Plant Building SystemTM Overview

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc.
 Introduction

Plant Prefab was founded to make it easy and efficient

to build custom, sustainable, and extremely durable
homes. While most prefabricators build standard homes
that they design, Plant was created specifically to
empower individuals, developers, and architects with
a better way to build their custom designs.

The Plant Building System TM (PBS) accommodates just

about any style of architecture, allowing us to efficiently
prefabricate all housing typologies. We’ve had the
privilege of building high-end spec homes, multi-family
developments, affordable housing solutions, tiny homes,
resort homes, and everything in between. Ray Kappe,
KieranTimberlake, Yves Béhar, and Brooks + Scarpa are
among the many talented architects and designers
who have entrusted their projects to Plant.

The purpose of this guide is to provide an overview of

PBS and how it can be utilized to build your project to
your exact design specifications quickly, precisely, and
sustainably. We welcome your questions and look
forward to supporting your project, so please don’t
hesitate to reach out!

This 2,372-sf single-family home designed by Toby Long was built

as six Plant Modules and installed in one day.
Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 2
 PBS System Overview

The Plant Building System TM (PBS) combines specialized

components, Plant Panels TM and Plant Modules TM,
with advanced software tools to achieve maximum
efficiency from design, to manufacturing, installation,
and completion.

• Flexible component design enables project-specific

construction to meet your design goals and budget Engineering Manufacturing
needs, transportation and site access requirements,
industry-leading energy performance and durability
standards, and all local code requirements.
Plant
• Advanced engineering translates architectural plans
Building
into virtual building instructions faster, and far more
accurately, than traditional methods. The Plant
System
Virtual Build Process checks and confirms design,
structural, and manufacturing compliance before
a single board is cut. End-to-End
Efficiency
• Precision manufacturing provides rigorous quality
control, ensuring high-quality craftsmanship, an
efficient and reliable production schedule, and
minimal waste.

• Detailed installation instructions ensure precise and

efficient assembly and finish work.

PBS is an end-to-end system, optimized to the specific Components Installation Instruction

needs of custom, residential homebuilding.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 3
 PBS Components

PBS utilizes a combination of specialized panels and

modules, both designed and patented by Plant.

Plant Panels
Plant Panels are an entirely new form of panelized
building technology. Other leading panel products
(like SIPs) only incorporate framing and insulation,
requiring a significant amount of labor on the jobsite to
assemble, wire, plumb, and finish. Plant Panels
incorporate plumbing, electrical, and finish materials,
and are custom-built to achieve maximum efficiency,
durability, and performance for each specific project.

Panel dimensions are optimized to each project’s

design and installation requirements. Panel design is
regionally code-driven by air, water, and heat transfer
analysis, coupled with local structural and seismic
requirements, ensuring optimal thermal performance
and durability for the specific local climate.

Plant Modules
Plant Panels are used to construct Plant Modules, which
can be large, fully-volumetric modules (for entire sections
of a home), or smaller “core” modules (for kitchens,
baths, mechanical areas, or combinations of them all).

This flexibility enables the efficient construction of

almost any design, in any climate, for any kind of
residential project, from single-family homes and multi-
family developments, to accessory dwelling units
(ADUs) and remodels (room or floor additions).

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 4
 PBS Component Detail

Component Families

Exterior Wall Panels Volumetric and “Core” Modules Quick Connect Integrated:
• Autonomous quality
“Easy Set” System certification
Interior Quick Connect • Serialized product
Wall Panels record-keeping and
• Can be sized up to 12x40’ traceability
for efficient transport • Labeling and palletizing
• Can integrate preinstalled by installation order
finishes and windows • Sustainable materials
Floor Panels
• Can integrate various levels and manufacturing
of mechanical, electrical,
and plumbing MEP Quick Engage
Window and
Door Families Datum-Based Alignment
Concealer Chase

