How Prefabrication and Modularization Can Improve Safety solution for thousands of families ‘bombed out’ during A World War II, offsite construction is becoming more popular today. The benefits of offsite construction include saving time, money and the number of workers required. The Safety The safety benefits involved are the most important reason why the usage of offsite construction should be encouraged. Some of the causes of accidents (falling from heights, perhaps) can be reduced, others like flooding from heavy rainfall can be completely prevented. Benefits Most construction companies are found to use some method of prefabricated construction. The modular construction of an entire property offsite is now becoming more popular. of Offsite Prefabricated vs Modular Construction Any building can be referred to as a prefab if one or more of its’ sections are constructed offsite and carried onsite as part of the building. For a prefab to be described as a modular building, the main components used to create the complete building are Construction made offsite. Unlike panelized or component levels of prefabrication, in modular construction most of the interior and exterior finishes are put into place in the factory. They are up to 80-95% complete when they leave the factory.
For example, a plumbing system may be assembled offsite through prefabrication. Through modular construction, a
Request a Demo 2 complete bathroom pod could be put together, including an professionals in the US were surveyed online, some involved in installed plumbing system. or introducing offsite construction.
Between 2010 and 2016, figures from a survey taken by the FMI/ • 58% who were already involved in offsite construction, BIM (Building Information Modeling) Forum show that project and said safety was the number one reason for its’ work using prefabrication has almost tripled during this time. importance. Also, contractors are now spending 20% of their working hours • 49% of those not involved, said safety was the main in prefabrication, compared to 12% in 2010. reason that they wished to introduce offsite construction. Reasons why offsite construction has become more popular, Looking at the number of worker fatalities in the construction include: industry, it is easy to see why safety is such an important issue. • Time saved In 2015, 4,379 worker fatalities were recorded in the US. 1 in 5 of • Money saved these were in construction. The Fatal Four are recorded as the most common causes of death. • Lower waste levels • Ability for deconstruction and rebuilding The Risk of Constructions’ Fatal Four • Higher quality In 2015, 937 or 21.4% of all American worker fatalities occurred • Safety in the construction industry. 602 of these were caused by one of the Fatal Four: The Importance of Safety 1. Falls 2. Struck by an Object The improvement of safety conditions, working in a controlled, 3. Electrocution permanent environment is an important reason why offsite 4. Caught in Between Objects construction is becoming more popular in the US. Offsite modular construction is important in the UK, since modular construction accounts for 15-20% of the houses built there”.
In 2011, 100s of AEC (Architecture, Engineering, Construction)
Request a Demo 3 The risk of these hazards causing injury or worse, is significantly • Struck by a falling object reduced through offsite construction. • Hit by a construction vehicle Prevention of the Fatal Four Through Offsite Construction • Crushed or caught in a cave-in of heavy material • Caught in-between cramped machinery 1. Falling From Heights Being provided with a lot more space, a job will be easier to When modular buildings are transported onsite, up to 90% carry out safely in a cooler location, usually with more available of the building could already be constructed. Through offsite oxygen. A cluttered workspace could also obstruct a workers’ construction, more work takes place at ground level. This could view onsite, maybe not even hearing nearby construction reduce the need to work at heights by as much as 80%. vehicles or machinery.
Of the hospitalized accidents and fatalities occurring in the 3. Electrocution construction industry, the most common cause of death is falling from heights. These falls are usually the result of The three most common causes of death through electrocution falling from a roof, as well as unstable scaffolding or ladders. are: Permanent scaffolding remains in place offsite, without the need for scaffolding or ladders onsite. • Contact with overhead power lines The danger of falling from heights is even greater in unsafe • Contact with an energized source weather conditions, like a strong wind or thunderstorm. Falling from heights due to weather conditions can be completely • Incorrect use of extension cords prevented through offsite construction. In offsite construction, there is less danger of workers hitting 2. Struck by or Caught in Between Objects an overhead powerline. Most of their onsite construction will take place at a low, safe level. Power tools are more likely to With less machinery, construction vehicles, heavy materials, have a permanent location, without extension cords being and construction workers onsite at any time, there is a lower accidently left across a walking space. They should be kept risk of workers being: in a dry area without exposure to moisture. This could be the cause of wet weather conditions.
Request a Demo 4 The Risk of Unsafe Weather Conditions • Delays, if areas need to be pumped dry • Washing away important equipment Weather conditions can often be the reason for losing time onsite, on a day when it could be too dangerous to work in: Ice on a cold construction site can be a dangerous trip hazard, • Strong winds sometimes damaging pipes and other equipment. Fog and heavy rain are two weather conditions that can make visibility poor. A • High or low temperature direct lightning strike could even result in fire. • Lightening • Heavy rain • Fog
Strong winds can make it more dangerous to work at heights. The winds have the chance of blowing away important tools or damaging moveable scaffolding. They can also make hearing difficult, even if a large vehicle is moving close by.
