Building commercial halls: Prefab vs traditional

In recent years, the number of companies and organisations opting for prefabricated constructions has significantly increased. This is due to the ever-improving quality of prefabricated buildings and dissatisfaction with traditional construction.

Modular buildings play a key role in numerous constructions, including Industrial units, pilots, chalets, villas and much more besides. However, there are still plenty of arguments to be made that traditional construction offers more for your money.

In this article from Ripstaal Group, we weigh up the pros and cons of both prefabricated construction and traditional building methods. This applies to often large buildings such as commercial halls or industrial sheds, as well as homes, housing projects, and other structures.

Ripstaal Steelframing – Building Prefabricated Industrial Halls 

At Ripstaal Group are we proud to offer a full range of Prefabricated building services that we can offer our clients. Naturally, our team believes that modular buildings offer a range of advantages compared to traditional construction.

However, we are here to take an honest look at Prefabricated vs traditional construction. We are committed to providing our customers with the best facilities to meet their needs. The last thing we want is to build a modular solution when buildings made of, for example, brick, are more reliable or offer better value.

Modular Buildings vs. Traditional Construction: The Pros and Cons

Brick construction has been the standard of the construction industry in the Netherlands for hundreds of years. Most houses and businesses in the Netherlands are built from brick and cement. In the past, this was the most reliable and affordable construction method. Traditional construction also meets the building regulations for residential, commercial and industrial properties.

Modular or prefab construction is a relatively new style of building. Prefabricated buildings, if expertly constructed, can meet all building regulations for any type of property. Failing to adapt to new and evolving construction techniques can lead to all sorts of problems. As standards improve and the industry continues to advance, it's more important than ever that you take advantage of the best in modern construction.

The pros and cons of traditional building

You are probably familiar with how brick and cement construction works. Following the initial planning procedure and once you have obtained planning permission, the site is excavated. Your contractors will then lay foundations in the ground and erect walls using brick and mortar. Once the walls are complete, the roof is put in place. This process can take several weeks, or even months, depending on the size of the property and any issues that arise along the way.

For complete housing estates, traditional construction can take many months or even over een jaar to be seized in full completion. This only includes the shell or exterior of the building. Once the exterior of the building is ready, the interior must be finished. It can then still take many weeks or even months before the house is habitable. Also, do not forget the amount of labour required for this. And that in a tight labour market.

What are the advantages of traditional, brick construction?

Traditional construction is reliable and durable. These buildings can survive many years in harsh environments and require little maintenance. They can be built in a wide range of shapes and sizes. Brick buildings, if constructed correctly and maintained when necessary, multiple generations go along.

What are the disadvantages of traditional buildings?

Unfortunately, there are also many disadvantages to traditional brick construction. However, this was not seen as a disadvantage or problem until alternative construction methods emerged. Some of the disadvantages of traditional construction are:

1. Project time – One of the biggest problems is the time required to build a brick building. This form of construction is no longer suitable for projects that require a quick turnaround time. In many cases, project time can be extended by factors over which you have no influence, such as the weather, staff availability or delays in material delivery.
2. Disruption – Traditional building causes a lot of disruption in the surrounding area. A lot of noise is released when building with brick. Furthermore, this method is bad for the environment because there is a lot of material wastage. The disruption caused by these projects is unavoidable.
3. Costs – Aside from the high material costs, the large number of workers required will significantly drive up the project's expenses. In the past, this has led to some projects being abandoned once most of the work was already done. The inability to pay construction companies is a major problem, especially when a project is delayed or runs over budget for any reason.
4. Non-customisable – Traditional buildings are difficult to adapt once they have been erected. Adding an extension to the property can be quite a substantial building project in itself. Therefore, if the building ever becomes unsuitable, the owner will have to move or pay for expensive renovations.  

