There are proponents for both sides of the prefab construction Pop-Up factory concept. While some say it could be the answer for more housing and commercial building, others say that in the end, it will always cost more than a traditional modular or offsite factory when transportation and the setup and teardown of the Pop-Up is factored in.
When Bob Secours Mercy Health added a new medical facility in Cincinnati, Ohio, they turned to GBBN, an Architectural firm to design and build it. What is unique about GBBN is they turned to using a Pop-Up factory to build wall panels and other components.
As health systems plan for the future of their facilities, they’re navigating in a time of uncertainty. The problem they face is two-fold:
Ongoing supply chain issues. Material shortages and volatile fuel prices are compounding long-term issues (especially, skilled labor shortages) in a way that exacerbates market instability and increases owner’s risks. While the cost of many building materials leveled out over the end of 2022, that followed the dramatic price increases of the preceding years.
Increased demand for services. This is enough to make anyone involved in construction projects anxious, but health systems face a host of additional pressures. Most notably, an aging population is driving an increased demand for services, and healthcare systems need to take steps now in order to meet those needs. So, despite market uncertainties, many health systems are pushing forward with their projects.
Given this environment, what can healthcare providers do to control costs and mitigate the risk of getting caught in market fluctuations? One answer to consider is onsite prefabrication (or industrialized construction).
WHAT’S ONSITE PREFABRICATION? AND WHY DO IT?
Onsite prefabrication offers an important approach for health systems that are looking to manage this uncertainty. Its advantages include increased speed to market, decreased construction waste, better labor utilization, and lowered costs.
Distinct from traditional prefabrication, which occurs offsite, this approach fabricates building elements within a large, temporary manufacturing facility at the construction site. Imagine a 17,000 SF tent erected onsite where skilled workers work along an assembly line to produce large components of the building: exterior wall assemblies, interior wall assemblies, mechanical system assemblies, and so on. Working conditions are more predictable, ensuring increased safety, quality, and efficiency. This also makes the coordination of skilled trades much easier.
When they roll off the assembly line, these pieces—which can be as large as 13’ x 30’ (much larger than can be transported from offsite)—are hoisted into place by a crane. You can imagine the time saved.
THE PROOF IS IN THE PUDDING
GBBN is currently partnering with Bon Secours Mercy Health and Danis Construction on a project that is using this approach, and the results are impressive. At Mercy Health Kings Mills Hospital in the Cincinnati area, we’re seeing:
An 81% improvement in labor utilization rates
A 51% reduction in days onsite
Zero safety incidents
When all is said and done, we anticipate that our partnership with Danis and Bon Secours Mercy Health will help shave up to five months off the construction schedule. That’s a lot of savings in terms of labor and construction costs. It also means the building will be online, helping patients, and generating revenue sooner.
So, how do you know if this approach is right for you?
WHEN AND WHO? TRUSTED PARTNERS HELP YOU THROUGH UNCERTAIN TIMES.
There are some obvious constraints about when onsite prefabrication is appropriate. The scale of a project and the size of the site are key factors. Given the upfront cost in transporting the machinery and erecting the temporary structure, the project needs to be of a certain scale in order to recoup those costs. The site itself can also pose a difficulty. Even if the project is appropriately scaled, it might not be a prime candidate if the site doesn’t have room to accommodate the structure.
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Gary Fleisher is the Editor in Chief of Modular Home Source and Offsite Builder magazine. Email at [email protected]
Gary Fleisher, the Modcoach
