Innovative Approaches in Modern Methods of Construction: Techniques, Classifications, and Future Prospects

By Samudrapom DamReviewed by Susha Cheriyedath, M.Sc.Sep 24 2024

Modern methods of construction (MMC) are primarily a set of innovative alternatives to traditional construction approaches. These methods are characterized by the use of novel construction practices and materials that minimize on-site labor-intensive work.^1,2

Image Credit: petrmalinak/Shutterstock.com

MMC can increase environmental sustainability and boost the efficiency and productivity of new housing delivery. These methods are increasingly used in construction across different structures, including high-rises, traditional housing, warehouses, and factories.^1,2

Modern Methods of Construction: Overview

MMC represent a broad spectrum of building techniques and products aimed at improving efficiency, quality, and sustainability in construction. By shifting much of the building process off-site, MMC reduces on-site labor and construction time, making it a pivotal approach in addressing modern construction challenges. Key MMC types include:

1. 3D Modular Construction: This involves constructing full three-dimensional (3D) modules or units, such as entire rooms—kitchens, bathrooms, or bedrooms—in a controlled factory setting. Once completed, these modules are transported to the construction site and integrated with the rest of the structure, typically by stacking the modules vertically.

2. 2D Panel Construction: In this approach, flat panels (for roofs, floors, or walls) are manufactured off-site using a variety of materials. These panels are then transported to the site and assembled into the structure.

3. Hybrid Construction: This method combines both 3D modular units and 2D panels. For example, 3D modules (like bathrooms) may be integrated with 2D panels (such as walls or floors) to form a building. This allows for flexibility in design while maximizing off-site construction benefits.

4. Component and Sub-Assemblies: Prefabricated components such as windows, stairs, and mechanical systems are manufactured off-site and then installed on-site. This reduces on-site labor and ensures better quality control of individual building elements.

5. Site-Based MMC: While some elements of construction still occur on-site, this method uses advanced techniques like insulated concrete formwork (ICF) or spray concrete to speed up construction and improve thermal efficiency. These methods often reduce material waste and improve building performance.

MMC emphasizes the use of modern technologies and processes to minimize construction time, improve quality, and address labor shortages. By utilizing prefabrication and off-site manufacturing, MMC has become a key player in transforming traditional construction practices.³

Classification

MMC can be divided into two main categories: pre-manufacturing-led approaches (off-site and near-site) and site-based process improvement-led approaches.

1. Pre-Manufacturing-Led Approaches: These include the pre-manufacturing of 2D structural systems (panelized construction), 3D structural systems (volumetric construction), non-structural assemblies, sub-assemblies, non-systemized structural components, and additive manufacturing for both structural and non-structural components.

• 2D Primary Structural Systems (Panelized Construction): Producing flat panels off-site for rapid on-site assembly.
• 3D Primary Structural Systems (Volumetric Construction): Fabricating full modules in factory settings to be combined on-site.
• Non-Structural Assemblies and Sub-Assemblies: Prefabrication of windows, mechanical systems, and other building elements.
• Additive Manufacturing: Using 3D printing technologies to create structural and non-structural components such as walls, roofing, or even entire buildings.

2. Site-Based Process Improvement: This approach focuses on reducing labor and improving productivity through innovative site processes and the use of advanced building products. These improvements can include labor-saving techniques and novel construction processes.

• Innovative Processes: Examples include the use of digital tools like virtual models, augmented reality, drones, robotics, and driverless equipment to streamline construction.
• Labor Reduction and Productivity Enhancements: Using advanced construction materials and techniques, such as insulated concrete formwork and standardized processes, to reduce labor and speed up construction times.

Among these methods, the most commonly used are site process-led labor reductions, productivity improvements, and pre-manufactured 2D and 3D structural systems.^2,3,4

Advantages of MMC

MMC are revolutionizing the construction industry by offering innovative approaches that overcome the limitations of traditional methods. MMC streamlines the building process, making it faster, more efficient, and environmentally friendly. These methods shift much of the work off-site, where controlled conditions enhance the quality and consistency of the final product. Below are the key advantages of MMC that are driving its adoption across the construction sector.

Reduced Waste and Increased Efficiency

MMC significantly reduces waste during the construction process by utilizing precision manufacturing techniques in controlled factory settings. This leads to more efficient use of materials and minimizes site waste. Additionally, construction projects are completed 20-60 % faster due to the off-site production of components, which is not affected by external factors such as weather delays.²

Improved Quality and Durability

MMC ensures consistent quality through rigorous quality-control processes and digitalization. Building components are produced with high levels of accuracy in factory environments, which helps maintain the durability and performance of the structures. This level of precision contributes to the long-term reliability of the buildings and ensures they meet strict performance requirements.²

Enhanced Sustainability

MMC contributes to the creation of sustainable buildings by improving air-tightness and energy efficiency. Better air-tightness leads to higher energy performance ratings, reducing energy consumption and carbon emissions. This results in lower energy bills and greater comfort for occupants. Furthermore, MMC reduces embodied carbon by encouraging the use of low-carbon materials and supports circularity by optimizing material usage and minimizing waste.²

Cost Reduction and Affordability

By integrating MMC with standardized designs and a steady supply of materials, construction costs are reduced. This increases the affordability of housing, making it more accessible for tenants and purchasers. The consistent production process and scalability of MMC also help in keeping construction costs manageable.²

Workforce Diversity and Stability

The use of indoor factory environments in MMC provides consistent working conditions and regular hours, which attracts a more localized and diverse workforce. This helps to improve diversity in the construction industry and offers stable employment opportunities for workers.²

MMC presents a forward-thinking approach that addresses many of the challenges facing the construction industry today. By reducing waste, improving quality, enhancing sustainability, cutting costs, and fostering workforce diversity, MMC is driving the future of construction.

