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Complete guide to prefabricated facades: modules, concrete, and performance

Understanding prefabricated facades

Prefabrication involves manufacturing building components in a factory under quality control before transporting them to the construction site for assembly. In the field of facades, this method takes the form of modules, prefabricated walls or prefabricated facade panels (glazing units or opaque elements) or prefabricated concrete panels. The modules are manufactured in a factory in a repetitive manner, with a level of precision that would be difficult to achieve on a traditional construction site.

They can integrate the structure, thermal insulation, air/vapor barrier, cladding, and even windows. This industrialization aims to improve quality, reduce lead times, and control the environmental footprint.

Surveys of contractors show that prefabrication brings significant benefits: 66% of respondents believe it reduces construction time, 92% believe it improves productivity, and 70% believe it generates a better return on investment. Industrialized methods are therefore developing in a context of labor shortages, budget constraints, and the search for more sustainable solutions.

Different types of modules

• Unified glass/aluminum facades: in this case, the frames and glazing are assembled in the factory to form complete panels that are attached to the structure. STEKAR’s prefabricated curtain walls integrate the glazing directly into the frame, which facilitates installation and optimizes project execution thanks to the repeatability of the modules.
• Precast concrete panels: molds are used to form thin but strong panels, reinforced with additives. According to manufacturer Megaton, these panels offer consistent quality, quick installation, high durability, and varied design possibilities. They are used in residential, commercial, public, and industrial buildings, particularly due to their low maintenance requirements.
• High-performance unified systems: these are complete panels that integrate structure, insulation, air barrier, cladding, glazing, and accessories. Multifaçades, for example, for high-traffic urban projects, can be prefabricated and applied to unified systems from certain manufacturers. This means it works with all cladding and glazing options and allows for almost unlimited design freedom.

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Avantages of Prefabricated Facades

Quality & Performance

Factory manufacturing allows for rigorous quality control. In a protected environment, materials are not exposed to the elements and tolerances are better respected. Prefabricated facades can incorporate innovations such as steel air/vapor barriers, cold-rolled steel framing, and advanced insulation systems that achieve effective R-values of 33 and above. Controlled assembly reduces errors and ensures a highly airtight and watertight envelope.

Precast concrete panels are manufactured to uniform standards. They are highly resistant to fire, water, and chemicals, making them suitable for seismic zones or heavy-duty applications. These panels also offer a long service life with low maintenance and are available in a wide range of textures, materials, and colors.

Timeframes & Costs

Industrialization allows modules to be manufactured while the foundations and structure are being built, reducing the overall construction time. Prefabricated facades can reduce the construction schedule by three to six months. Factory integration of windows speeds up the weatherproofing process, protecting the interior from the elements more quickly. In addition, advance planning with the prefabrication team reduces redundancies and supply delays.

Modular projects reduce construction time by 4 weeks to half the time compared to traditional construction. Standardization of components through BIM modeling improves accuracy and reduces measurement errors, resulting in time and cost savings.

Security & Labor

Assembly in the workshop limits work at height and on-site handling, reducing the risk of accidents. Prefabricated facades require fewer workers on site, which is an advantage in the context of labor shortages. A prefabricated facade requires only a few workers spaced apart during installation, whereas traditional brick and glass installation requires large teams. This was the case during the renovation of the facade of Charles-Lemoyne High School in a busy Montreal neighborhood.

Reliability of supply and sustainability

Since the modules are manufactured prior to installation, material orders can be placed well in advance. This approach avoids delays related to supply chains and ensures that materials are available at the time of installation. In addition, some companies offer prefabricated facades that are aligned with environmental objectives.

Limitations and points to watch out for

Although prefabrication offers many advantages, it requires coordination well in advance. The choice of partner must be made at the beginning of the design process in order to define the scope, types of modules, and installation strategy. This collaboration allows the architect to understand the manufacturing and erection constraints in order to design a feasible model. It is also important to select a system that offers material flexibility, limited joints, and documented quality control.

Prefabricated facades often involve a higher initial investment than traditional systems. However, labor savings and reduced lead times generally offset this investment.

Precast Solutions

Precast concrete panels offer a combination of strength and modularity. Manufactured in a factory, they are then transported and installed on site.

1. Standardized, high-quality production: factory inspection reduces errors and ensures consistent quality.
2. Time savings: installation is faster than for cast-in-place concrete, as the panels are delivered ready to assemble.
3. Durability and low maintenance: the panels are weather-resistant and retain their appearance without the need for frequent recoating.
4. Structural strength: thanks to additives and mold manufacturing, the panels are thin but very strong, particularly in terms of fire and earthquake resistance.
5. Architectural flexibility: custom molds allow for the creation of different textures and colors, suited to both classic and modern styles.

