The Evolution of Prefabricated Construction: Focusing on High-Skill Components

The modular construction industry is undergoing a shift, prioritizing the prefabrication of complex, high-value components over entire buildings. This change addresses the challenges of high transportation costs, labor shortages, and escalating project timelines. The first post delves into this evolving strategy. It highlights innovative solutions from industry leaders such as Green Canopy NODE and Tedd Benson and insights from the European Batimat (Building on Automatic) exhibition. Later posts will explore panelized facades and the growing popularity of bathroom and kitchen units.

A prefabricated bathroom module is being installed instead of constructed on-site. Fully functional bathroom pods, with plumbing and electrical systems, can be rapidly integrated into new builds, dramatically reducing construction time and labor costs. This image is from an advertisement for Baudet, a French bath-pod manufacturer.

In conventional modular housing, the ideal is to construct entire homes offsite, transport them, and install them on a lot—promising speed, factory-level quality control, and lower costs. However, many in the modular industry are rethinking this approach due to high transportation costs for bulky, low-skill sections like bedrooms and living areas. A more efficient method is to prefabricate only the complex, high-cost components—such as kitchens, bathrooms, or wall cassettes that integrate plumbing, HVAC, and electrical systems into a single module.

During my visit to manufacturers like Green Canopy NODE, Dorthy Homes, and Ted Benson, as well as insights from the recent Batimat exhibition in Europe, I explored this evolving strategy. The shift towards prefabricating critical systems could be the key to addressing construction’s most significant challenges: spiraling costs, labor shortages, and on-site delays.

Prefabricating Critical Building Systems

Bec Chapin stands in front of Green Canopy NODE’s patented utility wall, which incorporates a ventilation stack and all the mechanical and electrical systems for the bathroom, kitchen, and laundry.

I met Bec Chapin, Co-CEO of Green Canopy NODE, at the Washington Mall during HUD’s 2024 Innovative Housing Showcase. They exhibited a prefabricated, modular mass timber building system, including a proprietary utility wall that caught my eye. Chapin calls it a ‘Building Kit’ designed to turn construction into assembly. Two people can carry and install the plywood cassette in minutes. Their concept had heavyweight institutional support, including Housing and Urban Development, the US Forest Service, the American Wood Council, the US Endowment for Forestry and Communities, and Mercer Mass Timber. They were also working with Virginia Tech under a multi-million-dollar grant, so I knew the company had to have some depth of thought and execution. I wanted to see the factory when I heard they had used the system on over 400 units.

Innovative concepts in modular mechanical cores often remain experimental, serving as demonstrations of potential offsite construction methods. However, Tedd Benson, CEO and founder of Bensonwood and Unity Homes, has been at the forefront of transforming these ideas into functional systems. His work with the Open Source Building Alliance (OSBA) and the Open Prototype Initiative (OPI), facilitated through MIT’s House_N, aimed at integrating sustainable building practices with advanced technologies to create homes that are not only adaptable but also highly responsive to environmental needs. A key advancement from this work is the core wall system, which integrates essential mechanical, electrical, and plumbing (MEP) systems into a streamlined, modular unit. This core wall, initially developed in a German R&D project with Hans Porschitz—now Bensonwood’s Operations Officer—embodies a major step forward in the efficient, offsite assembly of homes, allowing for faster installation and improved sustainability.

Besonwood and MIT House_n developed the core wall concept as an infrastructure backbone. Digital representation of the core wall by MIT House_n and Bensonwood Homes. Source: (Open Prototype Initiative 2006), as published in “Evaluating the Utility Core in the Prefabricated Building Industry – past, present and future,” December 2017 Enquiry the ARCC Journal for Architectural Research 14(1):37-47 by Carlo Carbone, Université du Québec à Montréal.

Benson explained that while the core wall succeeded as a proof-of-concept, full-scale production has been challenging due to diverse project portfolios and varying local codes. “We need a minimum of about 250 projects per year to commit to allocating the required personnel and production space at the factory. At that scale, we think we can be cost-competitive with on-site electrical and plumbing work,” explained Benson. However, the main obstacle comes with diverse local regulations, making standardizing units across regional markets impossible. 

