Off-Site Manufacturing and the Outdoor Living Industry

For generations, outdoor living projects have been handled with an on-site, make it happen, strategy. A set of plans and a team of skilled builders made it all come together. However, times have changed and the number of skilled craftspeople available for any particular project has dwindled to a point of near extinction.

According to an NAHB survey, approximately 85% of builders and remodelers state they cannot find enough skilled carpenters to keep projects on track, driving up the costs of construction and making more projects unprofitable.

Enter Off-Site Manufacturing (OSM). A construction technique where building products are manufactured in a controlled factory environment and then installed on-site in order to reduce the number of skilled workers needed to complete the project. The benefits of off-site manufacturing for outdoor living projects are wide and varied.

Architects and designers can specify a product and know the product they choose will deliver quality to their client and look just as they designed. For builders and contractors, OSM can shorten build time, offer a higher quality finished product, reduce build costs, increase job site safety, and reduce waste.

Despite the growing need and the fact that “kit homes” were being sold by Sears, Roebuck & Co. starting in 1908, off-site manufacturing has mostly remained a niche building approach. Until recently.

With a shortage of skilled workers on the rise, companies in the outdoor living industry are turning to off-site manufacturing to cover the skilled labor gap and provide products that exceed those being built on-site. 

Three outdoor living manufactures leading the way are Structureworks, makers of pergolas and shade structures, Danver, manufacturer of stainless steel outdoor kitchens and Eldorado Stone, an architectural stone manufacturer of modular fireplaces.

So why do these companies believe in the value of off-site manufacturing?

“Our end goal is simple; “bring the architect’s or designer’s vision to life”, stated Andy Sears, VP/COO at Structureworks, “By manufacturing the structure in our factory, where capabilities are almost limitless, we can achieve so much more from a design perspective. The end product will be true to the designer’s intent and prove to be more durable with less maintenance over its lifespan. OSM allows us to ship a kit that is easily assembled on-site without needing a highly-skilled team. ”

Traditionally, designers were forced to make a choice: build on site with design freedom and a custom fit or buy a standardized product that isn’t a perfect fit and doesn’t live up to the aesthetics of the project. Structureworks doesn’t force designers to choose. Completely custom structures can be factory built in a range of materials for residential and commercial applications with the confidence that what shows up on site will go together exactly as expected. These structures can be fully engineered for code compliance with stamped plans for any location in North America. Additionally, factory finished products offer a level of durability that simply cannot be achieved with on site finishing.

“It’s difficult and time-consuming to build an outdoor kitchen from stone or stucco. You are at the mercy of masons, if you can find a good one. Many times the job site is cluttered with construction debris and you’re chasing workers who can take weeks to get the job done. We offer a better solution,” says Mitch Slater, president of Danver Outdoor Kitchens, “The process is just better, easier and quicker than traditional methods. Using off-site manufacturing is the future of building”.

Danver Outdoor Kitchens are made from environmentally friendly, quality stainless steel and powder-coated in an array of colors to match your taste. The quality is better due to a QC process in a controlled manufacturing facility. Because the kitchens are built to order in Connecticut, they are easily customizable and shipped to the job site fully assembled, allowing them to be installed in a matter of hours – not days or weeks. With over twenty years of engineering, design and manufacturing expertise going into every product, Danver makes it easier to bring outdoor living spaces to life.

“Outdoor spaces are in particularly high demand in today’s residential market, with increased interest for commercial spaces as a result of the global experience of COVID-19,” said Sarah Lograsso, Director of Marketing at Eldorado Outdoor. “This opens up great opportunities to step in and help alleviate pressure for teams that are stretched thin when it comes to specialized training. Through our Eldorado Outdoor line of products, specifiers can choose from a variety of factory pre-scratched fireplace kits that are ready for quick, easy assembly and may be dressed with any of our manufactured stone or brick veneer products for the ultimate masonry appearance.”

Fireplaces from Eldorado Outdoor present a bold design statement to complement any outdoor space. The kits ship with all essential structural elements, including strong, lightweight modular components that are easy to assemble and do not require a concrete footing, reducing installation time by an average of nearly 50 percent compared to traditional masonry fireplaces.

While the lack of skilled trade professionals may be an uphill battle for many in the outdoor living industry, the value proposition for Off-Site Manufacturing is strengthening every day. Architects and contractors that embrace OSM as a way to ensure projects are finished on budget, on time, and per plan will differentiate themselves and build a reputation for out performing their peers.