At PrimeFab, we believe the future of construction isn’t just built – it’s engineered. By shifting critical building processes from the jobsite to our advanced 100,000-square-foot facility in Midland, Ontario, we provide developers with a smarter, more predictable path to project completion.
But what exactly happens behind the doors of our production facility? Here is the step-by-step journey of a PrimeFab panel, from digital model to rapid site installation.
Step 1: Digital Design and Prefab Coordination
Every high-performance prefabricated panel begins with a comprehensive drawing review and coordination process. Our in-house engineers and architectural technologists convert existing plans into a panelized system, generating detailed shop drawings that identify and resolve potential issues long before material is handled. This digital twin ensures that every wall is optimized for cost-effectiveness and fits together perfectly on-site.
Step 2: Precision CNC Cutting and Component Fabrication
Once the design is finalized, our panel manufacturing process utilizes precision CNC cutting for all components. This process is optimized to significantly reduce material waste and increase overall cost-effectiveness.
- Structural Elements: Beams and columns are created using a semi-automated nailer to ensure structural consistency.
- Sub-Component Assembly: Skilled carpenters assemble intricate sub-components utilizing CNC-cut parts for maximum accuracy.
- MEP Readiness: Panels are pre-drilled for hoisting or Mechanical, Electrical, and Plumbing (MEP) requirements as dictated by project specifications.
Semi-Automated Prefab Wall Assembly
The core of our off-site construction advantage is our advanced production line, featuring state-of-the-art European machinery from the WEINMANN brand.
- Framing: Lumber and sub-components are combined in a semi-automated framing machine to create fully framed panels.
- Sheathing: Panels are sheathed and nailed exactly to technical specifications with precision-cut openings for windows and doors.
Step 4: Vertical Line Integration
After framing, a self-adhered Water Resistive Barrier (WRB) is applied and rolled before the panel is lifted into our vertical production line. This specialized vertical line supports the installation of windows, doors, and unique elements. Our technicians complete the WRB application above openings to create the correct lapping for a perfect watershed, ensuring superior building envelope performance.
Step 5: Quality Control and Certainty
Unlike traditional stick-building, where inspections happen in the wind and rain, every prefab wall assembly is completed under a controlled environment. This level of oversight is critical to driving project performance. As our partners at GeoFocus noted during our Midland grand opening:
“It was impressive to see how their integrated approach comes together in practice. That level of coordination and control is critical to driving certainty, efficiency and overall project performance. Seeing our own panels in the facility… reinforced the value of advancing work off-site in a controlled environment.”
Step 6: Prefabrication Logistics and Rapid Installation
Our off-site construction process is designed to make on-site assembly as seamless as possible:
- Protection: Panels are fixed into place on custom platforms to protect them from damage and are wrapped to guard against the elements during transport.
- Load Planning: We utilize strategic load planning so panels arrive on-site in the exact order required for installation.
- Hoisting Readiness: All panels are pre-strung with hoisting straps, allowing for safer and more efficient crane work.
- Flexible Delivery: Delivery is arranged to suit site requirements, such as available staging space or specific crane schedules.
Experience the PrimeFab Difference
The opening of our Midland facility marks a significant expansion in Ontario’s prefabrication capacity. Backed by our state-of-the-art machinery and a vertically integrated supply chain, we are proud to set a new standard for quality and sustainability.
Ready to see the precision of off-site manufacturing in action? Explore PrimeFab’s solutions and discover how we’re building a smarter tomorrow, today.