In the industry of construction, time is money. The quicker a building can be constructed, the quicker that space can be occupied and put to use. Steel building systems use a method of construction known as “building systems” that significantly reduces the time it takes to occupy a space. Building systems can not be effectively utilized in site-based construction.
The primary fabrication of the building's structure occurs at the construction site, and the time it takes to construct a building can be drastically reduced if the primary fabrication of building structure occurs at a manufacturing facility.
1. Manufacturing Schedule Breakdown
The benefit of prefabrication can be maximized if the primary fabrication of the building structure occurs at a manufacturing facility, instead of the construction site. The manufacturing schedule can be broken down to three components as follows:
Engineering and Design (2 to 4 Weeks): The final design calculations for a building can be made with the help of BIM technology and construction software. The building’s digital representation facilitates detection of potential design errors and constructability issues.
Procurement of Raw Materials (1 to 3 Weeks): High-grade steel can be obtained to the exact dimensions required to comply with the local building codes.
Fabrication (3 to 6 Weeks): Using automated and robotic fabrication processes, building structure elements can be assembled for shipping to the construction site.
2. Construction Schedule Comparison
There are numerous financial and time savings to the use of prefabricated structures during the construction of a building.
Project Phase Traditional Site-Built Construction Prefabricated Steel Construction Time-Saving Mechanism
Site Prep and Foundation 4 - 8 Weeks 4 - 8 Weeks Both paths are parallel: Steel can be fabricated at the manufacturing facility while site work and foundation is completed.
Construction Timeline
Structural Fabrication 6 - 12 Weeks (On-site cutting/welding) 3 - 6 Weeks (Off-site automation) The machines we build are fully automated and work 24/7. They are immuned to weather delays.
On-Site Erection 8 - 16 Weeks 2 - 4 Weeks Rapid bolted connection allows quick assembly.
Total Est. Timeline 18 - 36 Weeks 9 - 18 Weeks Overall, schedules have been reduced by 30-50%.
3. Key Logistics and Delivery Variables in Global Supply Chains
While the factory fabrication process is rapid, successful delivery is dependent on effective logistics. These variables must be properly managed to ensure the project timeline stays on target.
Structural Complexity: Standard clear-span warehouse structures lend themselves to fast-track construction. Complex, multi-span structures with heavy crane configurations or mezzanine decks take longer to fabricate.
International Logistics: Delivery of oversize steel members requires expertise with break bulk shipping and port logistics to optimize container stuffing to avoid demurrage.
Foundation Readiness: Proactive alignment of foundation and prefabrication schedules allow the arrival of prefabricated components to align with the curing of the foundation, minimizing site congestion.
4. Operational Advantages of Prefabricated Steel Buildings
Efficiencies with prefabricated construction offer an operational and financial buffer for business growth. Eliminating extensive on-site welding and fabrication is possible because components arrive pre-drilled and pre-punched.
Simplified erection processes greatly reduce the number of labor hours required on site. As a result, there is less exposure to local labor shortages, higher workers’ compensation premiums, and adverse weather conditions. Also, the accelerated schedule allows businesses to implement systems and equipment to improve efficiency (i.e. racking systems, automation and processing systems, etc.) much earlier than in a traditional schedule.
Reliable Industrial Steel Integrator Partner
An engineering partner should be able to accurately evaluate engineering designs, and manage logistics and the supply chain to provide engineered solutions for industrial clients.
We provide a full supply chain, including the procurement of raw materials and international logistics, and can efficiently fabricate pre-engineered buildings of any complexity. This control allows us to maintain delivery time schedules.
Contact us to find out how rapidly you can commence operations at your facility and for an assessment of potential structural solutions for your project.
Frequently Asked Questions (FAQ)
How much time can I save by choosing a prefabricated steel building?
Use of a prefabricated steel building system can result in 30-50% savings in project schedule. In a traditional method of construction, there is a sequence of steps that have to be completed before the next set of activities can begin. With a prefabricated building, these activities can be done concurrently resulting in a shorter overall project duration. The construction of a prefabricated steel building is broken into 3 main phases. Phase 1 consists of the engineering design and modeling phase and typically takes 2 to 4 weeks. The second phase consists of the procurement of the raw materials and takes 1 to 3 weeks. The third and final phase is the fabrication phase and takes 3 to 6 weeks.
What effect does weather have on the construction schedule for prefabricated buildings?
Factors such as weather usually have no impact on the construction schedule of prefabricated buildings. The main part of the building is usually fabricated in a factory and hence in a controlled environment. Also, since the on-site assembly of a prefabricated building is faster, the building can be closed and protected from the weather much faster than a traditional building.
What is the most important logistics for projects abroad?
There are three key elements that must be effectively coordinated in order for international projects to be successful: container loading, Customs clearance and international shipping, and timing to coincide with the curing of the foundation to ensure the materials do not arrive too early or too late.
What makes on-site erection of prefabricated steel so fast?
The steel components can be manufactured to very high levels of precision and with a modular bolted connection, which eliminates the need for field work to cut and drill to join, and thus reduces construction time and cost.