Prefabrication

Prefabrication Options

NFPL develops each prefabrication solution to suit the project, thereby ensuring it is fit for purpose.  As such, there are a number of options for each project that may focus around one system or a hybrid solution that utilises a number of different prefabrication solutions.  Prefabrication options include:

Panelised Solutions:

Panelised solutions are typically segregated into two main types:

Open Panels:

Open panels can simply be framed and braced panels, right through to framed, braced, wrapped, installed joinery, installed utilities, installed insulation, etc.  Open panels allow for walls to be installed more traditionally, with accessible fixing of the bottom plate and intersecting walls.  The site finishing would then include interior linings, architraves and skirting, plastering and painting. 

Closed Panels:

Closed panels are typically the most advanced open panels, with the addition of interior linings being fitted in factory.  Closed panels typically have more complex systems to fix the panels to the floor substrate and to effectively connect intersecting and adjacent panels.

In addition to the wall panel solutions, cassette systems are also commonly used to support the balance of the house.  Cassette solutions are typically broken into three main types:

Floor Cassettes:

Floor cassettes are typically constructed from a series of parallel floor trusses or joists that are interconnected with strong backs, boundary joists or bracing.  The system is then tied together with flooring material in a diaphragm configuration to optimise the strength, minimise wastage and maximise the span relative to the depth of the system. 

Rafter Cassettes:

Similar to floor cassettes, rafter cassettes are constructed from a series of parallel solid rafters or rafter trusses that are tied together with purlins and ceiling battens. Depending on the roof type, the system can have the purlins clad in a sheet bracing material.  Typically a maximum of one side of the rafter cassettes are clad.

Truss Cassettes:

Similar to rafter cassettes, truss cassettes are typically constructed from a series of parallel trusses that are tied together with purlins and ceiling battens.  Efficient transportation is the largest challenge with truss cassettes; therefore they are best suited to lower, mono pitch roof designs.

Modular Solutions:

Modular solutions can include compartmentalised solutions such as individual rooms or smaller clusters of rooms, right through to complete buildings. 
Common modulated areas include wet rooms (bath/powder rooms, kitchens, laundries, etc) or renovation extensions.  Modules are typically scaled to fall within the Land Transport regulations to avoid complex routing logistics and higher costs related to extensive piloting or utility adjustment along routes (i.e. managing telephone and electricity cabling, and tree de-limbing, etc).
By completing entire modules in the factory, it allows for all services to be installed and tested and all or the majority of internal finishing to be completed in factory.  This is extremely beneficial for multi-level buildings and renovations.

By installing completed modules above ground level, it reduces the need for fall protection underneath the upper floor and can also remove the need for scaffolding during the primary construction phase.  This improves the operating safety and supports in heavily reducing costs and delays while having to wait for safety systems to be installed before the next level or phase of construction can commence.
Modules level of finish can extend from lining through to the complete installation of utilities, finishing of floor and wall linings, fitting of cabinets, white ware and fixtures and finished painted surfaces.

Complete Transportable Solutions:

Dependent on the scale and location, modular solutions can extend right up to complete transportation buildings.  Complete transportable structures vary between 10 – 120 m2, but can extend to larger sizes depending on the configuration and location. 
The functionality and design of complete transportable solutions can be customised to suit the application from ancillary bedrooms and offices, to secondary detached accommodation for family members, aged care and supplementary rental income streams, to worker accommodation on farms and more isolated industrial sites.