De voordelen van modulaire gebouwen zijn onder meer: * **Kostenbesparingen:** Modulaire bouw is vaak goedkoper dan traditionele bouw, omdat veel van het werk in een gecontroleerde fabrieksomgeving kan worden uitgevoerd. Dit vermindert afval en minimaliseert de noodzaak van arbeid op locatie. * **Snellere doorlooptijden:** Omdat modules tegelijkertijd kunnen worden geproduceerd terwijl de fundering op locatie wordt voorbereid, kunnen modulaire gebouwen aanzienlijk sneller worden voltooid dan traditionele gebouwen. * **Verbeterde kwaliteit:** Bouwen in een gecontroleerde fabrieksomgeving maakt striktere kwaliteitscontroles mogelijk, wat resulteert in een consistenter en hoogwaardiger eindproduct. * **Duurzaamheid:** Modulaire bouw genereert minder afval dan traditionele bouw. Bovendien kunnen de fabrieksomstandigheden efficiënter gebruik maken van materialen en energie. * **Flexibiliteit en schaalbaarheid:** Modulaire gebouwen zijn ontworpen om eenvoudig te worden uitgebreid, verplaatst of herconfigureerd om te voldoen aan veranderende behoeften. * **Minder verstoring op locatie:** De meeste bouwactiviteiten vinden plaats in een fabriek, waardoor hinder op de bouwplaats wordt geminimaliseerd, wat vooral gunstig is in drukke stedelijke gebieden of operationele omgevingen. * **Veiligheid:** Fabrieksmatige productieomstandigheden zijn over het algemeen veiliger dan bouwplaatsomstandigheden, met minder risico op ongevallen. De nadelen van modulaire gebouwen zijn onder meer: * **Initiële kapitaalinvestering:** De kosten van het ontwikkelen van een modulaire bouwontwerp en fabricageproces kunnen hoog zijn, vooral voor kleinere projecten. * **Ontwerplimieten:** Hoewel de flexibiliteit toeneemt, kunnen er nog steeds beperkingen zijn aan de ontwerpvrijheid, vooral voor zeer complexe of esthetisch veeleisende gebouwen. De grootte en het gewicht van de modules kunnen ook beperkt worden door transportmogelijkheden. * **Transport- en logistieke uitdagingen:** Het vervoeren van grote, geprefabriceerde modules naar de bouwplaats kan complex en kostbaar zijn, vooral naar afgelegen locaties of plaatsen met beperkte toegang. * **Noodzaak van gespecialiseerde vaardigheden:** De productie van modulaire componenten vereist gespecialiseerd personeel en apparatuur, wat niet overal beschikbaar is. * **Locatiebeperkingen voor fundering:** De fundering op locatie moet nauwkeurig worden voorbereid om de modules te kunnen ontvangen, wat specifieke planning en voorbereiding vereist. * **Potentiële problemen met verbindingen:** Hoewel de technologie verbetert, kunnen de verbindingen tussen modules soms kwetsbaar zijn voor waterinfiltratie of structurele problemen als ze niet correct worden uitgevoerd. * **Perceptie en acceptatie:** Sommige mensen hebben nog steeds vooroordelen tegen modulaire gebouwen en beschouwen ze als minder duurzaam of esthetisch aantrekkelijk dan traditionele gebouwen, hoewel dit beeld snel aan het veranderen is.

Prefab construction projects begin in the same way as traditional buildings. Evaluations will need to be carried out, the earth will need to be excavated, and foundations laid. Once the foundations are laid, modular construction can commence.
While the excavation and laying of foundations are underway, however, manufacturing has already begun. The components of modular buildings are not made on-site. Instead, they are produced elsewhere in a factory. This means that essential parts, such as walls, ceilings, and other surfaces, are built off-site to a high standard. Once the foundations have been laid, these components are delivered to the construction site.

De voordelen van modulaire gebouwen zijn onder meer: * **Snelheid:** Modulaire gebouwen kunnen aanzienlijk sneller worden gebouwd dan traditionele gebouwen. De modules worden in een gecontroleerde fabrieksomgeving geproduceerd, terwijl de bouwplaats wordt voorbereid. Dit vermindert de totale bouwtijd, vaak met 30-50%. * **Kostenbesparing:** Door de efficiëntie van de fabrieksfabricage, minder afval en een kortere bouwtijd, kunnen modulaire gebouwen kosteneffectiever zijn dan traditionele bouwmethoden. * **Kwaliteit:** De productie in een gecontroleerde fabrieksomgeving zorgt voor een hogere en consistentere kwaliteit. Externe factoren zoals weersomstandigheden hebben geen invloed op het bouwproces. * **Duurzaamheid:** Modulaire bouw genereert minder bouwafval omdat materialen efficiënter worden gebruikt in een fabrieksinstelling. Daarnaast is er vaak minder verstoring van de locatie zelf. * **Flexibiliteit en schaalbaarheid:** Modulaire gebouwen kunnen worden ontworpen om gemakkelijk te worden uitgebreid, verplaatst of aangepast aan veranderende behoeften. Dit maakt ze ideaal voor tijdelijke faciliteiten of bedrijven die verwachten te groeien. * **Veiligheid:** Werkzaamheden in een gecontroleerde fabrieksomgeving zijn over het algemeen veiliger dan op een bouwplaats, met minder risico op verwondingen. * **Minimale locatie-impact:** De bouwtijd op de locatie is korter, wat leidt tot minder geluidsoverlast, stof en verkeershinder voor de omgeving. * **Voorspelbaarheid:** De planning en de kosten zijn vaak beter voorspelbaar bij modulaire bouw vanwege de gestandaardiseerde processen en de controle over de productie.

