When clients start their self-build project by deciding on a prefabricated timber frame house, the process is very similar to any self-build project. The key differences are that the builder is already known, they are an integral part of the project from the very start, and the house elements are manufactured in a factory using Modern Manufacturing Methods to create prefabricated modules. These modules are transported to the client site and erected, where all the pieces fit together perfectly to reveal the completed house.
Most experienced self-builders will recognise the Baufritz Architectural process. It starts with an initial feasibility study to understand the viability of the project. Here cost implications are understood which means alternative design approaches may be necessary. They then create the outline proposal where Baufritz can work through the client’s ideas. Once the design is chosen and initial cost analysis completed, the house price is agreed before the plans are submitted to planning. This ensures that there are no nasty surprises in terms of build costs, once planning consent has been granted. This is where most traditional build projects start to go wrong. As the project price is agreed, the client can proceed, with the assurance that their overall budget will not be exceeded.
Once planning has been granted the client then starts engaging with the Factory to finalise the details of their project.
Baufritz has taken this method one step further to include all the interior elements, resulting in a completed house which is designed, manufactured and shipped like a giant jigsaw puzzle with detailed plans. Everything from taps to tiles is included. When an architect and client use a pre-fabricator like Baufritz, their approach should be slightly different from other building methods.
A good analogy is with a car configurator. Firstly, you start with an idea about the kind of car you want, then you select all the elements that make up your car (engine, wheels, trim levels etc). Once you’ve configured your car it’s then sent for manufacturing. Sometime later your car arrives adhering to the configurations requested, at the price and date agreed. Baufritz has used this idea for their latest innovation – The House configurator. This is a digital platform to help clients develop their house. Individual elements are selected and brought together using supported configurations. Room layouts, finishes and the location of elements are completed in a 3D rendered house. The vision here is to allow clients to work through their ideas before incurring costs or making expensive changes to their completed designs.
The Design centre in Germany is where a client can select the materials, finishes, fixtures, and fittings. This is also where they can start to engage with the interior designers to finalise their interior layout. The experience of Baufritz is invaluable to a selfbuilder. Their research and development can optimise materials and space to get the most out of the design. Once the details have been agreed the client will sign a final build contract that considers any changes the client may wish to make during the sampling process.
The Baufritz Architect works with the factory to create a set of handover drawings. These are determined by Building Regulations and include specific details such as wall thickness and type, as well as structural loading information.
The Factory then takes the Building Regulation Drawings and uses these to generate a set of Level 1 manufacturing plans which define the modular elements to millimetre accuracy.
The Computer-Generated Level 1 diagrams are used to manufacture each modular element, some of which are automated using the factory’s robotic tooling, others are completed by skilled craft people on the factory floor.
As the house is manufactured using a certified quality control process, high quality is guaranteed. The creation of each element follows a predefined series of manufacturing steps resulting in a fully tested final product. Quality Control is crucial to ensure that any discrepancies are identified early in the process. It is a well-known fact that any faults that must be corrected on site or later in the build process, cost in terms of quality, time, and money. Baufritz’s rigorous Quality Management process ensures any flaws are designed out early on to prevent this. Once the modules are completed, there is a high level of certainty that they will fit together perfectly as the manufacturing process is exact to the millimetre. This is important because low energy houses must not have any air gaps or thermal bridges. When everything fits together perfectly it makes construction a much simpler and quicker process.
Baufritz is continuously improving its houses. Their latest innovation, the modular plant room, is a prefabricated unit containing all the house’s technology elements. Namely heating and electrical systems including Battery and PV controller, home networking and entertainment system. It is also possible to include washing and storage space. Completed in the factory and delivered to site, the unit reduces the need for highly skilled on-site specialists.
The best way to understand the process is to book an appointment and come to the Factory in Erkheim Bavaria, where you can see the houses and watch the construction process.