Industry Transformation

Mass timber impacting how we approach cabinetry

By Sarah Hicks

Element5 4-storey, 40-unit modular apartment building

As we look to the future, it’s clear the next big step toward sustainable development involves the increased use of mass timber and a greater degree of off-site prefabrication. Factory-built solutions are the key to the significant gains in construction efficiency and building performance that we need to improve our built environment and reduce its carbon footprint.

In off-site construction, building components are prefabricated in a controlled indoor setting. This process reduces risk and significantly increases efficiency, quality, and building performance.

Depending on the size and complexity of the manufactured components, off-site prefabrication can considerably reduce a construction schedule that can generate significant cost savings over a strictly site-built project. Off-site construction provides many other benefits, including enhanced sustainability, predictable timelines, controlled expenses, reduced construction noise and other neighbourhood disruptions, more efficient use of material and labour resources, and improved worker health and safety.

POTENTIAL OPPORTUNITIES FOR CABINET MAKERS AND MILLWORKERS

In construction, the term ‘prefab’ can apply to many different levels of completion. At one end of the spectrum, it can be as simple as incorporating structural insulated panels into a primarily sitebuilt project to speed up the process of enclosing the building. Several steps up from that is an entirely panelized building like those produced by Ontario’s newest CLT manufacturer, Element5.

A modular, prefabricated mass timber building from Element 5 is flatpacked and shipped to the site with window, doors, and MEP openings precut. Many connections are preinstalled for quick assembly and finishing. At the other end of the prefab spectrum are complete volumetric units shipped with all building elements (windows, doors, kitchens, bathrooms, etc.) already installed so that construction on site consists of simply stacking and joining the finished modules together to complete the building. Ideally, only bolting and interconnection of the building services are required at the site.

As the construction industry shifts towards a greater degree of off-site manufacturing, there is a growing potential for cabinet makers and millworkers to tie into off-site prefabrication. Not only by working with volumetric constructors requiring cabinetry and millwork for completed units,

TOP: Assembling a pre-fab mass timber structure MIDDLE: Assembling a modular apartment building BOTTOM: Pre-fab construction process

Mass timber apartment interior

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but also with panelizers looking to expand their scope by being able to include modular kitchen and bathroom pods that can be inserted into assembled structures.

EXPAND SCOPE TO INCREASE COMPETITIVENESS

As the off-site industry expands and evolves, disrupting the current industry will create new opportunities for traditional suppliers. In the 4-storey, 40-unit modular apartment building shown here, the flat-packed CLT structure can be assembled in approximately 20 days, a rate of about one floor per week. Although the structure will be built and enclosed quite quickly, the overall speed of the total build could have been improved even further if the finished kitchen and bathroom pods could have been dropped into the units as each floor goes up.

There is a growing need for suppliers of kitchen and bathroom modules that can be shipped as independent units and craned into place, seamlessly integrating with flat-packed solutions. If there had been a supplier capable of providing kitchen and bathroom pods to this project, it would have gone that route. Already there is a potential to supply hundreds of units per year.

The construction industry is going to continue to progress in this direction. Future builds will endeavour to do as much off-site work as possible, and that will include volumetric kitchen and bathroom units to complement the speed of the modular and panelized construction methods already in use today. Eventually, it will become a matter of competitiveness, and producers who can pivot to offer volumetric kitchen and bathroom solutions will have a competitive advantage over other suppliers due to speed.

THE GRASS IS GREENER

For Grass, environmental protection is a fundamental corporate objective. The company pursues the goal of preventing or reducing environmental impacts at their very source. This means adopting an integrated approach to the product, considering all aspects from the initial product idea, through production and use to disposal.

“Sustainability is very important for Grass and for me,” said Nadja Mann, President of Grass Canada. “It has been even before it was popular. With environmental catastrophes all over the world, I don’t see how it isn’t for everyone.”

Many companies treat environmental concerns like an added cost to production, but Mann disagrees, particularly within manufacturing.

“Machinery works non-stop, making not only products but also energy,” said Mann. “It happens automatically. So we decided to harness that energy and use it for heating and cooling. That way, we don’t let it go to waste.”

As a result, 75% of Grass’ demand for electricity is generated by its own Combined Heat and Power station. This reduced their electricity consumption by 18% from 62 million kW/h to 51 million kW/h, and this extensive energy e ciency reduced their CO2 emissions by 640 tons per year.

These changes have not only bene ted the environment but helped Grass reduce operating costs. “There are cost-saving measures and rebates in place for companies that prioritize the environment,” pointed out Mann. “This is the future; companies need to start planning now for how they can change their processes and mandates.”

Grass is aware of the importance of the contribution of everyone, and especially of companies, the promotion of responsible practices that respect the environment. This is a clear advancement of society towards a better world, and for this reason, Grass has integrated environmental guidelines into its business strategy.

These guidelines are embodied in the Environmental Policy, which is inspired by two principles: compliance with all applicable environmental regulations and continuous improvement of activities to protect nature. With both principles, we are committed to the prevention, protection, and conservation of the environment through prioritizing saving energy, water, and resources in all company’s production processes.

Since the end of 2010, GRASS has been certi ed according to the international environmental management system DIN ISO 14001. They have been committed to sustainability, always complying with saving water and energy, reducing material consumption and Co2 emissions, increased reuse, and recycling, avoiding waste and contamination, and a push towards responsible action.

In terms of waste reduction, Grass’ volume of non-recyclable waste was reduced by 40%, from 1530 tons to 905 tons per year. When it comes to steel waste management, 100% of steel waste generated during production is recycled, coming in at 6650 tons per year. But Grass’ commitment to the environment extends beyond manufacturing.

“Head o ce will be carbon neutral by 2024,” said Mann. “And our Canadian o ce will follow suit. As it is, our new building is exceeding expectations.”