If construction occurs during times of high temperature; dehydration and tiredness are two common effects. Important Personal Protective Equipment (PPE) such as gloves could feel too warm to wear.
Too much rain can cause problems, such as: • Contaminating certain material • Collapsing of earth moving jobs • Blocking roads and pathways
Request a Demo 5 Prevention of Other Safety Risks Local Community disruption
There are other safety risks in construction that could be the With less noise and heavy vehicles around, modular construction cause of a minor, sometimes serious injury. causes less disruption for onsite workers, as well as local residents or workplaces. This is more important when extensions Manual handling injuries are being made for schools, hospitals, or active businesses that are still in use and is one of the reasons why the NHS has With repeated jobs taking place in a modern and permanent welcomed modular construction. factory setting; lifting, arranging, and securing different sections of a building can be done using light machinery. Concrete is one Case Study: NHS Adopting Modular Construction of the biggest causes of carbon emission. Materials used such as wood and steel are more popular in modular construction, much The UK National Health Service (NHS) began modular building lighter to carry and easier to recycle. framework in January 2017, when studies showed modular construction could occur 50% faster and cost 30% less. Slips, Trips, and Falls Sometimes extensions are required for buildings that are decades old and needed as soon as possible. Months of onsite Cleaner working conditions, more likely to be maintained in work could cause disruption, especially for hospitals that are in a factory setting, make it less likely for common accidents to use. occur. For example, slipping on a surface where water has been For example, at Croydon hospital a temporary ward space spilled or maybe tripping over objects such as buckets or other was required. ‘Elite Systems’, one of the companies within equipment left outside. Weather conditions could also be the this building framework, craned each constructed single-story reason for slipping on a wet or frozen surface. modular unit over the top of the hospital and into a courtyard. A Comparing offsite to onsite construction areas, studies have week later, the ward was ready for use. shown that the safety of the workstation is considered more important offsite. Designated storage areas are provided for Mike Twizell, the sales director at Elite ‘Systems’ states: equipment and other materials. Also, color coding walkways prevents workers from walking in an unsafe space or leaving any “One of the big bonuses of working with us is that we have equipment on the walkways. used the same subcontractors for many years. They know what is expected of them in terms of performance and workmanship.
Request a Demo 6 We have formed a strong bond of trust.” the same time, 30-50% is a common amount of time recorded Benefits for the NHS include: to be saved. Work will not have to be postponed in unsafe weather conditions. • One point of contact for the project involved
• Costs are unlikely to change While buildings are constructed offsite, work occurring onsite at • Less onsite work, which could cause disruption in the same time could include: occupied hospitals • Excavation
While safety is an important reason for offsite construction to • Site drainage be implemented, reduction in costs and the amount of time • Creating concrete foundations saved are two of the main reasons why it is introduced. They could be the result of safer working conditions. Money Saved
Other Benefits of Offsite Construction Apart from the amount of time saved through modular construction, money can also be saved through several other In 2011, a survey by McGraw-Hill Construction of 800 factors, including: architecture, engineering and contracting professionals working in prefabrication and modular building in the US, found: • Lower insurance rates • 66% reported project schedules decreased, 35% by 4 • Lower water and energy costs weeks or more • Less unexpected labor costs, maybe caused by problems • 65% reported project budgets decreased. such as weather conditions • 77% reported onsite waste decreased. • Less onsite labor required
Along with a decrease in accidents occurring onsite, other Lower Waste Levels benefits include: Concrete is one of the biggest causes of carbon emission Time Saved in the world. Figures from 2016, show that construction and With site development and offsite construction happening at demolition waste accounts for 25-40% of the national solid
Request a Demo 7 waste stream in the US, with only 20% being recycled. the offsite construction industry. According to the UK Waste and Resources Action For example, the Katerra factory, based in California, builds Programme (WRAP), modular construction can decrease the wall panels, floor systems, utility walls, roof truss assemblies amount of different materials used by up to 90%, e.g. less and cabinetry. Although only 9% of the broader construction wooden pallets, concrete, bricks, cement, cardboard. industry are female, they account for 40% of workers in this factory. Built for Deconstruction, not Demolition Some of these benefits are more relevant to different Sometimes referred to as Lego bricks, modular buildings workers, but safety is still important for everyone involved. can be permanently located or made relocatable; deconstructed onsite and rebuilt on another. This reduces Effect of Modular Construction on Different Workers the amount of raw materials and energy required for a completely new building. The most common markets in “You have the contractors interacting with the mechanical this form of construction are education, retail, healthcare, contractors interacting with the designers and architects. and construction-site offices. Emergency housing, could be In the past, everyone worked in their own little bubbles and temporarily needed after a disaster such as an earthquake. that separation made it a challenge to meet common goals.” (Graham Watts, chief executive at UK Construction Industry Higher Quality Council).