Finish & insulation removed for visualization Quick Connect

Floor Panel Construction Wall Panel Construction Core Module Construction

Sheathing Sheathing/Finish Wall Panel 1 Wall Panel 6

Radiant Heat Tubing Structural Framing

Wall Panel 2
and Insulation
Various MEP
Sheathing
Framing and
MEP Kit
Joists
Wall Panel 5
Interior Finish
Wall
Connection Panel 3 Wall Panel 4
Chase
(Baseboard) “Core module” with integrated kitchen, bath, and mechanical

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 5
 PBS Component Configurations

Because Plant’s focus is solving design challenges for Plant Panels Plant Modules
custom, architectural projects, we developed PBS to
offer much greater flexibility than other prefabricated MIX
systems. MORE LESS

PBS allows us to create an optimal construction solution Smaller components solve Height and width requirements
Design Flexibility complex designs limits design flexibility
for each unique project design, budget, and site
access requirements (including transportation and Design
Site must be accessible for larger
installation restrictions). We work with you and your Site Access Build virtually anywhere
trucks and cranes
architect to determine the most efficient combination
of PBS components: Palletized panels reduces truck Mods require special trailers,
Shipping Efficiency
count and size permits, and escorts (possible)
• All Plant Modules: Large, fully-volumetric modules,
Transport
smaller “core” modules, or combinations of both
Must check routes for obstacles;
Shipping Routes No limitations
• All Plant Panels: Panelized components of varying extra costs for mods
sizes and construction
• Hybrid: A combination of Plant Modules and Plant Cranes Cost Smaller, less expensive cranes Larger, more expensive cranes
Panels
Site Install Time Slower to assemble many panels Faster to install mods
Clarifying the best approach occurs after the
completion of a feasibility analysis and during the
schematic design phase, when developing a sense for Site Labor Costs
More labor to install panels, MEP Less labor due to less joints and
the overall project design. See page 13 for a detailed connections, and stitching/finish more finish work done in factory
explanation of the entire project lifecycle.

More 2D Panels More 3D Volumetric

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 6
 System Benefits

PBS achieves significant advantages over other building

methods—both traditional, on-site construction as well
as other prefabricated systems.


Time & Cost Efficiency Access & Feasibility Design Flexibility Quality Health & Sustainability

Time is money, and PBS is PBS greatly reduces the PBS was created specifically to PBS engineering systems and Our health and sustainability
engineered to minimize both. transportation and installation solve the challenges of custom, advanced factory processes standards ensure that your
PBS reduces labor hours and barriers of traditional modular residential architecture, so it provide a level of precision project will be built responsibly.
provides an accelerated, construction, meaning more allows for much greater design and quality control that’s PBS was designed to minimize
reliable construction schedule sites are accessible and more flexibility than other methods of difficult, if not impossible, to the toxins, waste, and carbon
that’s up to twice as fast as on- projects are feasible for pre- prefabricated construction. provide on a traditional job footprint of every project,
site construction. Page 8 fabrication with Plant. Page 9 Page 10 site. Page 11 regardless of spec. Page 12

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 7
 Time & Cost Efficiency

Our integrated processes drive increased efficiency at Project Timeline: PBS Versus Site-Built
all stages of the project, providing a reliable schedule
that’s much faster than traditional construction:
• Fabrication at Plant is conducted concurrent with
site work, reducing the construction timeline by 20- PBS-Built Project: Offsite Installation &
50%* over traditional, on-site construction (in which Construction Site Restoration
the foundation must be finished before vertical
Site-Built Project:
construction can even begin). PBS-Built Time Savings
(Construction costs reduced by up to $850/day**)
• PBS shop drawings integrate utilities and structure to
prevent any conflicts during fabrication.
• Trades work concurrently, and components that
Site-Built Unpredictability
would otherwise need to be sequenced, such as
(Timeline hampered by weather delays, trade scheduling issues,
building the first and second floors of a home, Design & Permits &
mistakes, material damage, etc.)
happen simultaneously. Engineering Approvals
• Labor productivity itself is increased, as crews are
equipped with precise tools and machinery, and Site Prep & On-Site Site
work in an all-weather facility designed to provide Foundation Construction Restoration
ideal conditions for each building function, enabling
them to achieve higher-quality deliverables, faster.
• Close coordination with the on-site general
PBS projects enter production at Plant as soon as site prep begins. Precise factory processes and quality control measures facilitate an
contractor can achieve further time savings, efficient, predictable schedule that’s 20-50* shorter than that of site-built projects.
depending on the complexity of the project and/or
the level of customization. The more work that can
*McKinsey & Company. “Modular Construction: From Projects to Products.” 18 June 2019. Confirmed by multiple Plant clients.
be completed off-site, the greater the savings ($850
**Cotrell, Glenn. “What Is the Cost of Quality Construction?” 29 March 2017.
or more** per day of site work reduced).
• A best-in-class datum structure for alignment,
coupled with the use of quick connect/sealing
features and precise virtual instructions (P-FID),
ensure efficient installation on the job site.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 8
 Access & Feasibility

