architects:                      Specify prefabrication            into your pre-construc-          remain competitive.
                                                                                                 Understand and educate           and modularization in             tion planning and bids.
                                                                                                 clients on the benefits of       your design. Once you             Prefabrication provides          Manufacturers:
                                                                                                 prefabrication and mod-          get the client’s buy-in,          predictable results for your     Promote the green ben-
                                                                                                 ularization. As the initial      make sure you include             schedule and costs. The          efits of your products.
                                                                                                 interface with the client, the   prefabrication/modular-           research shows that it can       Although most architects,
                                                                                                 architect has the greatest       ization into your design.         decrease the purchase and        engineers and contractors
                                                                                                 influence during the design      The early decision to bring       installation costs of mate-      do not view prefabricated
                                                                                                 phase in determining if pre-     it into the project allows        rials and compress project       and modular products as
                                                                                                 fabrication and modular          for greater continuity of         schedules. These factors         a primary way to achieve
                                                                                                 construction will be used in     design maximizing poten-          can ultimately decrease the      their green building objec-
                                                                                                 a project.                       tial productivity gains. The      project budget and allow         tives, all professionals
                                                                                                    Understand the key            number one reason engi-           GC and CM firms to be            agree that these processes
                                                                                                 benefits that prefabri-          neers and contractors give        more competitive.                reduce waste and the
                                                                                                 cation/modularization            for not using prefabrication         Include the green             amount of materials used
                                                                                                 offer, such as improved          or modularization is that the     factor. It is clear that pre-    on projects. Manufacturers
                                                                                                 project productivity, pro-       architect did not include it      fabrication and modu-            need to raise awareness of
                                                                                                 ducing more sustainable          in the project design.            lar construction can help        these green benefits.
                                                                                                 buildings and ultimately                                           reduce waste and result             Create BIM objects
                                                                                                 increasing ROI for the client    Engineers:                        in a greener construction        of prefabricated and
                                                                                                 and other members of the         As the professionals              site. Given that green has       modular products. BIM
                                                                                                 project team. Architects         primarily responsible for         become a major factor in         use continues to rise, and
                                                                                                 should educate clients that      the structural integrity          the construction market-         BIM is a driver to increased
                                                                                                 using prefabrication/modu-       and systems efficiency            place, the fact that prefabri-   use of prefabrication/
                                                                                                 larization can measurably:       of buildings during their         cation/modularization can        modularization. ■




                                                                                                 SmartMarket Reports                   McGraw-Hill Construction   6  www.construction.com

SMR0411_Recommendations.indd 6                                                                                                                                                                                                      4/29/11 1:34:20 PM
Data:­Section Hed1
                                                                                                         Introduction
                                                                                                            Construction Trends
                                                                                                            Driving Prefabrication/Modularization




                                                                                                            P
                                                                                                                      refabrication and modularization are certainly not new to the
        Prefabrication and Modularization: Increasing Productivity in the Construction Industry  data




                                                                                                                      construction industry. However, current influential construction                    Note About
                                                                                                                      trends, such as the increasing interest in lean construction, the                   the Data
                                                                                                                      rising use of BIM technologies and the growing influence of green                   The data in this report
                                                                                                            construction have caused many practitioners to reconsider their appeal. In                    are based on an online
                                                                                                            fact, the National Research Council’s 2009 report on improving productivity in                survey of 809 contrac-
                                                                                                            the construction industry recommends prefabrication/modularization as an                      tors, architects and
                                                                                                            “opportunity for breakthrough achievement.”1 These factors, combined with                     engineers. The con-
                                                                                                                                                                                                          tractors comprise 65%
                                                                                                            recent advances in prefabrication/modularization, make this a critical trend in
                                                                                                                                                                                                          of the total respon-
                                                                                                            the construction industry.                                                                    dents, while architects
                                                                                                                                                                                                          total 12% and engi-
                                                                                                            Lean Construction                                                                             neers 23%. The large
                                                                                                            The strong increases in productivity offered by using prefabrication and                      number of respondent
                                                                                                            modularization fit squarely into the lean building model. The difficult                       firms in all three player
                                                                                                            economic conditions in the construction industry have increased the appeal of                 categories provides
                                                                                                                                                                                                          a statistically mean-
                                                                                                            lean methods and practices. For more information on the use of prefabrication
                                                                                                                                                                                                          ingful sample for the
                                                                                                            and modularization to achieve a lean approach, see pages 24 and 25.                           study conclusions.

