Prefabrication experiments - 497 - Industrialization in the Building Industry

 

With a flattering foreword written by Moshe Safdie and an auspicious introduction by R. Buckminster Fuller, Barry James Sullivan's Industrialization in the Building Industry (1979) encapsulates an era's zeitgeist by composing a comprehensive and optimistic overview of offsite construction presenting its diverse potentials to tackle onsite-building challenges. Called a masterpiece by Fuller, the publication outlines how industrialization of the building industry shifts paradigms in design and construction to develop the built form quickly, more efficiently and with greater quality.

 

Sullivan leveraged knowledge from prewar and postwar experiments, from academic research in California notably on school construction systems, and from the lessons of Operation Breakthrough to present industrialization's state-of-the-art in the USA and abroad. One chapter tells the tale of successful standardisation in the steel industry, relating an evolution that Sullivan defines as a model for collaborative sectoral advances. Metal/Steel building manufacturers like the Butler Manufacturing (1901) deployed a pattern-building approach to coordinate everything from design catalogues to material attributes, span tables and joinery through cross-pollinating founding companies' experiences. 

 

Their shared knowledge, specifications, and modular coordination principles helped the industry grow from a $250M dollar industry in 1966 to a $770M dollar industry in 1974, an incredible growth in less than 10 years. Four basic building frames were agreed upon, the rigid portico frame, the tapered beam, the post-and-beam and finally the truss beam. Everything from panel design, to cladding and insulation types would be included in design-build packages or turnkey proposals to erect buildings cost-effectively, safely and with equivalent performance parameters in any part of the country. 

 

The steel industry as a whole benefited from this normalization and continues to benefit and build on the systemic work done during the 1960s. Shared specifications have evolved to include current criteria, and the same coordination principles that led to model buildings are being included in virtual building configurators, or BIM models, to pursue the same simple streamlined design-to- fabrication-to-site process highlighted by Sullivan's analysis.

left: progression of metal building industry ; right: typical building frames

Prefabrication experiments - 496 - Refabricating Architecture (2004)

 

Manifestoes claiming how offsite construction can inflect productivity and reform construction from site intensive to factory-intensive processes have been written and often reflect different eras’ crises or technological advances, and sometimes both. Henry Ford's assembly line, Toyota's principles of no waste manufacturing, and today’s digital platform giants have all influenced offsite theory and narratives. Progressing from mass production to mass customization and influenced by the post-war building booms offsite construction literature framed and advocated for a better understanding of the rationalized application of manufacturing methodologies in architecture. 

 

Well known for their prototypes, the Loblolly House built overlooking the Chesapeake Bay  and the Cellulose House presented at the MoMA exhibit Fabricating the Modern Dwelling, the team of Kieran and Timberlake penned what is arguably one of the most important statements on prefab theory in the last 20 years, redirecting the discussion toward neoteric analogies for architecture's production. Proposing a narrative based on digital manufacturing methods Refabricating Achitecture compares two historic figures central to construction culture, the « master builder », with the highly specialized contemporary « master assembler » of components. The authors highlight a missing link between these two disciplinary approaches - one defined by a highly integrated process versus the other by a fragmented one. 

 

Elucidating examples of complex industrial objects, planes, automobiles and naval yard management methods the architects portray an architecture potentially assembled from integrated factory-made chunks designed and manufactured to facilitate onsite coordination in favor of greater predictability. These building chunks (modules) are modular sub-assemblies that can include many subsystems completed in a quality-controlled environment to avoid the wasteful entanglement of conventional construction.

 

Explored in both their prototypes and their practice, the authors present a systemic model of three interrelated offsite approaches for structure, skin and service cartridges or cores harmonized in a digital environment to virtually build and coordinate all elements before their fabrication. All components can then be optimally bundled for on-site delivery and sequenced to simplify their setting. The model argues for a new type of master designer/fabricator/manager to bridge design and construction. A veritable «how-to» of DfMA, Refabricating Architecture is one of the strongest expressions of a required paradigm shift in construction in the 20th and 21st centuries combined. 

master builder versus master assembler - Refabricating Architecture (2004)

Prefabrication experiments - 495 - Literature fundamentals

 

Along with exhibitions, literature has played an important role in spreading knowledge about prefabrication. The wealth as well as the depth of narratives outlining the many potentials of industrialized construction have and continue to make the case for higher levels of manufacturing integration in construction to ease recurring challenges: labour shortages, lack of specific trades, waste generation, and low productivity levels. Beginning with Albert Farwell Bemis’ The Evolving House, Rational Design published in 1936, identifying rationalization as an advantage of factory production, many have fostered an ever-expanding catalogue of viewpoints with similar undertones across varying eras. 

 

Burnham Kelly’s The Prefabrication of Houses (1951), Maurice Revel’s La prefabrication dans la construction (1966), Barry James Sullivan’s Industrialization in the Building Industry (1980) which includes a foreword by Moshe Safgdie and an introduction by Buckminster Fuller, Stephen Kieran and James Timberlake’s Refabricating Architecture (2004), and Andreas Vogler’s The House as a Product, all contextualize prefab’s links to industrialization, mechanization, and mass production using similar examples and archetypes. 

 

In 2008, related to the renaissance of interest in offsite construction, the well-known German periodical Detail published a comprehensive treatise entitled Components and Systems -  Modular Construction - Design Structures and New Technologies. The 240-page publication, while informative, strays little from others before it by covering the vast history of iconic experiments before going through the potentials of modular prefabrication by analysing contemporary built projects throughout Europe. The basic principles provided by the authors epitomize how little has changed when comparing this publication with Bemis’ discourse from 1936. 

 

The module, the grid, dimensional coordination, geometric positioning, assembly and setting along with transport still define the rigorous design criteria that offsite construction demands. One diagram presented as a design principle depicts the relationship between modules and grids as positioning devices for harmonising building systems is comparable to Bemis’ definition of dimensional coordination. While digital technologies are marginally discussed by Detail’s special edition, many argue that digital tools are providing the long-awaited inflection point for the industry. However forward-looking this may seem, the fundamental ideals in literature regarding offsite can be distilled down to greater dimensional rationalization.

left: Bemis - 1936 ; right: Detail - 2008.