I read Benson’s comments to Chapin when I visited their factory in Seattle, Washington. They explained that the company overcame this obstacle by designing an open box that a building inspector could scrutinize on the job like any other construction project. It also helps that Green Canopy NODE develops multifamily complexes, builds for others, and sells the Building Kits to third-party developers; this varies in their operations and provides multiple outlets for the kits—all in all, they hope to ramp up to 500 units annually by 2027. The concept for the kits came about as a joint venture between Chapin’s NODE, a small modular company, and their partner Sam Lai, founder of Green Canopy, a developer, and CAO of the combined enterprise.

According to Chapin, the “utility kits” are manufactured offsite in 23 hours, plumbed, and pre-wired. They require one hour for installation and 2.5 hours of plumbing and mechanical hookup. The electrical work does not add time, as it’s done at the shop. The electrician only needs to connect cables to the sub-panel. They claim to close an entire project in 30 days, having completed nearly 400 homes.

Chapin describes their work as a partnership of two “place-based businesses.” Manufacturing is place-based, and so is construction. The obstacles between them are always distance and the need to move manufactured components from the factory to the job site. Green Canopy NODE is developing a ‘pop-up factory’ to manufacture components on-site, reducing transportation challenges. Supported by a Department of Energy grant, they are piloting this model at Virginia Tech while continuing to streamline their building kits for greater efficiency. In the meantime, Chapin and their team continue perfecting the building kits to simplify and streamline the manufacturing process.

Green Canopy NODE’s plywood cassettes snap together with precision, similar to Japanese joinery, eliminating the need for fasteners. Modular kits use sub-components, such as shower or sink modules, separated by spacers, allowing flexibility while maintaining production efficiency.

Net-zero townhouses developed by Green Canopy NODE on Bainbridge Island, Washington, all featuring the Building Kit to rationalize the service core.

Many small innovations help speed up assembly at the shop and in the field; for example, they install Romex wiring into slots rather than drilling holes. Plumbing walls have several positions for waste lines, so the installer can easily adjust to the exact location of a drain without requiring a new wall configuration. 

Rather than drill holes and pull wire, Romex slips into slots routered by the CNC machine.
An ABS drain has three can fit in one of three positions on this bathroom vanity wall to more easily accommodate minor variations in cabinet and sink locations.

Mass timber framing is another integral part of the Green Canopy NODE system, including a raised platform subfloor. Spacers between the structural floor and a ¾-inch plywood layer create a gap, allowing wires and pipes to run diagonally without drilling through joists. This design also reduces sound transmission between units. While adding cost, Chapin explains that labor savings in the electrical and mechanical trades and noise reduction more than offset the expense.

Did You Know: About Cultural Differences in Appliances?

If you have traveled to Europe or South America, you may have noticed that when you order water or soft drinks at a restaurant, the liquid comes at room temperature and without ice. Many folks around the world find iced drinks an unnecessary nuisance – with those cold cubes nipping at warm lips. Because Europeans don’t use much ice, German, Italian, and other external appliance manufacturers don’t offer icemakers in their refrigerators, be they Liebherr, Míele, Bosch, or Gaggenau. Although for the US market, they provide conversion kits with an ice maker as an upgrade.

dishwasher

In the same vein, European dishwashers come without a heated dry cycle. Since many of us run the dishwasher at night, or after breakfast and the dash off to work, the dishes will dry on their own. Some European brands now pop the door open slightly to allow circulation is helping dishes to air dry.

My source: Mountain High Appliances

 

Did You Know: Why we Frame at 16-inches On Center

Our wood construction traditions came from England. Where English carpenters were right at home building houses framed with studs set at about 16-inches on center for walls with wood lath and plaster.

The lath was made from riven slats, deftly pealed with a hand ax off logs about 32-inches long. This was the length a man could reliably cleave a flat ribbon of lath with a single blow. Because applying plaster over 32-inch slats of lath nailed only at the ends proved springy and unstable, carpenters added a center stud to stiffen the lath. Hence, studs were set a 16-inches on center.

