The life sciences community is making great strides in discovering novel drugs and groundbreaking therapies that help prevent and cure rare and chronic diseases with greater efficacy. Behind these remarkable breakthroughs are the state-of-the-art buildings and facilities where these advancements occur. Gilbane Building Company is leading the construction of advanced research and manufacturing facilities, shaping the future with each build. In today’s market, construction teams face tremendous pressure to complete high-quality projects on schedule while meeting client expectations. A key design and construction strategy gaining prominence is prefabrication.
The Connection Between Prefabrication, Speed, Quality, Safety, and Client Satisfaction
What is prefabrication? In simple terms, prefabrication involves the manufacturing of factory-made components of a project and transporting them “made ready” for assembly and final installation on-site. If properly planned, it is akin to assembling a colossal jigsaw puzzle with great benefits on productivity, efficiency, waste reduction, quality control, and construction safety. This approach significantly improves speed and team coordination and results in higher client satisfaction.
In 2015, B. Braun awarded the expansion of its Daytona Beach facilities to Gilbane. The project provided additional production lines, and prefabrication strategies were instrumental in ensuring timely completion. Gilbane was tasked with demolishing and remodeling the existing production space, building a new CUP, commissioning the remodeled facilities, and receiving new production equipment from Germany, Italy, Switzerland, Canada, and throughout the U.S., all within a 14-month schedule.
A prefabrication approach allowed work to be carried out off-site while concrete and steel installation activities occurred on-site. Prefabricated MEP racks arrived at the site factory-tested, insulated, labeled, and equipped with valves and tags.
Prefabrication wasn’t limited to MEP runs. We also prefabricated skids for WFI, Compounding, and Solution Mixing Systems. Working in a controlled manufacturing environment minimized waste and enhanced the quality of the prefabricated components. It also reduced manpower density on-site which in turn increases safety.
Managing the triumvirate of quality, schedule, and safety at any active/operating regulated facility can be a complex task. Prefabrication enhances field operations through Lean practices. It also increases the speed of construction. Picture this: while site preparation is in full swing, your building components are simultaneously manufactured and pre-assembled off-site. These concurrent schedule paths, made possible by prefabrication, offered us a powerful antidote to delays even during the COVID-19 pandemic.
Prefabrication is a paradigm shift in project scheduling, a departure from traditional, linear construction processes. The notion of ‘waiting time’ is dramatically reduced. Components are designed, manufactured, and delivered just when needed, paving the way for a smooth, uninterrupted workflow.
From a client perspective, the benefits are significant. B. Braun could see the project taking shape much faster, reducing schedule uncertainty. Moreover, the reduction in schedule can also result in a cost reduction.
Importance of Trade Coordination and Prefabrication
Collaboration is key as each team member and trade partner takes on a starring role. From the meticulous detailing mapping out intricate components to the diligent engineer verifying the structural integrity of each unit and to the factory worker ensuring the precision of each assembly, the success of the prefabrication process rests on the overall project team. Effective communication is the guiding principle to a seamless performance. This involves clear and consistent exchanges of information and ideas, allowing each team member to understand the unique requirements of their role and how it intersects with the tasks of others. The designer must understand the specifications to create a conforming design. The engineer needs to understand the factory team capabilities and constraints to ensure that the components are manufacturable. An effective coordination strategy also facilitates proactive problem-solving. Issues can be detected early, addressed promptly, and resolved.
Innovation & Technology: Virtual Design and Construction
During the prefabrication process, technology takes center stage. B. Braun’s consistent engagement with the Gilbane VDC team and vendors was key. BIM is a notable technology, centered on 3D models that provide professionals with a more real image making design and planning far much easier. It combines all design elements into a single platform, enhancing the precision of prefabricated parts, reducing discrepancies, and resolving design clashes.
Building the Future
Looking ahead, prefabrication holds the key to a more efficient, prosperous future in construction where waste is minimized, costs are better controlled, and speed, quality, and safety are further improved. We can anticipate a future where prefabrication isn’t merely an option but the standard. The potential of prefabrication is immense; it’s not only changing how we build but also how we plan. Prefabrication opens new horizons, shifting the paradigm from a linear approach to a more concurrent process. It’s a future where teams are united in their common purpose and break the silos, working harmoniously to deliver high-quality projects on time. The future is here, and it’s looking bright.
