UNSW research outlines where prefab adds value for industrial construction
Prefab performance depends on site and project context according to UNSW research.
Qualitative and quantitative analysis of prefabrication remains challenging in construction, particularly given the variability between projects, procurement pathways, and delivery contexts. However, a New South Wales-based research team has provided a clear set of comparative data based on real-world projects—offering fresh insights into where and how prefabricated systems deliver measurable value.
Led by researchers at UNSW, the study analysed four common wall systems used in industrial construction: factory-made precast concrete, on-site tilt-up concrete, prefabricated light gauge steel (LGS), and traditional on-site steel framing. A recently completed multi-warehouse project in Dapto served as the central case study, supported by five additional builds across regional and outer-metropolitan NSW.
Among the clearest findings was the performance of prefabricated LGS panels in non-load-bearing applications. Compared with on-site steel framing, LGS panels reduced installation time from 13 to 4 working days and delivered around 39 per cent cost savings. The reduced labour requirement—two workers for four days compared with four workers for nearly three weeks—translated directly into lower labour costs, reduced equipment hire, and simplified site operations.
For structural walls, the study compared precast and tilt-up systems. On the study's Dapto site, tilt-up panels delivered an estimated 26 per cent saving over the equivalent precast approach, driven largely by lower transport and crane requirements. Both systems offered comparable installation durations, but tilt-up was able to avoid some of the overheads and logistics associated with offsite manufacturing.
However, the researchers were cautious about generalising the result. Tilt-up systems require substantial clear space for casting and lifting operations, making them less viable on constrained or complex sites. Precast systems, while generally more expensive, allow for parallel production and site preparation and may offer better tolerances and repeatability in factory-controlled conditions.
Rather than favouring a particular method, the study highlights the importance of context. While LGS showed consistent advantages for non-structural walls, the choice between tilt-up and precast for structural systems should be based on design complexity, access, logistics, and buildability. As the industrial building sector continues to adopt more prefabricated components, the findings support a more evidence-based approach to system selection—matching the right method to the right site.
