Prefabrication is significantly transforming the mechanical HVAC industry in numerous ways. Overall, prefabrication enhances efficiency, reduces project duration, and helps in maintaining a more predictable schedule. But that’s not all.
Prefabricated restroom piping
Efficiency and speed are often some of the biggest benefits of prefabrication. Prefabricated HVAC components are manufactured off-site in controlled environments, which reduces the time needed for on-site installation. Some examples of these components are sections of ductwork, piping and plumbing systems. This leads to faster project completion and minimizes disruptions at the construction site. Modern prefabrication techniques allow for a high degree of customization, enabling HVAC systems to be tailored to specific project requirements while maintaining the benefits of mass production. Bryan Baker, VDC Manager, shared “Most duct and piping take-offs are done during the coordination process. We recently started extracting more of this data from our coordinated models via Autodesk software. Not only can this information be used to fabricate duct, piping, and hangers; it can also be used for quick and easy procurement. This has saved us countless hours of manual take-offs and has enabled us to purchase items before impending price increases.”
Quality is another factor. Since components are built in a controlled factory setting, they undergo rigorous quality checks, ensuring higher consistency and reliability compared to traditional on-site construction. High-quality control in prefabrication reduces the likelihood of errors and rework, which can otherwise cause significant delays in traditional construction methods.
Prefabricated ductwork
Cost savings created by prefabrication can be passed along to the customer. By reducing on-site labor and minimizing material waste, prefabrication can lead to substantial cost savings. This is particularly beneficial in large-scale projects where budget management is crucial.
Prefabricated underground piping
Safety is paramount for our workers. Prefabrication reduces the amount of on-site work, which in turn lowers the risk of accidents and enhances overall safety for workers. Tasks that might otherwise be performed at heights or in challenging site conditions can be done at ground level in a safe, well-lit, and climate-controlled facility. "We had our safest year on record in 2024 from a standpoint of OSHA recordable incidents and lost-time injuries, and we attribute that, to some degree, to the amount of prefabricated work being done in a safe, controlled fab shop, off lifts and ladders on the construction site," said Erica Peet, VHV's Safety Manager. Secondly, safety incidents can impact a project schedule and affect other contractors.
Prefabrication has a significant impact on project schedules in the mechanical HVAC industry. Using digital tools to manage prefabrication schedules ensures that all stakeholders are aligned. Real-time tracking of production and delivery schedules helps in maintaining project timelines and quickly addressing any delays. Prefabrication allows for off-site manufacturing of HVAC components while on-site preparations are still ongoing. This parallel processing reduces the overall project timeline. Operations manager Mike Keenan had this to say, “As the construction industry evolves, projects are expected to be completed in shorter timeframes, while the workforce continues to shrink. Prefabrication helps ease the pressure by enabling faster installations that maintain the high-quality standards we're known for. By shifting work to the pre-construction phase, we reduce the need for overtime, which not only impacts our bottom line but also boosts team morale. This approach allows us to better manage peak workloads, delivering projects on time without compromising quality or employee well-being.”
Prefabricating components significantly help in balancing the workload of the workforce. Spreading out the work requires fewer workers on site at any given time thus improving scheduling and reducing the number of workers on site. Prefabrication helps in creating a more predictable and streamlined workflow. With components being built in a controlled environment, there are fewer delays due to weather or other site-related issues. Since components arrive ready for installation, the time spent on-site is minimized. This leads to faster assembly and less disruption at the construction site.
Overall, prefabrication is driving innovation in the HVAC industry, making it more efficient, cost-effective, and sustainable.