In California (and most other states), prefabricated

homes can be built anywhere—that is, they can’t be
excluded from a site because they are prefabricated,
and banks cannot deny financing because they are
factory built. (Note that cities and banks can and do
exclude manufactured/mobile homes from many sites
and methods of financing.) There is no disclosure
requirement on title for prefabricated homes, and the
resale value of factory-built homes is consistent with
site-built homes.

However, conventional modular construction comes

with several limiting factors that severely inhibit its use:
Not every job site can be accessed by the large trucks
required to ship huge modules, or the large cranes
required to install them. Plus, trucking big, empty boxes
is expensive, so shipping distance can render modular
construction financially impractical for many project
locations and designs.

PBS provides the means to build your project in a way

that reflects its unique challenges and opportunities:
Variable component design allows us to determine the
optimal dimensions, combination, and configuration of
Plant Panels and Plant Modules for your specific site
conditions, access and installation requirements, project
design, and budget. For example, if site access and/or
transport distance are an issue, we can build your
project entirely as Plant Panels, which require much
smaller cranes to install and are less expensive to
transport than larger modules.
A combination of Plant Modules and Plant Panels of varying sizes and finish made it fast and cost-effective to prefabricate this residential project.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 9
 Design Flexibility

We know design matters. We founded Plant Prefab a

decade after launching an award-winning design
studio, and that same talented team now drives
design innovation at Plant. We’ve had the esteemed
privilege of partnering with some of the industry’s top
architects and designers, including Ray Kappe, Yves
Béhar, KieranTimberlake, M-Rad, Sagemodern, Toby
Long, and Brooks + Scarpa, to name a few.

This experience and passion for world-class design is

what drove us to create a new kind of building system;
one that delivers the efficiencies of prefabrication,
without the usual design barriers.

PBS’ flexible component design enables architects to

address diverse architectural styles that could not be
built using conventional modular construction. And
because PBS components are custom-built for each
project, they are tailored not only to the project’s
climate and zoning requirements, but also to your
architect’s exact finish specifications.

PBS includes a clear set of design guidelines written by

architects, for architects, specifically for PBS components
and processes. We engage your architect early in the
process, ensuring that PBS works with—not against—
your design goals. In this way, your project’s production
at Plant is an integral part of your architect’s overall
design approach.

This 5,400-sf custom Ray Kappe LivingHome was prefabricated as ten Plant Modules with panelized decks and trellises.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 10
 Quality

PBS utilizes the efficiencies and controls of highly

evolved manufacturing processes to ensure quality
and precision throughout the project lifecycle:
• The Plant Virtual Build Process engineers your
architect’s creativity by virtually constructing your
project before it enters production. This ensures
design, structural, and manufacturing compliance
before a single board is cut, facilitating faster
production and a higher-quality deliverable.
• Construction work is conducted in a monitored
manufacturing setting using precise fabrication tools
such as CAD/CAM. This allows Plant to automate
processes, facilitating a consistent, high level of
quality control. The precision fabrication of exterior
wall components also produces a much tighter
building envelope with fewer air leaks.
• All MEP systems are tested for function before
shipping, minimizing the use of expensive trade
labor on the job site. This quality control is especially
beneficial for the installation of sensitive, high-tech
components, such as smart home equipment, fire
and security systems, and sensor-based
environmental controls.
• Building components are produced and stored in
an enclosed facility, reducing exposure to humidity
and other environmental factors that cause
moisture-related damage, and in turn, decrease the
durability of the components and increase the
potential for mold growth that’s harmful to
occupant health.
With all trades in house, Plant is able to install all finishes and fixtures to exacting quality standards, including cabinetry, millwork, flooring, and tile.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 11
 Health & Sustainability

