Embracing prefabrication strategies in construction projects can improve overall build quality, reduce construction time, and enhance worker safety. An important factor that is often overlooked when evaluating the costs and benefits of prefabrication is freight.

The primary determinant of freight costs is the distance between the manufacturing facility and the construction site. Longer distances typically lead to higher transportation expenses due to increased fuel consumption, the length time, labor costs, and potential delays caused by traffic. Therefore, it’s crucial to carefully consider the geographic location of manufacturing facilities when planning prefabrication projects.

Additionally, the weight and dimensions of prefabricated components significantly impact freight costs. Heavier and larger pieces require specialized transportation equipment and experienced drivers, which can increase transportation expenses. Oversized components may require additional permits and escorts, further adding to the overall cost.

Transporting oversized components often involves navigating areas with height or width restrictions, requiring meticulous route planning and additional permits. In some cases, police escorts or pilot cars are necessary to ensure safe passage, particularly in urban areas or during peak traffic hours.

Loading plans for transporting the prefab components also matter. A recent study in the Journal of Computational Design and Engineering looked at the logistical processes used to move prefabricated exterior wall panels from the factory to the building site and found that there is a marked difference in outcomes when transporting the panels vertically vs horizontally¹. Other freight optimization considerations:

Hoisting strategies:
Center of gravity and pick points can be accommodated in product designs (e.g., complicated assemblies affecting lifting)

Volumetric vs. Panelized assemblies:
Volumetric assemblies increase “shipping air” and decrease site labor required while panelized assemblies decrease shipping costs from less air but increase on-site labor.

Stabilizing assemblies:
Essential for quality control during shipping (e.g., delicate materials like glass or drywall need additional handling for rough roads or railroad tracks).

To mitigate these costs, companies should consider selecting manufacturing facilities closer to the construction site or modularizing components to fit standard transportation methods. Collaborating with experienced logistics partners early in the project planning phase can help identify potential challenges and develop cost-effective solutions.

Analyzing freight costs from many angles is essential for planning prefabrication projects. By accounting for the distance, weight, and dimensions, and loading/unloading strategies, construction projects can optimize their budget and timeline, leading to more efficient and successful outcomes.