When we kicked off the BHS project, prefabrication wasn’t even on the radar. Fast forward to today, and we’ve evolved into a fully prefabbed operation, covering everything from ductwork and plumbing to underground piping systems. The transition wasn’t without its challenges, but the rewards have been substantial.
This shift all started with a visit to a member company of our peer group, B&I Contractors, through our connection with The Unified Group. That trip opened our eyes to what was possible, providing firsthand exposure to a mature, prefab-focused workflow. We left energized and inspired—and committed to adapting what we saw to fit our team and our projects. Here’s a look at what worked, what didn’t, and the valuable lessons we picked up along the way.
What Worked – Game Changing Wins
Rethinking Duct Assembly
During our visit to B&I, we observed a key difference in their duct assembly approach, they completely skipped cleating. Instead, they used screws every 6 inches and sealed all TDF connections from the outside. We adopted this method for non-exposed ductwork, and it paid off, our duct pressure testing even came in under budget. For exposed duct, we still cleat for visual appeal, but elsewhere, this new method proved faster and equally effective.
A small but impactful lesson: if a transition or elbow isn’t clearly labeled or intuitive to assemble, don’t seal it yet. Keep it loose. Early on, we had to disassemble several factory-sealed sections that were prefabbed in reverse. When in doubt, leave it open and do it right the first time.
Duct on Wheels
Mounting duct bundles on strut wheels was a major breakthrough. We pre-stacked prefab sections to fit our box truck, banded and tagged them by work pack, then rolled them directly into position. Two team members could move 50 pieces of duct through a building with minimal effort. This wasn’t just a time saver; it was a productivity shift.
Spiral Prefab – Mixed Results, Valuable Takeaways
We fully committed to prefabbing all round duct for this project. While we’re not sure if B&I does the same, it delivered mixed results for us. On the positive side, the jobsite stayed exceptionally clean. No scattered cut ends, which impressed a GC who emphasized site cleanliness. The challenge? A single mis pick could lead to time consuming piece swapping. However, our investment in a spiral cutting machine sped up fabrication and enhanced safety in the warehouse. Overall, the benefits outweighed the setbacks.
Why Prefab Was the Right Choice
Prefabrication proved to be a key strategy in meeting tight timelines while enhancing jobsite safety and cleanliness. The advantages were clear, and the results spoke for themselves. Some of the most impactful benefits included:
- Significantly faster installation across all systems
- A cleaner, more organized, and highly mobile jobsite
- Efficient cart stacking tailored to specific work areas
- Minimized on-site material handling
- Prefabricated toilet carrier banks that cut installation time by more than 50%
- Smooth, efficient underground PVC DWV installation—quick and unobstructed
- Aboveground DWV performed well, especially when coordinated ahead of other trades
- More work completed on benches, less from ladders, improving ergonomics and safety
- Reduced on-site labor demands
- Fewer safety incidents due to the shift toward controlled shop environments
Not everything went smoothly. Along the way, we encountered some challenges—some of which we’re still working to resolve:
Aboveground DWV Difficulties
Performance was inconsistent. When other trades arrived ahead of us, installing our prefabbed sections became a major headache, often requiring rework and causing understandable frustration on-site. The lesson here is clear: early coordination and staying ahead of the schedule are critical.
Cart Organization Issues
Our cart loading process is still a work in progress. Cold temperatures led to cracked fittings and pipe during transit, and locating the correct bundles on site proved time consuming. With such a high volume of material movement, maintaining order is tough. We're exploring solutions such as Air Tags to improve tracking and organization.
Cultural Resistance to Change
Adoption hasn’t been universal. Some crew members remain tied to traditional methods and are hesitant to embrace new technology or the prefab workflow. This shift is as much about changing mindsets as it is about changing methods and it takes time.
Cast Iron Complications
We’ve held off on prefabbing cast iron, and for good reason. Achieving proper pitch, avoiding pipe roll during transit, and preventing broken fittings presents serious logistical challenges. We’re not opposed to exploring it in the future, but we’re not ready to commit just yet.
Oversized Prefab Pitfalls
Bigger isn’t always better. Oversized prefab sections quickly become difficult to move, awkward to cart, and require more hands to install. The takeaway: balance is everything, optimize for manageability, not just efficiency.
What’s Needed to Scale Prefab Successfully
To ensure prefabrication remains efficient, sustainable, and scalable on future projects, several essentials must be in place:
- Covered Laydown Area
Protecting carts and materials, especially PVC and black iron. This is non-negotiable for maintaining quality and avoiding delays. - Large Telehandler Basket
Crucial for safely transporting loaded carts and prefabbed carrier banks into buildings and up to higher floors. - Robust VDC Team
Sufficient staffing and lead time are essential for modeling, spooling, and building before field crews mobilize. - Accurate and Current Modeling Catalogs
If model dimensions don’t match real-world fittings, the result is rework and wasted time. Updated catalogs are a must. - VDC Training
Teams need a solid understanding of fitting flow, code compliance, and how each system behaves to avoid issues downstream. - Copper Prefab - Including Small Sizes
Even smaller copper piping should be precut, cleaned, beveled, bundled, and clearly labeled. Every detail adds up to major time savings. - Dedicated Material Scheduler
This role is increasingly vital in prefab-heavy operations, serving as the link between the VDC team and field foremen to keep material deliveries aligned with installation schedules. - Team Tracker Usage and Training
While we currently use Team Tracker with some success, its value hinges on consistent, informed use. Ensuring crews are trained, disciplined, and held accountable for daily updates will be a key focus going forward.
Final Thoughts
This project has fundamentally reshaped our approach to prefabrication, and it all traces back to that pivotal visit to B&I Contractors. Through our connection with The Unified Group, we had the opportunity to learn from a peer company that’s been doing it right—and it gave us the blueprint to take our own operations to the next level. We’ve seen firsthand that with the right planning, mindset, and tools, prefab can deliver real, measurable results. It’s not without its challenges, but the progress we've made is undeniable. And we’re heading in the right direction.
Prefab isn’t just a construction method; it’s a strategic advantage. And with each project, we’re improving how we implement it.