                                                                                                            BIM                                                                                           For full methodology,
                                                                                                            The increasing use of BIM also contributes to the potential for increased use                 see page 52.
                                                                                                            of prefabrication and modularization. In a recent study about the use of BIM
                                                                                                            on green projects, McGraw-Hill Construction (MHC) found that the use of
                                                                                                            BIM model-driven prefabrication on more than one quarter of their projects
                                                                                                            is expected to increase from 37% to 73% among practitioners who use BIM
                                                                                                            for green work. Even those who are currently not using green BIM expect an
                                                                                                            increase from 22% to 57%.1 BIM helps enable prefabrication of tightly inte-
                                                                                                            grated MEP systems, allowing designers to maximize space for other uses in
                                                                                                            high-tech buildings like hospitals.

                                                                                                            Green Building
                                                                                                            Green building has grown into a substantial part of the overall construc-
                                                                                                            tion market. MHC’s Green Outlook 2011 estimates that nonresidential green
                                                                                                            building will comprise 28%–35% of the total market by the end of 2010. This
                                                                                                            dramatic increase in market share, from less than 5% in 2005, reflects the fact
                                                                                                            that green building sustained steady growth throughout the recession, even
                                                                                                            as the overall construction market shrunk by nearly one-third.2
                                                                                                                MHC also predicts that the growth of the market share for green will not
                                                                                                            abate as the construction industry recovers from the recession. By 2015, MHC
                                                                                                            projects that 40%–48% of nonresidential construction will be green.
                                                                                                                As the results of this study demonstrate, this has strong implications for
                                                                                                            rising interest in prefabrication and modularization, which helps eliminate
                                                                                                            waste onsite and conserve resources.

                                                                                                            Bringing the Trends Together                                                       1 National Research Council of the National Academies. Advancing
                                                                                                                                                                                               the Competitiveness and Efficiency of the U.S. Construction Industry.
                                                                                                            What is most striking about prefabrication/modularization is its ability to        Washington DC: The National Academies Press, 2009. 2 Green BIM
                                                                                                                                                                                               SmartMarket Report: How Building Information Modelling is Contrib-
                                                                                                            enable all these trends, in addition to being more prominent because of them.      uting to Green Design and Construction. McGraw-Hill Construction.
                                                                                                                                                                                               July, 2010. 2 Green Outlook: Green Trends Driving Growth, 2011.
                                                                                                            It brings all of them together to improve productivity in construction.            McGraw-Hill Construction, October, 2010.




                                                                                                        	                                       McGraw-Hill Construction   7  www.construction.com                                   SmartMarket Reports



SMR0411_Data_Intro_MarketActivity.indd 7                                                                                                                                                                                                                               5/2/11 11:53:49 AM
Data:­Market Activity and Opportunity
                                                                                                        Sectors with Opportunity for
                                                                                                        Prefabrication/Modularization

                                                                                                                                                                            Building Sectors Using
                                                                                                        Currently, prefabrication /modularization is being used on          Prefabrication/Modularization
        Prefabrication and Modularization: Increasing Productivity in the Construction Industry  data




                                                                                                        many types of building projects demonstrating its appli-            Source: McGraw-Hill Construction, 2011

                                                                                                        cability across nonresidential construction.
                                                                                                                                                                            Healthcare Facilities
                                                                                                          The five sectors using prefabrication/modularization in                                                                     49%
                                                                                                        over 40% of projects are:
                                                                                                                                                                            Higher Education (e.g., Dorms, College Buildings)
                                                                                                         Healthcare (49%)
                                                                                                        ■■
                                                                                                                                                                                                                                42%
                                                                                                         Higher Education (42%)
                                                                                                        ■■
                                                                                                                                                                            Manufacturing
                                                                                                         Manufacturing (42%)
                                                                                                        ■■                                                                                                                      42%

                                                                                                         Low-Rise Office (40%)
                                                                                                        ■■                                                                  Low-Rise Office (1–4 Stories)
                                                                                                                                                                                                                            40%
                                                                                                         Public (40%)
                                                                                                        ■■

                                                                                                                                                                            Public
                                                                                                        These sectors also present strong opportunities in the
                                                                                                                                                                                                                            40%
                                                                                                        construction market, which bodes well for a vigorous
                                                                                                        prefabrication/modularization future market.                        Commercial Warehouse
                                                                                                                                                                                                                           37%
                                                                                                        Healthcare
                                                                                                                                                                            K–12 School
                                                                                                        Healthcare is a sector that is well-suited for prefabrica-
                                                                                                                                                                                                                           36%
                                                                                                        tion/modularization techniques. The interior layout of
                                                                                                        hospital rooms allows for efficient use of modulariza-              High-Rise Office (5+ Stories)
                                                                                                        tion, and it is a sector highly responsive to strategies that                                                30%
                                                                                                        shorten schedule—a particular benefit prefabrication
                                                                                                                                                                            Hotel
                                                                                                        brings to a project (See page 18).
                                                                                                                                                                                                                     29%
                                                                                                            According to McGraw-Hill Construction’s economic
                                                                                                        forecast, the market activity for healthcare construction           Retail
                                                                                                        is expected to increase in 2011 and 2012 to become more                                              24%
                                                                                                        than a $28 billion market opportunity in 2012.
                                                                                                                                                                            Multifamily