Sustainability is core DNA for Plant, so regardless of

your finish spec, building with PBS will minimize the
toxins, waste, and carbon footprint of your project:
• The factory production of PBS components provides
optimal control of material use, drastically reducing
material input and waste. Framing cut lists are
produced with shop drawings to minimize lumber
overages, and the majority of surplus material and
fall-off are captured for use.
• Precision manufacturing processes produce a
tight building envelope, increasing thermal and
energy performance for the life of the home.
• We source the most sustainable materials possible
to meet your architect’s specification, including
mold-resistant drywall and zero-VOC paints, stains,
and sealants. These strict standards, coupled with
our operational efficiency, climate-specific
component design, and enhanced logistical
value engineering, minimize the negative health
impacts and embodied carbon of our material use.
• On-site finish of PBS projects generally requires less
workers, vehicles, and material storage, minimizing
site disturbance and noise pollution.
If you engage Plant as your architect, your project
will also be designed to meet net-zero standards,
following our rigorous health and sustainability
program, Z6. Learn more about Z6 and our carbon
pledge on plantprefab.com.
We use the most sustainable materials possible to minimize negative impacts on the planet and your building inhabitants.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 12
 Process
These are the detailed steps involved in building your project with PBS. Note that a number of these tasks can occur in parallel.

Project Bid
You’ll share your project and we’ll prepare a rough order of magnitude (ROM) bid that specifies anticipated costs, inclusions, and exclusions.
Time: 1 - 2 weeks

Bid & Site Feasibility

Feasibility We’ll evaluate your lot, and the route from our factory to your lot, to make sure it’s feasible to deliver and install prefabricated components. In general, if a
foundation can be engineered, we can install prefabricated components on it. However, impediments like overhanging trees and power lines, low bridges,
narrow roads, severe curves, and steep slopes along the route will determine what we can build and deliver. We’ll perform an initial analysis for free, using
Google Maps. If no major impediments are found, we’ll execute a full, detailed, paid analysis. This analysis is required in order to move forward.
Time: 1 - 3 weeks

Initial Design Review

You’ll share your plans and we’ll make sure they can be prefabricated at Plant. We’ll give you and your architect a sense for what kind of changes may be
required, if any, to make your design work with Plant Modules and/or Plant Panels.
Time: 1 - 2 weeks

Design
We’ll work with you and your architect on any changes that may be required to make your design efficient for prefabrication. You should connect with us
before your plans have been engineered, as the requirements for offsite construction vary from those for site-built projects. If you’re still developing your design,
we’ll help you optimize it for prefabrication and advise the most cost-effective, healthy, and sustainable options for finishes, fixtures, and other materials.
Time: 12 - 16 weeks
Design &
Engineering
Engineering & Approvals
Engineering and approvals for prefabricated components are governed by state authorities. Engineering and permitting for the foundation and site work is
governed by local authorities. The site general contractor (GC) will coordinate engineering and local permit submittal. Plant will submit the architect-prepared
package to the state. Plant can also support you or your GC as needed by recommending engineers who are experienced in prefabricated construction.
Time: Varies by jurisdiction

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 13
 Process (continued)
Pre-Construction
This is when you will finalize finish specifications, and when we’ll work with you to determine the scope of work between Plant and the site GC. We’ll create
production drawings using our 3D virtual build process, and we’ll finalize pricing for the production of your design. This is also when we’ll submit the supplied,
complete ASMEP drawing package for the prefabricated components to state authorities for approval.
Precon Time: 8 - 16 weeks
Agreement
Fabrication
Your project will be built in our all-weather facility in parallel with site work. All required inspections will be completed in our factory, so we’ll be able to deliver
your project with the walls sealed and finishes installed! You will be invited to tour the project in production.
Time: 8 - 16 weeks

Fabrication Site Work and Foundation

& Sitework
Plant does not perform site work, but we collaborate with your site GC on the preparation of the lot and foundation, maintaining oversight and quality control.
Time: 8 - 16 weeks

Delivery & Installation

You or your site GC will secure installation resources and a transportation company, then schedule delivery of the prefabricated components. (If needed,
Plant can recommend providers.) The transport company will secure any necessary permits (for things like police escorts or parking), pick up the components
at Plant, and truck them to the job site.