Harnessing AI and Machine Learning for Sustainable Construction

Challenges in MMC

Despite its many benefits, MMC faces several challenges

• High Initial Costs: MMC often requires significant upfront investment in factories, equipment, and workforce training. This deters smaller firms despite long-term savings through efficiency.
• Supply Chain and Logistics: Prefabricated components rely on a limited supplier network, which can cause delays. Transporting large modules also presents logistical challenges, especially in urban areas.
• Skilled Labor Shortage: MMC demands a specialized workforce for assembly and installation. Training takes time, and there is often resistance within the industry to adopt new methods.
• Regulatory Barriers: Many local building codes are not fully adapted to MMC, resulting in delays during planning approvals. Updating regulations to accommodate modern techniques is essential.
• Design Flexibility: Standardization limits design options, posing challenges for projects needing customization. Finding a balance between efficiency and creative flexibility remains a hurdle.
• Perception Issues: Some clients still perceive traditional construction as superior, slowing MMC adoption. Additionally, MMC markets in many regions lack maturity, complicating its scalability.
• Sustainability Concerns: Though MMC reduces on-site waste, sustainable practices must also be adopted in manufacturing and logistics to realize its full environmental benefits.
• Integration with Existing Structures: Retrofitting older buildings with MMC components can be complex and costly, requiring careful planning to integrate new and old systems seamlessly.

Despite these challenges, MMC's potential to revolutionize construction remains strong, and addressing these issues will be key to its future success.

Future Outlook and Conclusion

One of MMC's greatest advantages is its contribution to sustainable construction. With major industry players such as AECOM,  Saint-Gobain, Skanska, and Siemens AG driving innovation and adopting sustainable building practices, the future of MMC looks promising. Leading firms like Morgan Sindall Construction and Balfour Beatty have already embraced MMC to enhance efficiency and build sustainable structures.^6,7

In the UK, the government and industry leaders have outlined a vision in the Construction 2025 Strategy, focusing on reducing the trade gap, cutting greenhouse gas emissions, lowering operational costs, and shortening project durations. Recent research published in the Ain Shams Engineering Journal highlights that MMC is particularly effective in achieving these goals, especially in reducing emissions and improving trade outcomes.⁸

In conclusion, while MMC holds immense potential for boosting sustainability, efficiency, and productivity in the construction industry, challenges such as supply chain issues and high initial costs must be addressed to unlock its full benefits.

What to Expect from the Construction Industry by 2030

References and Further Reading

1. Modern methods of construction [Online] Available at https://www.istructe.org/resources/design-and-construction/mmc/ (Accessed on 24 September 2024)
2.  Modern Methods of Construction Introductory Guide [Online] Available at https://www.gov.ie/en/publication/e5e78-modern-methods-of-construction-introductory-guide/ (Accessed on 24 September 2024)
3. Modern Methods of Construction: barriers and benefits for Irish Housing [Online] Available at https://www.ciob.org/industry/policy-research/MMC-Ireland (Accessed on 24 September 2024)
4. Modern methods of construction (MMC) - A long and ongoing journey! [Online] Available at https://www.istructe.org/resources/blog/modern-methods-of-construction-(mmc)-a-long-and-on/ (Accessed on 24 September 2024)
5. Layon, L.B., Siyabi, M.S.A.A., Garcia, A.R.M., Umar, A.A. (2024). Barriers Affecting the Implementation of Modern Methods of Construction (MMC) in Oman. Journal of Civil Engineering Research & Technology. https://www.onlinescientificresearch.com/abstract/barriers-affecting-the-implementation-of-modern-methods-of-construction-mmc-in-oman-4588.html
6. Offsite and Modern Methods of Construction (MMC) [Online] Available at https://www.morgansindallconstruction.com/our-approach/modern-methods-of-construction-mmc/ (Accessed on 24 September 2024)
7. Accelerating the use of Modern Methods of Construction [Online] Available at https://www.balfourbeatty.com/media-centre/latest/accelerating-the-use-of-modern-methods-of-construction/ (Accessed on 24 September 2024)
8. Maqbool, R., Namaghi, J. R., Rashid, Y., Altuwaim, A. (2023). How modern methods of construction would support to meet the sustainable construction 2025 targets, the answer is still unclear. Ain Shams Engineering Journal, 14(4), 101943. DOI: 10.1016/j.asej.2022.101943, https://www.sciencedirect.com/science/article/pii/S2090447922002544

Disclaimer: The views expressed here are those of the author expressed in their private capacity and do not necessarily represent the views of AZoM.com Limited T/A AZoNetwork the owner and operator of this website. This disclaimer forms part of the Terms and conditions of use of this website.