                                                                                                        Dormitory and Education Projects                                                                   23%
                                                                                                        Like healthcare buildings, dormitories and school proj-             Bank
                                                                                                        ects have features that are well-suited to prefabrication/                                   18%
                                                                                                        modularization. Dorms and classrooms allow for use of
                                                                                                                                                                            Food Service (e.g., Restaurants, Convenience Stores)
                                                                                                        modular room design, and these projects also benefit
                                                                                                        from faster construction schedules.                                                        16%
                                                                                                            As the largest construction sector by value (over $43           Auto (e.g., Garages)
                                                                                                        billion in 2011), education presents a significant oppor-                              14%
                                                                                                        tunity for prefabrication/modularization—both currently
                                                                                                        and in the future (see page 10).                                    Transportation (e.g., Train Stations, Bus Depots)
                                                                                                                                                                                               14%
                                                                                                        Variation by Player
                                                                                                         Contractors: Across the board, contractors report
                                                                                                        ■■                                                                       (46%), followed by commercial warehouses (43%).
                                                                                                         heavier current involvement in prefabrication/                          Engagement in the other sectors is 30% or lower.
                                                                                                         modularization, predominantly in healthcare (61%),
                                                                                                                                                                            ■■Architects: Their heaviest use is in low-rise offices
                                                                                                         dormitory/education (50%) and public buildings (46%).
                                                                                                                                                                              (43%) and healthcare facilities (36%), with less than a
                                                                                                         Engineers: Engineers are using prefabrication/modu-
                                                                                                        ■■                                                                    third reporting use in other sectors.
                                                                                                          larization most often in manufacturing buildings


                                                                                                        SmartMarket Reports 	                 McGraw-Hill Construction   8  www.construction.com

SMR0411_Data_Intro_MarketActivity.indd 8                                                                                                                                                                                                    5/2/11 11:54:14 AM
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Mhc prefabrication modularization_smr_2011