These panels can be used in homes, shopping centers, public buildings, and industrial buildings. Their quick installation and minimal maintenance make them an attractive option for large-scale projects or energy-efficient renovations.

The Multifaçades prefabrication solution

The Multifaçades system is a rain screen cladding system for building envelopes. Using mainly a pressure-balanced system, the independent panels incorporate an aluminum frame and a patented flush window system. The system allows different materials (glass, aluminum, stone, composite panels, BIPV, etc.) while ensuring high thermal and acoustic performance. It offers design flexibility and exceptional durability; panels can be individually removed to replace glazing or cladding without affecting the whole. The design facilitates installation and reduces thermal bridges, making the system suitable for a variety of projects, from institutional buildings to residential towers.

Complementary to a high-performance wall

The Multifaçades system is not a load-bearing wall: it is a ventilated exterior skin that is attached to a wall or support. For high-rise buildings or projects where codes require non-combustible assemblies above 8 or 10 stories, the combination of a prefabricated unitized wall structure and Multifaçades becomes strategic. The unitized wall provides the structural skeleton, insulation, and fire resistance. The Multifaçades system is attached to this wall, providing the exterior finish, ventilation, and desired design, while integrating the flush window.

This combination offers several advantages:

• Speed of execution: with a 100% prefabricated unitized wall, construction time is significantly reduced. Multifaçades panels are easily attached to the structure, allowing floors to be delivered sequentially and the building to be closed more quickly. The entire installation is mainly carried out from the inside, which is safer and limits the use of cranes or aerial work platforms outside.
• Thermal and acoustic performance: the integration of Multifaçades panels in front of a highly insulated unitized wall further improves insulation and reduces thermal bridges thanks to the principle of balanced pressure and controlled ventilation.
• Architectural versatility: the Multifaçades allows for a variety of materials and formats (up to 5 m² per panel). Combined with a unitized wall, it gives the appearance of a curtain wall without the structural limitations. This opens the door to mixed facades where glazing alternates with opaque elements, meeting energy performance and comfort objectives.
• Adaptability to renovation projects: for deep energy retrofits, the unitized wall + Multifaçades combination is a true “plug-and-play” system. The panels arrive ready to install and immediately improve insulation, waterproofing, and aesthetics. STEKAR has demonstrated this approach on projects such as the Snowdon Theater in Montreal, where the historic facade was preserved on the ground floor while a Multifaçades envelope was added to the upper floors, providing excellent thermal and acoustic performance.

Application guide for architects and general contractors

1. Define objectives and constraints: before choosing a prefabricated system, it is essential to assess the building’s use, height (and therefore non-combustibility requirements), target energy performance, location (climate, urban density), and budgetary constraints.
2. Involve partners early on: the benefits of prefabrication depend on early collaboration between the project owner, architect, engineer, envelope consultant, and manufacturer. This approach optimizes panel dimensions, transport logistics, and assembly sequence.
3. Assess the flexibility of the system: choose solutions that offer a variety of coatings and compatibility with different types of glazing. Check the possibility of integrating flush windows or photovoltaic panels to meet aesthetic and environmental requirements.
4. Check performance and certifications: ensure that the chosen system has been tested by independent organizations and that it meets wind, water, and fire resistance standards. Thermal performance values (R or U) must be appropriate for the climate of your project.
5. Plan site logistics: prefabrication reduces time on site but requires precise management of transport and handling. It is essential to provide temporary storage space and coordinate with other trades. Installation from the inside requires training for teams but increases safety and productivity.
6. Anticipate system integration: when combining a unitized wall and a Multifaçades system, anchor points, tolerances, and the continuity of air/vapor barriers must be planned for. The use of standardized components facilitates this coordination and limits finishing work.

Conclusion

Prefabrication of facades is booming. Prefabrication modules and precast concrete panels improve quality, reduce lead times, and enhance safety. High-performance unitized systems offer a complete, prefabricated, ready-to-install envelope that achieves high levels of energy efficiency and can be installed quickly. The Multifaçades system, meanwhile, offers a stylish, high-performance ventilated skin that can be combined with a prefabricated wall to create a hybrid solution that is particularly well suited to high-rise buildings or major renovation projects.

By adopting these approaches, architects and general contractors can optimize construction timelines, control quality, and address the challenges of climate change and labor shortages. The key to success lies in collaborative planning and a thorough understanding of the chosen systems.