Off-site Construction Research Centre

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Offsite construction is reshaping the way we think about building projects, offering significant advantages in terms of speed, efficiency, and sustainability. But the question often arise like: how much faster? How much more efficient? What is the difference in cost?

One consultancy at the forefront of the shift is Cast Consultancy, a UK-based construction consultancy focused on providing innovative solutions for developers, investors, policymakers, and the supply chain. They specialize in off-site construction and modular building techniques aimed at delivering sustainable homes and places. With expertise spanning real estate, construction, and policy-making, Cast is driven by a mission to address societal and environmental challenges through modern construction methods. Their team of specialists is committed to helping shape the future of construction, promoting efficiency, and advancing industry standards through research and data-driven insights.

Through its extensive experience, Cast Consultancy has gathered valuable insights into the performance of offsite construction projects, providing a data-driven approach that could influence future strategies for construction efficiency and innovation.

Why off-site construction?

The UK construction sector is under increasing pressure to reduce carbon emissions and address significant workforce shortages, with an estimated shortfall of ~250,000 workers over the next few years. These challenges, along with a track record of budget overruns and delays in traditional construction projects, have driven the need for more efficient building methods. Offsite construction offers a potential solution by moving parts of the construction process away from the site and into controlled environments, improving project delivery and reducing waste.

Figure of Cast Consultancy’s performance metrics via webinar presentation slides

What is categorized as off-site construction?

It’s common to think that the only thing that can be considered off-site construction is the delivery of complete volumetric units to the project site for assembly. However, the term “pre-manufacturing” encompasses any processes executed away from the final project site, including remote factories near site, or on-site pop-up factories.

The UK has recognized the following category definitions that encompass varying degrees of off-site construction applications:

Category 1: Pre-manufacturing (3D primary structural systems)

Category 2: Pre-manufacturing (2D primary structural systems)

Category 3: Pre-manufacturing components (non-systemized primary structural)

Category 4: Additive manufacturing (structural and non-structural)

Category 5: Pre-manufacturing (non-structural assemblies & sub-assemblies)

Category 6: Traditional building product led site labor reduction / productivity improvements

Category 7: Site process led site labor reduction / productivity / assurance improvements

The role of data in construction innovation

A key element of Cast Consultancy’s approach is leveraging data to demonstrate the benefits of offsite construction. Historically, clients have relied on time, cost, and quality as the primary measures of project success. However, with evolving regulations and an emphasis on sustainability, new metrics such as embodied carbon and technology adoption, among many others, are becoming more critical.

By gathering data across various construction metrics, Cast has shown that offsite construction can help achieve these modern objectives. The consultancy’s ability to analyze performance across multiple areas — such as cost predictability, schedule certainty, embodied carbon, waste and more — allows for a more comprehensive understanding of how offsite solutions impact overall project success.

Figure of Cast Consultancy’s performance metrics via webinar presentation slides

Pre-Manufactured Value (PMV) and MMC

An insight presented by Cast was the concept of Pre-Manufactured Value (PMV). PMV measures how much of a project can be completed offsite, reducing the reliance on onsite labor and increasing efficiency. The consultancy’s preliminary data has started to show that higher PMV levels are linked to better outcomes across various performance metrics. This approach helps quantify the value offsite construction adds to a project, offering clients a clear understanding of when and where offsite methods are most suitable.

Figure via Cast Consultancy’s webinar presentation slides

Cast Consultancy's case studies offer insights into how offsite construction is adaptable to various contexts. For example, in a UK regeneration project, a mixed-method approach using pre-cast facades and frame systems allowed for scaffold-free construction and a rapid project completion. Additionally, Cast supported the repurposing of an Olympic athlete village into residential housing, using pre-cast walls and slabs to speed up on-site work and enhance build quality. These examples demonstrate the flexibility and efficiency that offsite solutions can bring to both new and repurposed builds, with off-site solution wins such as increased productivity, reduced schedule, minimized waste, and more. Learn more about their off-site construction project statistics by watching the webinar recording.

A key takeaway from Cast’s research is finding the optimal level of pre-manufacturing for each project. While the potential of offsite construction is clear, many projects benefit from a hybrid approach that combines traditional and offsite methods. As the industry evolves, we’re likely to see more of these blended strategies, with project-specific solutions driving the success of offsite construction.

Conclusion

Offsite construction offers a promising solution to many of the challenges facing the construction industry today, from labor shortages to sustainability targets. By gathering and analyzing data, Cast Consultancy has provided clear evidence of how offsite methods can improve project outcomes. As the sector continues to evolve, the lessons learned in the UK could play a pivotal role in shaping the future of global construction.

Interested in learning more about off-site construction? Join us on the third Thursday of every month for a deep dive into offsite construction with leading experts. Email offsiteconstruction@unb.ca to be added to the mailing list to be the first to know about these professional development sessions.

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