  • 1. SmartMarket Report Prefabrication and Modularization: Increasing Productivity in the Construction Industry Premier Partners: Partners:
  • 2. ■ Design and Construction Intelligence SmartMarket Report McGraw-Hill Construction Prefabrication and Modularization: President Increasing Productivity in Keith Fox the Construction Industry Vice President, Product Development SmartMarket Report About McGraw-Hill Kathryn E. Cassino Executive Editor Construction Harvey M. Bernstein, F.ASCE, LEED AP McGraw-Hill Construction McGraw-Hill Construction Editorial Directors (MHC), part of The McGraw-Hill Research & Analytics/ Industry Insights & Alliances John Gudgel Companies, connects people, Michele A. Russo, LEED AP projects and products across the Vice President, Industry Insights & Alliances Managing Editor design and construction industry, Harvey M. Bernstein, F.ASCE, LEED AP Donna Laquidara-Carr, LEED AP serving owners, architects, Senior Director, Research & Analytics Director, engineers, general contractors, Burleigh Morton Design & Production subcontractors, building product William Taylor manufacturers, suppliers, dealers, Director, Partnerships & Alliances John Gudgel Art Director/Production Manager distributors, and adjacent markets. Alison Lorenz A reliable and trusted source Director, Green Content & Research Communications for more than a century, MHC Contributing Art Directors Michele A. Russo, LEED AP Segal Savad Design has remained North America’s Harry Segal, Principal/Creative Director leading provider of construction Reproduction or dissemination Alex Flannery, Designer project and product information, of any information contained Editor plans and specifications, industry herein is granted only by contract Enver Fitch, LEED Green Associate news, market research, and or prior written permission from industry trends and forecasts. In Contributor McGraw-Hill Construction. recent years, MHC has emerged Bruce Buckley as an industry leader in the Copyright © 2011, McGraw-Hill Research Project Manager critical areas of sustainability and Construction, ALL RIGHTS RESERVED Dana Gilmore, MRA, PRC interoperability as well. Research Analyst In print, online, and through Mevhibe Barton events, MHC offers a variety of For further information on this tools, applications, and resources SmartMarket Report or for any that embed in the workflow of our in the series, please contact: customers, providing them with McGraw-Hill Construction the information and intelligence Research & Analytics they need to be more productive, Crosby Drive, Suite 201 successful, and competitive. Bedford, MA 01730 Backed by the power of Dodge, 1-800-591-4462 Sweets, Architectural Record, MHC_Analytics@mcgraw-hill.com Engineering News-Record (ENR), GreenSource and SNAP, McGraw-Hill Construction serves Environmental Benefits Statement: This report is printed using more than one million customers soy-based inks on New Leaf ReincarnationMatte, made with 100% recycled within global construction fiber, 50% post-consumer waste and processed chlorine-free with a community. To learn more, visit cover on New Leaf Primavera Gloss, made with 80% recycled fiber, 40% us at www.construction.com. post-consumer waste, processed chlorine-free. By using this environmentally- friendly paper, McGraw-Hill Construction saved the following resources (calculations provided by New Leaf Paper, based on research conducted by Environmental Defense Fund and other members of the Paper Task Force): 20 fully grown 9,200 gallons 6 million 559 pounds of 1,910 pounds trees of water BTUs of energy solid waste of greenhouse gases SMR0411_Masthead.indd 2 4/29/11 1:28:54 PM
  • 3. SmartMarket Report Introduction P refabrication and modulariza- Last year, in the Green BIM SmartMarket Prefabrication and Modularization: Increasing Productivity in the Construction Industry tion are construction processes Report (2010), we looked at the conver- that the industry has used for gence of the BIM and green trends and centuries. So why in 2011 is found that construction professionals who McGraw-Hill Construction conducting for- use BIM on green projects are more likely ward-thinking market research on what to do model-driven prefabrication than many consider to be old, well-established non-green BIM practitioners. These green methods used on construction projects? BIM practitioners saw model-driven prefab Harvey M. Bernstein Well, to paraphrase the song, everything as a way to design and construct greener F.ASCE, LEED AP old about prefab and modular is new again. buildings and have a greener site. Vice President Industry Insights & Alliances This reemergence of prefab and modular Now, in this SmartMarket Report, we McGraw-Hill Construction as a “new” trend is tied to the rise of BIM take a new look at prefabrication and and green building, critical new trends modularization and their impact on a major identified by McGraw-Hill Construction and initiative within our industry—improving other industry leaders. productivity. Through an Internet survey The emergence of building information of hundreds of AEC professionals, we modeling (BIM) is influencing design and gathered data on the impact of prefabri- construction processes and how project cation and modularization on key industry teams collaborate. In the Business Value productivity metrics including project of BIM SmartMarket Report (2009), we schedules, costs, safety, quality, eliminat- found that a key benefit of BIM is enabling ing waste and creating green buildings. the increased use of prefabrication and Some of the most significant productivity John E. Gudgel Director, modularization, which in turn improves findings from prefabrication and modular- Partnerships & Alliances worksite productivity and overall project ization users include the following: McGraw-Hill Construction ROI. Contractors were especially excited, ■■66% report that project schedules are with 77% believing that BIM would allow decreased—35% by four weeks or