Learning from industry experts at Casais

Spending a month at Casais, a leader in industrialised construction, was an enlightening chapter in my academic journey. This secondment offered a unique opportunity to deepen my understanding on multi-family housing projects built with industrialised methods and explore ways to integrate customisation strategies within their processes. From semi-structured interviews with diverse practitioners to factory and site visits, the experience provided rich insights into both the potential and challenges of industrialised construction.

The cornerstone of my secondment was the series of interviews I conducted with key professionals across Casais and Blufab, its manufacturing division. Engaging with individuals like Miguel Pires, Technical Director, and Filipa Rocha, Project Coordinator, helped me appreciate the transdisciplinary collaboration integral to their operations. These conversations revealed how industrialised construction can optimise time, reduce waste, and enhance environmental sustainability through precision and digitisation.

Highlights included discussions on how prefabricated components, built in controlled environments, become traceable material banks that reduce lifecycle costs. Equally interesting were the efficiency gains from high levels of digitisation, such as Building Information Modelling (BIM), and collaborative tools like a Common Data Environment (CDE). These enable effective coordination, clash control, and integration of learning loops to refine fabrication processes.

However, the interviews also shed light on significant barriers to customisation. A major challenge is the mismatch between traditional design approaches and industrialised systems like CREE or Blufab. Often, projects arriving at Casais are not designed with these systems and their constraints in mind, leading to inefficiencies when attempting to "industrialise" them post-design. Economic limitations and low digitisation further restrict flexibility, highlighting the need for early decision-making and client commitment to reap the full benefits of industrialised methods.

Factory visit to Blufab: Precision and Potential

At Blufab, I observed the production of bathroom pods—a fascinating glimpse into how standardisation and customisation could intersect. Each pod's light steel frame is pre-cut, labelled with unique codes, and mechanically assembled, ensuring both precision and future disassembly potential. Additionally, a Kanban system tracks assembly progress digitally, allowing managers to address delays promptly.

The potential for customisation in Casais’ assembly line lies in a catalogue of standard wall dimensions that enable variability while maintaining efficiency. However, introducing greater diversity in panel sizes can slow production, a challenge that could be addressed with increased automation. Sustainable innovations, such as replacing concrete bases with lightweight solutions and transitioning to horizontal tile installation, demonstrate how Casais continually refines its processes.

On-site at Valença

My visit to a student housing project in Valença offered a firsthand view of industrialised assembly. The structure and façade, built with the CREE system, and 3D bathroom pods exemplified just-in-time delivery and reduced on-site storage needs. Observing the interplay between traditional construction elements and prefabricated components highlighted the importance of understanding tolerances and sequencing for seamless assembly. Furthermore, analysing interconnected systems as a whole, rather than in isolation, proved vital for understanding the complex dynamics of industrialised construction.

Although the project’s standardised design suited its purpose as student housing, it highlighted the trade-offs between flexibility and efficiency. Insights from this visit will inform strategies for balancing standardisation and customisation in more varied housing typologies.

Towards a platform approach

One of the most promising takeaways from my secondment was recognising the potential of the platform approach. Unlike the current focus on standardising entire buildings, standardising individual components, its fabrication processes, controlling its supply chain and storing the company’s expertise, could enable greater flexibility and scalability. This shift could support customisation while maintaining efficiency, allowing  Casais to improve its housing solutions.

Reflections for my research

The secondment built on methodologies I developed during my earlier placements at La Salle and TU Delft. It allowed me to evaluate the industrialisation degree of a multi-family housing case study and identify barriers and enablers to implement mass customisation. By engaging with the professionals at Casais, I gained a deeper understanding of transdisciplinary collaboration’s role in fostering innovation.

These insights will nurture the study I am developing, outlining short-, medium-, and long-term strategies to integrate flexibility into industrialised housing projects. This approach aligns with Casais' broader goals of improving efficiency, sustainability, and adaptability in their construction systems.

All in all, my time at Casais reinforced the importance of bridging traditional construction mindsets with innovative approaches. By fostering collaboration and leveraging digital technologies, we can unlock the full potential of industrialised construction to create more resilient, adaptable housing solutions for the future.