Beatriz Gimeno Frontera, Project Manager at Metro7, talks about industrialised construction to the Fundación Laboral de la construcción, coordinators of the #BuildOffsite project.

Fundación Laboral de la Construcción, through the #BuildOffsite project co-financed by the Erasmus+ programme of the European Commission, met with Beatriz Gimeno Frontera, Project Manager at Metro7, to learn more about this construction company that is committed to sustainability, eco-design and has specialised in the field of passive house (Passivhaus).

How did you come up with the idea of carrying out projects based on industrialised construction and how has the process of transition from traditional construction to off-site construction been?

The idea arose as a result of numerous variables around 2020: price volatility and the need for developers to know an estimated budget in advance, the desire to innovate and improve following Lean methodology and the low yield of resources in traditional construction work, the increase in demand for wood construction and other components that do not require water, the bad experiences of individuals in the execution of works, the need for adaptability of our buildings to changes in use during their useful life, the optimisation of surfaces and spaces, as well as the evolution of construction and structural systems. We began with small projects, designed more as small extensions that would facilitate, for example, teleworking in times of confinement and that would not lose the quality of a new building in terms of comfort and efficiency; but we soon saw the potential of modular construction that could be adapted to all kinds of uses and final dimensions. Thus, we moved forward with the execution of 3 office lots composed of 8 modules and 2 porches of more than 250 m2 each. From here, we started to work on a modular product manufactured off-site, but at the same time customisable and adaptable to any requirement. Since then, we have been commissioned for all kinds of applications: single-family homes, offices, corporate meeting rooms, high-rise tourist flats and a student residence for a special education centre, among others. Most of them outside our immediate working environment, which has allowed us, for example, to work internationally. At company level, we still have traditional construction projects that we combine with off-site construction, to which we try to transfer the lessons learned.

What would you say are the main advantages of industrialised construction over traditional construction?

Industrialised construction allows for better quality and economic control, as well as a significant reduction in time with fewer deviations and unforeseen events. In addition, risks are reduced and the quality of the jobs is improved, as work is carried out in a controlled environment, the variable of the weather is eliminated and travel is reduced. Industrialised construction is an opportunity to implement values linked to sustainability, such as efficiency in the consumption of resources and the use of materials with low environmental impact and low water consumption.

What are the construction phases that are carried out in the off-site constructions you develop and what are their main characteristics?

Except for the foundations, we carry out the construction completely off-site in 3D modular form. We divide the building into modules that we take completely finished to the construction site and, once on site, only require the connection between them. These modules are built with a solid CLT wood structure and their design is based on sustainability and user health criteria. They have high thermal insulation thicknesses and high-performance exterior carpentry that guarantee their energy efficiency.

Within the manufacturing line, we have a first phase of structure where the assembly of metal bases and cross-laminated timber structure is carried out. Afterwards, the modules are placed next to each other inside the building, but in their final position to carry out the installation and finishing phase, taking into account their future connections and alignments. Once manufacturing is complete, the modules are separated and loaded onto the lorries that will transport them to their final location.

What professional profiles and/or occupations are needed in your day-to-day work and how do you manage to cover these needs? Where and how do you carry out the recruitment process?

We need a multidisciplinary profile that is able to combine different skills in the assembly and installation of different components. The basis is that of an assembler with knowledge of carpentry and dry masonry, due to the wooden construction system. The design of the installations is made in such a way as to allow quick connections on site.

What industrialised construction project would you highlight from the ones you have developed or are currently carrying out? How did the project come about? What could be highlighted about its construction process?

Our industrialised construction product is called MINIMAL. Through this system we have projected more than 100 modules that represent a built surface of more than 2,700 m2. This summer we will begin the installation of a student residence for a special education centre with 32 modules and 2 porches, which will be installed in 2 phases: one in the summer of 2024 and the other in the summer of 2025. It is almost 1,000 m2 of accessible facilities designed to improve the comfort and quality of life of the end users. In addition, we are about to start manufacturing our most ambitious project. It is a 6-storey high-rise building between party walls to be installed in a central street in Zaragoza for hotel use.

Do you think that in the future it will be possible for most construction to be carried out off-site instead of in the traditional way? How do you see the future of industrialised construction in Europe and Spain?

The sector requires an evolution towards the optimisation of resource consumption (materials, human resources, waste reduction, etc.) and process improvement. To this end, industrialisation is one of the key tools that can make this possible. The increased use of dry-laid components and more sustainable materials makes it possible to reduce the carbon footprint, not only during execution, but also taking into account the dismantling phase and possible reuse or adaptation to changes in use or needs. They also allow for better economic control, safety and reduction of unforeseen events. We believe that industrialised construction is not only the future of Europe and Spain, but that it is already an increasingly demanded present.