more. them to use prefabrication on larger, more complex projects in the future. ■■65% report that project budgets are The phenomenal growth in green build- decreased—41% by 6% or more ing has also had an undeniable impact on ■■77% report that construction site waste the construction industry. Just last year, in is decreased—44% by 5% or more. Green Outlook 2011 we estimated that up to 35% of new nonresidential construction We would like to thank our premier part- is green, representing a $54 billion market ners including NIST, the Modular Building Donna Laquidara-Carr, opportunity that will grow to $120 billion or Institute, Island Companies, and Syntheon; Ph.D., LEED AP Manager, Green Research more by 2015. and our other corporate & association part- and Communications ners for supporting this study. McGraw Hill Construction Harvey M. Bernstein, F.ASCE, Professor with the University of ability. He has over 17 years of direction, analysis and content LEED AP, has been a leader in Reading’s School of Construction experience in technology project to the SmartMarket Reports, the engineering and construc- Management and Engineering in management in the computer and examining critical construction tion industry for over 30 years. England. Bernstein has an M.B.A. telecommunications industries. trends including BIM and green Currently, he has lead responsibil- from Loyola College, an M.S. in John has an M.S. in eCommerce building. Previously, with MHC’s ity for MHC’s market research engineering from Princeton Uni- from George Mason University, Dodge division, she has nearly group as well as MHC’s thought versity and a B.S. in civil engineer- an M.S. in Telecommunications twenty years of experience in the leadership initiatives in areas such ing from the New Jersey Institute from the University of Colorado construction news industry. Since as green building, BIM, interop- of Technology. and a B.S. in Geological Engineer- 2005, as Editorial Training and erability, innovation and global ing from the Colorado School of Policy Manager, she educated a construction markets. Previously, John E. Gudgel is responsible for Mines. team of over 250 reporters on key Bernstein served as the President managing MHC’s relationships trends in the industry, including and CEO of the Civil Engineer- with both national and regional Donna Laquidara-Carr, Ph.D., public-private partnerships and ing Research Foundation. He industry associations. He also pro- LEED AP, has been Manager of the evolution of project delivery currently serves as a member duces and offers thought leader- Green Research and Communica- methods. Donna has a Ph.D. from of the Princeton University Civil ship on construction technology, tions at McGraw Hill Construc- Tulane University, an M.A. from and Environmental Engineering managing MHC’s SmartMarket tion since December 2008. In that Boston University and a B.A. from Advisory Council and as a visiting Reports on BIM and Interoper- capacity, she provides editorial Middlebury College. McGraw-Hill Construction    1  www.construction.com SmartMarket Reports SMR0411_Letter-bio.indd 1 5/2/11 3:11:15 PM
  • 4. SmartMarket Report PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY TABLE OF CONTENTS 4 Executive Summary 4 Executive Summary 6 Recommendations 7 Data 8 Market Activity and Opportunity 8 Sectors with Opportunity for Prefabrication/Modularization 10 Building Sectors with the Most Significant Future Opportunity for Prefabrication/Modularization 12 Users of Prefabrication/Modularization 13 Levels of Use of Prefabrication/Modularization: Today and in the Future for Current Users 14 Future Activity by Current Non-Users of Prefabrication/Modularization 14 Firm Size of Prefabrication/Modularization Users 18 Productivity 18 Impact on Project Schedule 19 Impact on Project Budget 20 Impact on Site Safety Photo courtesy of Liam Frederick (cover); Photo courtesy of Perkins Wil (opposite page left); Photo courtesy of the Warrior Group (opposite page right) 21 Impact on Purchase and Installation Costs for Materials 22 Expected Impact on Project Schedule According to Prefabrication/Modularization Non-Users 22 Impact on Project Budget According to Non-Users 23 Impact on Reducing Onsite Resources According to Non-Users 23 Impact on Improving Project Quality According to Non-Users 29 Influence Factors 29 Drivers for Use of Prefabrication and Modularization 30 Factors Driving Future Use of Prefabrication/Modularization for Non-Users 31 Non-Users’ Current Reasons for Not Using Prefabrication/Modularization on Projects 32 Users’ Current Reasons for Not Using Prefabrication/Modularization on Some Projects 33 Prefabricated and Modular Building Elements 33 Influence of Job Site Conditions 34 Most Commonly Used Prefabricated and Modular Building Elements 39 Green Building 39 Using Prefabrication/Modularization on Green Building Projects 39 Construction Waste 40 Materials 41 Model-Driven (BIM) Prefabrication 41 Usage 42 Drivers SmartMarket Reports McGraw-Hill Construction  2  www.construction.com SMR0411_ToC.indd 2 4/29/11 3:33:48 PM
  • 5. Front cover: The Summit at Queens College Student Residence Hall, Queens, NY From left to right: Texas Health Harris Methodist Alliance Hospital, Fort Worth, Texas; Fort Sam Houston Medical Education and Training Complex Barracks, San Antonio, Texas CONTENTS 46 Contractors 46 Usage 47 Productivity 48 Drivers 49 Architects and Engineers 49 Usage 50 Drivers and Productivity 43 Data Sidebar: Drivers Behind Owner Adoption of Prefabrication and Modularization Sidebars 9 Brief History of Prefabrication/Modularization 25 Lean Construction Thought Leader Interviews 15 J. Doug Pruitt, Chairman and CEO, Sundt Construction 24 Gregory Howell, Cofounder and Managing Director, Lean Construction Institute Case Studies 16 Speeding Delivery to Meet a Military Mission: Fort Sam Houston Medical Education and Training Complex Barracks, San Antonio, Texas 26 Pushing the Envelope in Prefabrication: Texas Health Harris Methodist Alliance Hospital, Fort Worth, Texas 36 Innovation in Prefabrication to Achieve a Tight Schedule and Green Results: The Summit at Queens College Student Residence Hall, Queens, New York 51 Glossary 52 Methodology 53 Resources McGraw-Hill Construction 3     www.construction.com SmartMarket Reports SMR0411_ToC.indd 3 4/29/11 3:33:56 PM