Working in a controlled factory setting, thorough quality An accident is more likely to happen onsite. In the UK testing is carried out, discovering where certain problems manufacturing industry, major injuries are recognized to be have come from before anything is moved onsite. Each 20% less and worker fatalities 52% less than the construction constructed section must then be able to endure transport industry (2016). Bringing different trades such as architecture to and installation onsite. and construction together, into a permanent and controlled environment, is safer for everyone involved. Labor Shortages Working together, they will probably follow the same rules, In 2016, two thirds of the construction firms in America had making it easier for the project manager to notice any unsafe, trouble finding labor for the work required. Jobs often need usually common behavior and implement changes. to be made more appealing, maybe offering higher wages. Using more mechanical machinery and requiring less After a number of projects, workers are more likely to: specialized experience, there are more workers available in
Request a Demo 8 • Know who to contact for advice on different problems have a positive impression of modular homes and think they’re low quality. Younger people, especially with growing families, • Trust other workers enough to share any concerns or understand the benefits and wonder why everyone doesn’t opt suggestions on improvement for a modular addition.” • Recognize unsafe behavior, offering helpful advice (Michael Winn, owner of Winn Custom Modular, a division of Winn Design + Build in Falls Church) • Know the roles and responsibilities of everyone involved in a project, making them less likely to perform any overlapping Modular construction does seem to be more popular with work younger families, indicating that its’ popularity is now increasing. • Make sure that any problems in one project are not There are a number of reasons why. repeated in another More Specialized Design Apart from a safer working environment, time and money will probably be saved. Two workers performing the same job in a In the past, modular construction has been more popular new project can waste time and money doing work that doesn’t in buildings such as hotels, office buildings and hospitals, need to be repeated. where 100 identical bathrooms, or hotel rooms can be quickly constructed offsite. With many modular construction companies If construction workers notice any unsafe qualities in design, now building more customized structures, it is becoming a more they will be able to contact architects straight away and quickly popular method of house building. Extensions can be designed discuss any changes. Modern technology can be used to identify and made indistinguishable from the original building. A lot of these safety problems immediately. It is more popular in offsite this is to do with an improvement in technology. construction and is also making modular construction more popular with homeowners. The offsite construction of modular Improved technology housing is expected to increase in the future. “Cover”, a home building company based in California, states: A Future Increase in Modular Housing “We’re doing for homes what Tesla is doing for the car – using “It’s interesting that most of the homeowners who are choosing technology to optimize every step of the process, from design modular additions are young families. Older homeowners don’t and sales, to permitting and manufacturing.”
Request a Demo 9 Modern technology now uses different systems to come up Conclusion with every possible design solution available for a current project. Clients begin by filling out a digital survey of up to With workers’ deaths in the US falling from 38 a day (1970) 100 questions, describing their lifestyle, design choices and to 13 a day (2015) in just over 30 years, an increase in offsite other topics. Being posted onto Covers’ exclusive computer construction is hopefully one reason, why these figures will program, suitable designs are then developed to satisfy all continue to fall. The Fatal Four are accidents that can be these requirements. reduced, with some of the causes such as unsafe weather conditions being completely prevented. After a few business days, clients will be provided with “photorealistic renderings and plans”, including a full cost Apart from a safer working environment, benefits such as for each. Modern technology and the individual design less time taken and lower costs are other positive effects. A provided for each customer are some of the reasons safer working environment could be the reason that work is house building is becoming more popular through modular taking a less time, with dangers such as strong winds and construction. rain being avoided. Money could also be saved on the cost of accidents and illnesses that need to be treated. Global Warming While the US Modular Building Institute estimates that Scientists have estimated that global temperatures could modular construction accounts for approx. 3% of the market rise between 2.5°C and 10°C within the next century, if the share of modern construction, figures are estimated to rise emissions of CO2 and other greenhouse gases are not to 5% by 2020, and and given all the benefits that come reduced. With its’ lower emission of CO2, not just during with prefabrication, can be expected to continue to grow in the construction phase, but also due to benefits such as the future. improved insulation against drafts, modular construction is important in the future.
Request a Demo 10 A contractor orientation system built for the guys on the ground
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