Some of the major benefits that modular and prefabricated construction can offer include:

1. A faster construction project – The simplicity of modular construction means projects can be completed extremely quickly. While the foundations are being laid, the modular components are manufactured off-site in a factory. Once delivered to your building site, they can be erected in a short amount of time.
2. Cost-effective building Thanks to the low price of materials and shorter project timelines, modular construction is cheaper than traditional building. If you are looking for a high-quality building at a lower price, then modular construction is ideal.
3. A less disruptive construction Modular construction projects are much faster and less disruptive than traditional building. This makes them ideal for sites that need to remain operational during construction, such as hospitals and schools.
4. Environmentally friendly – Modular construction generates less waste and makes greater use of sustainable materials. As such, prefabricated buildings are among the most environmentally friendly in the world.

In addition to these major advantages, modular buildings are of a very high quality and are versatile. They can be adapted without much difficulty, including extensions and other renovations. They are also lighter in weight, which means they are more flexible in terms of design. Modular buildings also require fewer load-bearing walls, allowing for a more unique interior and exterior design.

De nadelen van modulaire gebouwen zijn: * **Beperkte ontwerpmogelijkheden:** Hoewel de ontwerpmogelijkheden verbeteren, zijn modulaire gebouwen nog steeds beperkter dan traditionele gebouwen. Je bent gebonden aan de beschikbare modules en afmetingen. * **Transportkosten:** Het transport van de modules naar de bouwplaats kan duur zijn, zeker als de afstand groot is of als er speciale transportvereisten zijn. * **Fundering:** Een solide fundering, net als bij traditionele bouw, is cruciaal en kan tijdrovend en kostbaar zijn. * **Moeilijkheden met terrein:** Complexe of moeilijk bereikbare bouwterreinen kunnen de installatie van modulaire gebouwen bemoeilijken. * **Esthetiek:** Sommige mensen vinden modulaire gebouwen minder aantrekkelijk dan traditioneel gebouwde structuren. Hoewel moderne modules steeds beter afgewerkt worden, kan er een steriele uitstraling zijn. * **Permanente structurele integriteit:** Als een modulair gebouw eenmaal is geïnstalleerd, is het moeilijker om het later aan te passen of uit te breiden dan een traditioneel gebouw. * **Waardebehoud:** De restwaarde van modulaire gebouwen kan soms lager zijn dan die van traditionele gebouwen. Dit hangt echter sterk af van de kwaliteit van de constructie en het beoogde gebruik. * **Aanpasbaarheid op locatie:** Hoewel de modules in de fabriek worden geassembleerd, kunnen er op locatie nog steeds aanpassingen nodig zijn, wat de oorspronkelijke tijdsbesparing kan beperken. * **Vergunningen:** Hoewel modulaire bouw vaak sneller verloopt, moet je nog steeds rekening houden met de benodigde bouwvergunningen en goedkeuringen, die per gemeente verschillen.

There are only two real problems with prefabricated building, and they are:

1. Delivery of materials – In some cases, delivering materials to the construction site can be a problem. Some of these modular components can be large in size, requiring a large vehicle. If there are issues such as narrow roads, low bridges, or heavy traffic, delivering these materials can be problematic.
2. Public perception The biggest stumbling block for modular construction by far remains public perception. Despite their high quality and reliability, prefabricated buildings are still viewed as rather weak or vulnerable structures. There is still a long way to go before modular buildings are accepted as the logical successor to traditional construction.

Costs

Thanks to modular construction, preparatory work on the building site and construction work off-site can commence simultaneously, which is a major advantage over traditional construction: speed. According to the McKinsey report on modular construction in 2019 can modular construction 20-50% faster then traditional construction. This time saving should not be underestimated, as time-related costs are much lower. Think of preparatory work, overhead costs, site accommodation, equipment rental, etc.