  • 6. Executive Summary Everything Old Has Become New Again! Building information modeling (BIM), modern manufacturing PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY methods, sustainability goals and recognized productivity gains rejuvenate centuries old-construction processes. Prefabrication and modular construction are processes that have been used by generations of construction professionals. Over the past century, these processes have developed a stigma of “cheapness” and “poor quality.” However, through modern technology, that image has changed. Now it’s a key component of the drive to improve construction industry productivity. Adoption and Usage Percentage of Prefabrication/ Prefabrication and modular building processes are Modularization Users Today (2011) not new activities—63% of those that are using these Source: McGraw-Hill Construction, 2011 processes have been doing so for five years or more. User Non-User Given that prefabrication/modular construction has been around for many years, it is not unexpected that Contractor 85% of industry players today are using these processes 84% on some projects—including 90% of engineers, 84% of 16% contractors and 76% of architects. Engineer By 2013, nearly all players (98%) expect to be doing 90% some prefabrication/modularization on some projects. 10% Among users, usage today is fairly low. Only about a third of users (37%) have been using it at a high or very Architect high level (more than 50% of projects). Over the next 76% two years, usage on projects is expected to moderately 24% grow, with high or very high usage reaching 45% by 2013. Among all players surveyed, the highest level of current Current Drivers to Use of and future usage is among fabricators, mechanical Prefabrication/Modularization contractors and design-builders. (By Player) Among all players, the primary reason they are Source: McGraw-Hill Construction, 2011 not using prefabrication and modularization on some Contractor Engineer Architect or all of their projects is that the architect did not design it into their projects. Owner resistance was the primary Improve Productivity reason given by architect users (39%) and non-users 92% (54%) for not including prefabrication and modularization 70% into their designs. 68% BUILDING SECTORS AND AREAS OF USAGE Competitive Advantage Adopters are using prefabrication/modular building 85% processes on a wide variety of commercial building proj- 60% ects. In particular, respondents today are using it on 52% healthcare facilities (49%), college buildings and dormi- Generates Greater ROI tories (42%) and manufacturing buildings (42%). These 70% respondents see the most future opportunity in health- 43% care facilities (14%), hotels and motels (11%), commercial 40% warehouses (11%) and other building types (10%) that included data centers, prisons, power plants and oil refin- Owner/Client Demand eries. These opportunities do vary by player type. 31% 51% 35% SmartMarket Reports McGraw-Hill Construction   4  www.construction.com SMR0411_ExecSum.indd 4 4/29/11 1:22:26 PM
  • 7. Executive Summary CONTINUED Level of Decrease in Project 40% Within a building, prefabrication and modular Schedule Due to Prefabrication/ PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY construction are used in a variety of areas but most Modularization often in the building superstructure (27%), mechanical, Source: McGraw-Hill Construction, 2011 35% 30% electrical and plumbing (MEP) systems (21%) and exterior walls (20%). When deciding whether or not to use prefabrication or modularization, the most important factor is the 20% job site accessibility (58%) followed closely by the number of building stories (53%) and the type of building 10% 14% exterior (52%). 10% 7% USAGE DRIVERS The most important driver to current usage of prefab- 0% rication and modularization is its ability to improve 1 Week 2 Weeks 3 Weeks 4 Weeks productivity (82%). This is particularly important to or More contractors (92%). All players also see these processes as making them more competitive in the marketplace (75%). Level of Decrease in Project Budget Due to Prefabrication/Modularization 30% Productivity Improvements— Source: McGraw-Hill Construction, 2011 Primary Future Driver Architects, engineers and contractors are also very closely aligned in the belief that the primary drivers to 24% 20% future usage will be the improvements that prefabrication and modularization can provide to elements of productiv- 19% 17% ity including project schedule, cost, safety and quality. IMPROVED PROJECT SCHEDULES 10% A key metric of productivity is the project schedule. 66% of user respondents indicated that prefabrication/modu- larization processes have a positive impact on project 5% schedules, with 35% of those respondents indicating that 0% it can reduce the project schedule by four weeks or more. Decreased Decreased Decreased Decreased 1%–5% 6%–10% 11%–20% More Than 20% REDUCED COST AND BUDGETS Another key productivity metric is project cost as measured by the project budget. 65% of user GREEN BUILDING AND WASTE REDUCTION respondents indicated that the use of prefabrication/ Green was not a major driver to prefabrication and modu- modularization had a positive impact on project budgets, larization adoption. However, when asked about elements with 41% indicating that it reduced project budgets by of green, including site waste and amount of materials 6% or more. used, a different story emerges. 76% of respondents indi- cate that prefabrication/modular construction reduces SITE SAFETY site waste—with 44% indicating that it reduced site waste More respondents (34%) believe that prefabrication and by 5% or more. In addition, 62% of respondents believe modularization can improve site safety versus those that these processes reduce the amount of materials who think the practices reduce safety (10%). Most users used—with 27% indicating prefabrication/modularization believe that these processes are safety neutral (56%). reduced materials used by 5% or more. McGraw-Hill Construction 5     www.construction.com SmartMarket Reports SMR0411_ExecSum.indd 5 4/29/11 1:22:27 PM
