Building Efficiently: minimal waste, effort and cost

In the journey toward sustainable construction, efficient design sets the foundation, while efficient construction ensures that the vision is realised by minimising resource consumption and waste, as well as effort and cost.

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This article focuses on the following efficient construction practices:

• industrialisation,
• Design for Manufacture and Assembly (DfMA),
• parametric design
• digital manufacturing

 

Industrialisation – a shift in mindset

Across the industry, there is a shift toward industrialisation, which is based on prefabrication, modularity and standardisation. Industrialisation is even more efficient if supported by lean manufacturing principles and advanced logistics practices (with fewer site deliveries and reduced transportation emissions). Several studies show that industrialised construction can reduce waste by up to 50% compared to traditional construction – needless to say how important it is: construction and demolition waste makes up more than a third of all waste generated in the EU. Industrialised construction also shortens construction times, which means less use of diesel generators, machinery, and temporary utilities and reduced disruption on-site (e.g. noise, dust, air pollution).

Prefabrication is a cornerstone of industrialisation – it involves the production of building elements (such as façade panels. columns, beams, etc.) in series, off-site, usually in a factory, which are then assembled on-site. To take it one step further, even whole units or modules (e.g. bathrooms) can be prefabricated off-site. Off-site manufacturing allows for more precise control over materials, reducing over-ordering and scrap. Materials in a factory environment can be better recycled or repurposed. This leads to a significant reduction in raw materials required to be extracted and transported, as well as the amount of construction debris sent to landfills post-construction. Additionally, controlled factory environments are typically more energy-efficient than on-site processes.  

Standardisation is another important feature of industrialisation. The production of components with uniform specifications facilitates repetition and boosts efficiency. Standardised components are also easier to disassemble and recycle or reuse at end of life, which encourages a circular economy in construction.

 

Design for Manufacture and Assembly – a practical approach

Efficient construction may be supported by Design for Manufacture and Assembly (DfMA). This design approach focuses on minimising the number of components and using commercially available standard components. It also strives for facilitating the assembly of components, for example by using modular design. As a result, DfMA uses less energy and carbon and creates less waste. In an ideal case, it is complemented by designing for disassembly in mind.

 

Parametric design – a flexible process

Parametric design is an innovative method also improving efficiency: rather than a fixed design, it is a process that generates adaptable and flexible designs by modifying variables. When one variable changes – such as window size or wall thickness – the rest of the design updates accordingly. This fluid design process supports optimisation at every stage and enables the creation of complex geometries, which can contribute to the efficiency of solutions.

 

Digital manufacturing – where accuracy is key

Digital manufacturing further increases efficiency. From Computer-Aided Design (CAD) to Computer Numerical Control (CNC) machinery and 3D printing, digital manufacturing allows us to turn virtual designs into precise physical components with minimal waste. For example, CNC routers and laser cutters produce components with millimetric accuracy, and the pieces are ready for assembly on-site. Another technology, 3D printing uses exact amounts of material, creating complex geometries layer by layer. Improved precision means resources can be used more efficiently, and waste can be minimized.

 

From the macro scale of urban typologies to the micro scale of structural joints, opportunities abound to maximise efficiency through thoughtful design and advanced construction techniques. In this way we are able to align the built environment with circular economy principles: reducing waste, conserving resources, and delivering value across the lifecycle of every structure.

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