Intelligent Prefabrication: How to Build Quickly and Without Hidden Costs

"If it still works, it doesn't need to be replaced!" This has been the guiding principle in the construction market in recent years.

Reduced research budgets, material selection based on price, and a lack of automation have contributed to a clear reluctance to adopt new methods that would lead to real progress for this industry.

Now, the question is no longer if the construction market will embrace technology, but when and how will it keep up with constantly evolving technologies? We continue to discuss passive prefabricated houses and how this niche can become one of the best solutions for many clients.

Prefabrication: A Game for Big Kids

When we started developing the Biobuilds production line, we took into account many aspects that we considered essential in obtaining an optimal product. Even so, during the research and development phase, many other issues emerged, for which we had to find solutions. In the end, the walls produced by us meet the Passive House Institute standards, and Biobuilds has become one of the few companies in the world that delivers prefabricated walls with a wooden structure and straw insulation at a semi-finished level.

More precisely, the walls leave the factory ready to be assembled on-site in no time. All finishing operations are performed in the factory, and the only actions required after assembly are any touch-ups. Windows and doors are also installed on the production line, making the house essentially a well-calculated assembly that fits perfectly and is much simpler to compose.

It took three years to test the system, and we went through four main stages of development before the production line worked flawlessly.

Smart Solutions, Spectacular Results

One of the great innovations we implemented is the automated cutting of excess straw that forms insulation, resulting in a finished-looking surface. We tried many methods, as there is no special equipment designed for this operation. And many factories still use rudimentary methods for this operation. The solution came from one of our engineers who designed an automated and highly accurate cutting system that leaves behind a completely smooth and uniform surface. The advantage is not only aesthetic but also functional, as it ensures the perfect positioning of the OSB board on the frame and, consequently, obtaining excellent airtightness.

Today, our factory can produce prefabricated straw insulation walls up to 12 meters long and 3 meters high, with negative carbon emissions of -90 kg CO2/m². The straw is pressed into the frame at 105 kg/m³, eliminating oxygen and becoming almost fireproof.

Straw: More Than Just Raw Material

To ensure such performance, the entire production chain must meet the highest standards. And, of course, it all starts with the primary source: straw. From how it is harvested, transported, stored… It may seem simple at first glance, but to ensure that our walls meet quality requirements, we make an extremely careful selection of straw suppliers. The wheat from which the straw comes should not have any grass blades in the crop, and after harvest, no wheat grains should remain on the ear. Baling is recommended after a week without any rain and after 12-13 hours to avoid moisture from dew.

It sounds more like the description of a painting exhibited at an art exhibition rather than the harvesting conditions of straw. However, the Biobuilds factory itself has some characteristics of a high-performance laboratory.