  • 8. Recommendations The research findings have varying implications for different industry players. Owners: Reduce project design and construction, help achieve green objec- PREFABRICATION AND MODULARIZATION: INCREASING PRODUCTIVITY IN THE CONSTRUCTION INDUSTRY Consider using schedules—sometimes engineers should evaluate tives should be promoted prefabrication and by a month or more. the quality and availability and emphasized in bids. modularization Decrease purchase and of prefabricated/modular processes on your installation costs of products and be the Specialty projects. This is not your materials—ultimately catalyst for their use. Contractors: grandpa’s prefab! With the decreasing the project Many engineering firms Adopt for competitive precision bestowed by BIM budget. today are already using pre- reasons. For some con- and the quality provided Increase construction fabricated /modular ele- struction specialty trades, by modern materials and site safety—resulting ments for the building such as mechanical and manufacturing facilities, in fewer accidents and superstructure, exterior electrical contracting, pre- prefabrication and modular lower insurance costs. walls, roof and floor, and fabrication/modularization construction offer the Eliminate significant they view their use as a way has become an integral part opportunity to obtain amounts of construction to differentiate themselves of their business. With the significant productivity site waste, making the from their competition. inherent efficiencies and gains on your projects. project greener. productivity gains and cur- Owner demand is the Allow the specification General rent projections showing primary driver for architects and installation of Contractors and increased usage on proj- to include prefabrication / better quality and more Construction ects, specialty contractors modular construction into sustainable building Managers: need to acquire experience their project design. materials. Build prefabrication/ with prefabricated/mod- modular efficiencies ular processes in order to Architects: Specify prefabrication into your pre-construc- remain competitive. Understand and educate and modularization in tion planning and bids. clients on the benefits of your design. Once you Prefabrication provides Manufacturers: prefabrication and mod- get the client’s buy-in, predictable results for your Promote the green ben- ularization. As the initial make sure you include schedule and costs. The efits of your products. interface with the client, the prefabrication/modular- research shows that it can Although most architects, architect has the greatest ization into your design. decrease the purchase and engineers and contractors influence during the design The early decision to bring installation costs of mate- do not view prefabricated phase in determining if pre- it into the project allows rials and compress project and modular products as fabrication and modular for greater continuity of schedules. These factors a primary way to achieve construction will be used in design maximizing poten- can ultimately decrease the their green building objec- a project. tial productivity gains. The project budget and allow tives, all professionals Understand the key number one reason engi- GC and CM firms to be agree that these processes benefits that prefabri- neers and contractors give more competitive. reduce waste and the cation/modularization for not using prefabrication Include the green amount of materials used offer, such as improved or modularization is that the factor. It is clear that pre- on projects. Manufacturers project productivity, pro- architect did not include it fabrication and modu- need to raise awareness of ducing more sustainable in the project design. lar construction can help these green benefits. buildings and ultimately reduce waste and result Create BIM objects increasing ROI for the client Engineers: in a greener construction of prefabricated and and other members of the As the professionals site. Given that green has modular products. BIM project team. Architects primarily responsible for become a major factor in use continues to rise, and should educate clients that the structural integrity the construction market- BIM is a driver to increased using prefabrication/modu- and systems efficiency place, the fact that prefabri- use of prefabrication/ larization can measurably: of buildings during their cation/modularization can modularization. ■ SmartMarket Reports McGraw-Hill Construction   6  www.construction.com SMR0411_Recommendations.indd 6 4/29/11 1:34:20 PM