Installation Then for the fun part! A crane is typically used to lift the components off the truck and lower them onto the prepared foundation, where they are bolted together.
to Move-In Depending on the size and complexity of the design, most projects are fully assembled in a matter of hours—not weeks or months. You’re invited to spectate!
Time: 1 - 3 days (depending on size of the project and balance between Plant Modules and Plant Panels)

Finish Work
Once the building is assembled, your GC will connect the water, sewer, electric, and appliances, and apply the finishing touches (like exterior siding where the
components were connected). Since most Plant modular projects ship 90% complete, with drywall, paint, millwork, tile work, and even the appliances in
place, on-site finish work is generally minimal. Landscaping is also typically done at this time.
Time: 6 - 16 weeks

Final Inspection
The local authority will perform the final inspection on the structural and utility connections, along with any other non-factory-produced site work, and issue the
certificate of occupancy. The project is officially complete!

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 14
 Sample Project

Architect: The Brown Studio

Location: Olympic Valley, CA

• 2,630-sf single-family home with 600-sf garage | 4 beds, 3.5 baths

• Built as four finished Plant Modules (majority of living area) and 35 Plant Panels (garage,
roof overhangs, and hallway areas between modules; indicated by red arrows on photo)
• Components set and installed in 15 hours
• 25 additional variants to be produced over 2020 and 2021

“We had a firm deadline

and tight budget tied to the
grand opening on January 3.
We considered several partners,
but ultimately concluded that
we could only do this with Plant,
because of their building and
engineering technology.
—Developer

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 15
 Sample Project: Module and Panel Configuration

The second floor consists of two modules (red), The remainder of the roof is comprised of
three wall panels (green), two floor panels (blue), six roof panels (orange).
and four roof panels (orange).

The first floor consists of two modules (red), seven wall panels (green), and three
floor panels (blue).

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 16
 Sample Project: Installation Day

As is always the case with Plant projects, PBS components are constructed in our factory while the foundation and utility connections are completed by a general contractor at the job site. On installation day (pictured),
a crane or other specified setting equipment is used to lift and set the components in place. The components are then secured to the foundation and one another, and utility connections are then completed by the
site general contractor. All components of this project (four large Plant Modules and 35 Plant Panels) were set in roughly 15 working hours.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 17
 Sample Project: Interior Finish

The hallway area (stairs photo) was constructed as Plant Panels, while the adjacent areas were constructed as finished Plant Modules. Joints between mods and panels can either be “stitched” (finished) for a seamless flow
or “celebrated” (exposed) as an intentional design element. In this project, the joints and intersections were stitched together to create a seamless aesthetic.

Plant Building System Overview, August 2020 | © 2020, Plant Prefab, Inc. 18
 Next Steps

We would love to give you a reliable, efficient way to

build your custom design.

If you have a project you’d like us to assess for

construction with PBS, please submit a project inquiry
on plantprefab.com/contact or email your project
details and plans (ideally at a schematic level, but can
be further along) to info@plantprefab.com. We will
perform a complimentary review and answer any
questions you may have about working with Plant.

Prior to production we’re available to serve:

• As a consultant, to optimize your drawing set for

prefabricated construction and coordinate with
your SMEP consultants;
• As an executive architect, to complete the
drawing set and state approval package based
on your schematic design and specifications;
• Any combination of the above.

Thank you again for your interest in Plant Prefab. We

look forward to supporting your project!

This custom-designed development of four 2,200-sf,

LEED Gold-certified town homes was prefabricated as
sixteen Plant Modules and installed in just two days.
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plantprefab.com
375 S Cactus Ave.
Rialto, CA 92376