Unless you’re finishing your walls with plaster over wood lath, there’s no point to framing with a 16-inches module, try 19.5, 24, or any other permitted spacing.

My source: Advance Residential Engineering Services

Did You Know: Why Dairy Barns Are Painted Red (or White)?

The traditional gambrel (or Dutch) barn roof comes from northern Europe and prevails in places like Wisconsin and Minnesota with a heavy northern European heritage. Many immigrants to these states came from milk producing regions with specialized knowledge of cheese making.

Early on, these cheesemakers separated curds from whey and considered the latter a waste product, used for fertilizer and whitewashing agricultural buildings. To keep the whey from spoiling, they blended it with iron oxide, which rusts, yielding a dull red we refer to today as “barn red.”

Later, as milk producers were promoting the quality of pasteurized and homogenized milk, they wanted to show off its healthfulness and began painting their dairy barns white to advertise dairy’s nourishing and pallid purity.

Unprocessed milk, incidentally, is often not white, but pale yellow.

My Source: The Science of Cheese

Did You Know Why: Why We Refer to The Harvest Moon?

Loggers that I have met tell me of the importance moon cycles have to the durability and strength of wood products. Timbers felled during a waning moon produce inferior lumber with a diminished resistance to insects and degraded structural strength.

Artisanal woodsmen decry commercial logging that disregards natural cycles, harvesting on timber a business rather than a lunar calendar.   I thought this was all a matter of superstition.

It turns out that moon harvesting has ancient roots as a method of preserving timbers because moon cycles impact tree sap in the same way the waxing and waning cause ocean currents to rise and fall. A waxing moon draws sap up a tree, filling fibers with a natural preservative that keeps insects at bay and extends the resulting lumber’s resistance to cracking, warping and checking as the lumber dries.

Eco Design Architects and Consultants form Woodstock, NY, has conducted research on this method of natural wood preservation and they recommend cutting, “During the 3 days before the New Moon, but only between the Autumn Equinox & Winter Solstice.”

Did You Know: Windows Can Get Altitude Sickness?

Double-pane windows have a hermetically sealed airspace between two sheets of glass, the gap provides the insulation. If the seal between windowpanes breaks, moisture can get between the glass sheets and cause fogging. However, the engineered, hermetic seal traps more than gasses between the panes, it traps the ambient air pressure as well.

Sort of like a scuba diver must decompress on the way up from a dive, windows made at low elevations face their own risk of “the bends” when traveling to the high country, which is where I live near Vail, Colorado.

A sealed glass unit built at low altitude and then installed here at higher elevation must incorporate tiny, stainless steel or aluminum capillary tubes that allow the insulated glass windowpanes to equalize and remain flat and parallel.

If you want to learn more, a lot more, check out: “Residential Windows: A Guide to New Technologies and Energy Performance 2nd Edition.”

Did You Know: China Consumes More Concrete?

Reading in the Economist last month, I ran across the surprising fact that over the previous 100 years the United States consumed a whopping 4.4 gigatons of cement. Meanwhile, during the three years between 2011-2013, China consumed 6.4 gigatons of cement, 45% more than we did during the last 100 years. According to economist Elliot Eisenberg, the reasons lie in China’s vastly larger population, and concrete-based building methods, whereas we use a lot of wood.

What’s in a Threshold?

In colonial times, the wealthier people had homes with stone floors. In winter, these slick floors became slippery, with muddy shoes and melted snow. To absorb the muck, homeowners spread thresh — or straw — onto the floor at the entry. This thresh would pile up and then spill out the door. To keep it in, homeowners installed a board in front of the door to hold the thresh. SOme say the this threshold eventually evolved to become today’s modern door sill that sits under the door, while the name stuck as the “threshold.”

Still others say that the board was put on the outside of the door, not to keep thresh in, but to keep barnyard debris out. I like the first story better, since it goes onto explain why folks that did not have stone floors were called, “dirt poor.”

Image: By Infrogmation of New Orleans – Photo by Infrogmation of New Orleans, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=18071782