  • 9. Data:­Section Hed1 Introduction Construction Trends Driving Prefabrication/Modularization P refabrication and modularization are certainly not new to the Prefabrication and Modularization: Increasing Productivity in the Construction Industry  data construction industry. However, current influential construction Note About trends, such as the increasing interest in lean construction, the the Data rising use of BIM technologies and the growing influence of green The data in this report construction have caused many practitioners to reconsider their appeal. In are based on an online fact, the National Research Council’s 2009 report on improving productivity in survey of 809 contrac- the construction industry recommends prefabrication/modularization as an tors, architects and “opportunity for breakthrough achievement.”1 These factors, combined with engineers. The con- tractors comprise 65% recent advances in prefabrication/modularization, make this a critical trend in of the total respon- the construction industry. dents, while architects total 12% and engi- Lean Construction neers 23%. The large The strong increases in productivity offered by using prefabrication and number of respondent modularization fit squarely into the lean building model. The difficult firms in all three player economic conditions in the construction industry have increased the appeal of categories provides a statistically mean- lean methods and practices. For more information on the use of prefabrication ingful sample for the and modularization to achieve a lean approach, see pages 24 and 25. study conclusions. BIM For full methodology, The increasing use of BIM also contributes to the potential for increased use see page 52. of prefabrication and modularization. In a recent study about the use of BIM on green projects, McGraw-Hill Construction (MHC) found that the use of BIM model-driven prefabrication on more than one quarter of their projects is expected to increase from 37% to 73% among practitioners who use BIM for green work. Even those who are currently not using green BIM expect an increase from 22% to 57%.1 BIM helps enable prefabrication of tightly inte- grated MEP systems, allowing designers to maximize space for other uses in high-tech buildings like hospitals. Green Building Green building has grown into a substantial part of the overall construc- tion market. MHC’s Green Outlook 2011 estimates that nonresidential green building will comprise 28%–35% of the total market by the end of 2010. This dramatic increase in market share, from less than 5% in 2005, reflects the fact that green building sustained steady growth throughout the recession, even as the overall construction market shrunk by nearly one-third.2 MHC also predicts that the growth of the market share for green will not abate as the construction industry recovers from the recession. By 2015, MHC projects that 40%–48% of nonresidential construction will be green. As the results of this study demonstrate, this has strong implications for rising interest in prefabrication and modularization, which helps eliminate waste onsite and conserve resources. Bringing the Trends Together 1 National Research Council of the National Academies. Advancing the Competitiveness and Efficiency of the U.S. Construction Industry. What is most striking about prefabrication/modularization is its ability to Washington DC: The National Academies Press, 2009. 2 Green BIM SmartMarket Report: How Building Information Modelling is Contrib- enable all these trends, in addition to being more prominent because of them. uting to Green Design and Construction. McGraw-Hill Construction. July, 2010. 2 Green Outlook: Green Trends Driving Growth, 2011. It brings all of them together to improve productivity in construction. McGraw-Hill Construction, October, 2010. McGraw-Hill Construction   7  www.construction.com SmartMarket Reports SMR0411_Data_Intro_MarketActivity.indd 7 5/2/11 11:53:49 AM
  • 10. Data:­Market Activity and Opportunity Sectors with Opportunity for Prefabrication/Modularization Building Sectors Using Currently, prefabrication /modularization is being used on Prefabrication/Modularization Prefabrication and Modularization: Increasing Productivity in the Construction Industry  data many types of building projects demonstrating its appli- Source: McGraw-Hill Construction, 2011 cability across nonresidential construction. Healthcare Facilities The five sectors using prefabrication/modularization in 49% over 40% of projects are: Higher Education (e.g., Dorms, College Buildings) Healthcare (49%) ■■ 42% Higher Education (42%) ■■ Manufacturing Manufacturing (42%) ■■ 42% Low-Rise Office (40%) ■■ Low-Rise Office (1–4 Stories) 40% Public (40%) ■■ Public These sectors also present strong opportunities in the 40% construction market, which bodes well for a vigorous prefabrication/modularization future market. Commercial Warehouse 37% Healthcare K–12 School Healthcare is a sector that is well-suited for prefabrica- 36% tion/modularization techniques. The interior layout of hospital rooms allows for efficient use of modulariza- High-Rise Office (5+ Stories) tion, and it is a sector highly responsive to strategies that 30% shorten schedule—a particular benefit prefabrication Hotel brings to a project (See page 18). 29% According to McGraw-Hill Construction’s economic forecast, the market activity for healthcare construction Retail is expected to increase in 2011 and 2012 to become more 24% than a $28 billion market opportunity in 2012. Multifamily Dormitory and Education Projects 23% Like healthcare buildings, dormitories and school proj- Bank ects have features that are well-suited to prefabrication/ 18% modularization. Dorms and classrooms allow for use of Food Service (e.g., Restaurants, Convenience Stores) modular room design, and these projects also benefit from faster construction schedules. 16% As the largest construction sector by value (over $43 Auto (e.g., Garages) billion in 2011), education presents a significant oppor- 14% tunity for prefabrication/modularization—both currently and in the future (see page 10). Transportation (e.g., Train Stations, Bus Depots) 14% Variation by Player Contractors: Across the board, contractors report ■■ (46%), followed by commercial warehouses (43%). heavier current involvement in prefabrication/ Engagement in the other sectors is 30% or lower. modularization, predominantly in healthcare (61%), ■■Architects: Their heaviest use is in low-rise offices dormitory/education (50%) and public buildings (46%). (43%) and healthcare facilities (36%), with less than a Engineers: Engineers are using prefabrication/modu- ■■ third reporting use in other sectors. larization most often in manufacturing buildings SmartMarket Reports McGraw-Hill Construction   8  www.construction.com SMR0411_Data_Intro_MarketActivity.indd 8 5/2/11 11:54:14 AM