COVER STORY
Unlocking efficiency and sustainability in modern construction
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Gavin Robinson, national business development manager – added value solutions at Polypipe Building Services, explains how off-site manufacturing of water management systems can give project teams greater certainty, reduce risks and offer environmental benefits that traditional on- site installation often struggles to deliver
s the UK construction industry faces the challenge of labour shortages, ambitious Net Zero targets, and evolving building regulations; prefabrication
is emerging as a solution that addresses efficiency, quality and sustainability in one package.
Addressing labour constraints
One of the most pressing issues in construction today is the shortage of skilled tradespeople. Plumbing, a complex specialism that is essential to the delivery of both water supply and drainage systems, is among the hardest-hit trades. Delays in these critical installations can ripple through a project, affecting schedules, budgets and subsequent trades. Prefabricated systems offer a practical solution. By moving a significant portion of installation work off-site, assemblies can be completed under controlled conditions. Factory environments allow specialists to work unhindered by weather, site congestion or other logistical constraints, and production-line methods reduce assembly time. As a result, fewer skilled workers are required on-site, and the installation of complex systems can proceed predictably and efficiently, reducing the risk of project delays.
Polypipe Building Services’ Advantage Off- site Prefabrication Service exemplifies this approach. By designing bespoke drainage and water supply solutions tailored to the project’s exact requirements, the service ensures that systems arrive on-site ready to install. Fully pressure-tested and supported by technical experts, these prefabricated solutions minimise the likelihood of defects, further mitigating schedule and quality risks.
Supporting refurbishments and continuous operation
The use of prefabrication is not limited to new- build projects. Refurbishments and upgrades of operational buildings present their own set
of challenges, particularly where maintaining functionality is critical. Off-site manufactured systems can be designed to fit precisely into existing structures and installed rapidly, helping buildings remain operational throughout the works. This approach reduces disruption for occupants, ensures continuity of services and allows project teams to work around tight schedules and challenging conditions without compromising quality.
Enhancing health, safety and sustainability
Simplifying on-site installation also reduces health and safety risks. Prefabricated units can lower the need for working at height, reduce reliance on hot works and minimise heavy lifting. This not only protects workers but also supports the creation of safer construction sites overall. Prefabrication also brings tangible
environmental advantages. Factory-controlled production uses materials more efficiently, allowing for precise cutting and simplifying the recycling of off-cuts to reduce landfill waste. Lightweight systems, such as HDPE drainage stacks, also require less energy to transport and install, cutting emissions associated with logistics and improving the overall environmental impact of a project.
Efficiency at scale
Beyond traditional builds, prefabrication is increasingly important for Modern Methods of Construction (MMC) and modular projects. High-rise apartments, mixed-use developments and off-site manufactured housing benefit particularly from bespoke, repeatable solutions. Prefabricated drainage stacks, configured in common layouts, can be installed up to 65% faster than loose components. This reduces repetitive on-site tasks, minimises waste and streamlines scheduling for multiple floors with identical layouts. Similarly, prefabricated water supply systems
remove the need for specialist on-site joints or hot works, saving time while maintaining performance reliability. For modular
manufacturers, these bespoke systems allow complete units to be installed with minimal disruption and maximum quality assurance.
Mitigating risk through quality and logistics
A key consideration for any construction project is risk management, and prefabrication addresses this on multiple levels. Factory production allows for rigorous quality control, including pre-delivery pressure testing. On-site installation is faster and more predictable, reducing the chance of delays. Meanwhile, coordinated logistics, supported by just-in-time delivery networks, ensure that prefabricated systems arrive precisely when needed, eliminating the need for costly on-site storage and reducing congestion. By removing complexity and uncertainty from a critical stage of construction, prefabrication provides project managers with confidence, enabling smoother coordination of follow-on trades and safeguarding overall timelines. For commercial and residential developments alike, this can be a decisive factor in meeting deadlines and aligning with budget constraints.
The wider impact
Prefabrication is not simply a technical solution; it could pave the way for wider industry change. By integrating off-site manufacturing with sustainability data, such as EPDs, construction professionals can take a holistic approach to carbon reduction. Projects generate less waste, require fewer deliveries and use materials more efficiently, while prefabrication also supports a more stable, factory-based workforce. As UK construction adapts to changing
pressures and increasingly stringent environmental regulations, prefabrication offers a practical, scalable path forward. Beyond immediate efficiency gains, it enables projects – whether new-builds or refurbishments – to deliver on both operational and environmental expectations, helping the sector meet today’s demands and prepare for future challenges.
10 BUILDING SERVICES & ENVIRONMENTAL ENGINEER OCTOBER 2025
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