Making the case for off-site construction

COMMENT The construction industry is at a crossroads. With escalating pressures from labour shortages, costs showing no signs of decreasing and safety, quality and efficiency all top priority, off-site construction is emerging as a pivotal solution. However, for all its promise, we know that embracing off-site methods wholesale is challenging in an industry built on incremental adaptation. The key to success lies in evolution, not revolution – taking deliberate, manageable steps that build confidence and capacity for a broader transformation. Take our Fulton & Fifth project as an example. With 876 homes and more than 33,000 sq ft of commercial space, it represents a behemoth of modern urban development and includes the tallest residential tower in Wembley Park. The scale alone presents logistical challenges, yet, by incorporating off-site manufacturing for the structure, envelope, bathroom pods and utility cupboards, we found a way to mitigate risks, manage labour shortages and maintain quality. Essential efficiencies Off-site construction brings undeniable advantages, including programme certainty and improved quality control. It shields projects from the unpredictability of weather and fluctuating labour efficiency while reducing waste and fostering a more sustainable construction model. Our in-house construction team is more than two-thirds of the way to completion at Fulton & Fifth, where four out of five blocks are being constructed concurrently. These efficiencies are not just beneficial – they are essential. Perhaps even more compelling is the potential for off-site construction to reduce the embodied carbon of buildings. By streamlining production in factory settings, the manufacturers can optimise material use, reduce waste and adopt energy-efficient production processes. Prefabricated components are often lighter and more precisely engineered, which reduces transportation emissions and minimises the carbon footprint of logistics. Standardised manufacturing processes also facilitate the integration of low-carbon materials, such as sustainably sourced timber and innovative concrete mixes, which can significantly lower a building’s overall environmental impact. For example, the off-site production of precast concrete panels at Fulton & Fifth allowed for precise control over materials, minimising excess and ensuring consistent quality. This approach not only reduced waste but also allowed the team to adopt lower-carbon manufacturing techniques that would have been more challenging on-site. The ability to plan and execute in a controlled environment enhances the opportunity to prioritise sustainable building, in a meaningful, practical way and at scale. Skilled workers Even as off-site methods reshape the industry, the importance of traditional trades – the “biblical trades” such as carpentry, masonry and steelwork – remains undiminished. These crafts form the backbone of construction, carrying centuries of expertise and ingenuity. As we have found, the successful integration of precast elements and off-site solutions is impossible without the skilled workers on-site to execute the complex assembly and finishing work. While off-site construction reduces some of the manual labour required on-site, it cannot replace the human artistry and adaptability that the trades bring. A bathroom pod fabricated in a factory still needs expert plumbers and electricians to connect it to the site’s systems. Precast panels rely on precise installation by steel fixers and crane operators to be fitted seamlessly into place. And, crucially, when unforeseen issues arise – as they inevitably do in construction – it is the skilled tradespeople who solve problems on the ground, ensuring the integrity of the final product. Balanced roadmap This is why a balanced approach is so critical. Off-site construction is not a replacement for traditional craftsmanship but complementary to it. It allows the industry to manage labour shortages and improve efficiency while retaining the artistry and problem-solving abilities of skilled workers. As the construction sector evolves, the challenge will be ensuring these trades adapt alongside new technologies, blending time-honoured skills with modern methods to build a resilient, future-ready workforce. Still, industry-wide change takes time. By building confidence with projects such as Fulton & Fifth – leveraging off-site solutions where they make the most impact while retaining traditional methods where they are indispensable – we can create a balanced roadmap for the future. In short, the construction industry doesn’t need a revolution to embrace off-site construction. It needs steady, measured progress that allows everyone – developers, contractors, manufacturers and the wider workforce – to adapt. This evolution must also preserve and celebrate the biblical trades that have shaped our cities and communities for centuries while recognising the environmental urgency of reducing embodied carbon. As we step into this new frontier land, let’s focus on walking before we try to run. Evolution, not revolution, will be the foundation of a sustainable, high-performing and environmentally responsible construction sector. Damien Cartmell is managing director of construction at Regal Photos: Portrait © RegalConstruction images © PCE