The effect of the higher speed This is naturally a faster return on investment for the customer, with lower overhead costs on the building site for the duration of the project. So, even if the construction costs were the same, the effective cost of the development is lower.

Additional factors that reduce the cost of modular construction are:

Automation

Modular construction utilises machinery and robotics that automate a number of typical human tasks. This means smaller construction teams are able to achieve higher productivity than is typically possible in traditional construction. The capabilities of automated machinery are likely to increase over time.

Reduced risk of cost overruns and delays

Modular building offers much greater cost and time certainty than traditional building because there are fewer risk factors causing cost increases and delays – fewer people and fewer contractors on site to manage, fixed costs for units, far less rework and variations, and much lower contractor overheads (pre-work, material costs, etc.).

Quality of workmanship and rework costs

Thanks to stricter control of the manufacturing process in the factory and precision engineering, quality is much higher and rework costs are generally lower with modular construction than with traditional construction. As a result, this expensive and time-consuming process of rectifying design flaws and production quality issues on a construction site has been almost entirely eliminated.

Material costs

This factor can actually go both ways (see below). The precision engineering used in modular building means there is less waste compared to traditional building. The improved engineering means modular buildings generally perform better and can deliver drastic savings later on in the building's maintenance costs. Both factors reduce the effective cost of modular materials. However, there are certain factors that increase the cost of modular building compared to traditional building.

Facility costs.

Building and maintaining a production facility for offsite construction is very expensive. So, if the customer has their own facility or outsources production to third parties, this will be reflected in the construction costs.

Logistics and transport

This must be taken into account as the parts built offsite must both be transported and assembled on the construction site. Depending on the distance of the construction site from the production facility and the transport restrictions en route for the vehicles transporting the parts, these costs can be considerable.

Security of funding

This is more difficult for modular construction, as it typically incurs a higher interest rate. Banks are hesitant about the higher bankruptcy risk associated with modular construction, as market participants are generally less reputable operators. However, this is expected to improve over time, as operators build a track record of sustainable operation, which will give lenders confidence.

Material costs

As stated above, these can also be more expensive for modular construction as a higher quality of materials is required when using automatic machinery. As structures built in a factory must withstand transportation and assembly, a larger volume of materials is used compared to traditional construction, making it more expensive.

Given all these points, it can be stated that in a cost comparison between the two construction methods, one of the methods may be preferred, depending on the specific characteristics of the project. However, it is important to note that the costs of modular construction may decrease as innovative manufacturing techniques continue to improve and more competitive market participants enter the market.

Design

The design of modular construction projects needs to be finalised at a much earlier stage than that of traditional construction projects. This is because the design needs to take into account manufacturing and assembly, whereas traditional designs can be much more fluid and often only finalised once works have commenced on site.

This can be interpreted both positively and negatively in favour of modular construction, as there is greater certainty throughout the supply chain, but it can also be seen as too rigid and expensive to adapt if unavoidable changes occur that necessitate altering the design.

Sustainability

This has never been more important for construction projects than it is now. Authorities, buyers, and investors have become more aware of the environmental impact, and we therefore need to ensure that construction is sustainable.

The use of renewable materials and the limitation of emissions are therefore essential considerations for a building project. Modular construction seems to have the upper hand in this regard, as although the use of renewable resources is possible with both construction methods, there is often less material wastage and the buildings produced with modular construction are better, as previously discussed.

Modular construction projects also tend to cause less emissions. The number of workers is usually smaller, fewer people have to travel to the construction site, and there are fewer heavy, fuel-powered machines on site, all of which contribute significantly to lower emissions.

How do you choose which construction method to use for a building project?

This needs to be done at the earliest stage of a construction project.

Each project has its own unique limitations and development goals, and given the variety of factors involved in choosing your construction method, there is no objective answer to the question of which is best. A good evaluation of your development objectives is needed to assess which construction method is most suitable for your project.

So how do we evaluate all these points to make a decision on which construction method to choose for your specific building project?

This is currently happening during the feasibility stage of a project, a manual, labour-intensive and costly process where location and market conditions are evaluated, and a conceptual building design and cost estimate are prepared using tools such as Microsoft Excel and Autodesk Revit.

At Ripstaal, we believe the modular construction sector needs a new set of tools to demonstrate the value of modern construction methods to contractors, architects, and project owners still wedded to traditional methods.

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