Pre–engineered with a Twist

Cookie-cutter construction has given way to customized creativity

by Shawn Barrett

Once upon a time, pre-engineered buildings were something you picked out of a catalog and ordered over the phone. Then, about four weeks later, the components arrived on your job site. Basically, you got a big tinker-toy set with an assembly manual. Some thought this method of construction was a dream; others equated it with a lack of imagination and creativity. Today, however, cookie-cutter construction is generally a thing of the past.

Leaders in the pre-engineered building industry have listened to their critics and have found ways to customize their products in order to expand their customer base. As the industry grows, the structures are getting bigger and better. They are not only popular in industrial areas but in residential and commercial areas, too. A friend's home, your supermarket, your office, or your church—all of them could be pre-engineered buildings.

They may be all the buzz. But misconceptions still abound, leaving many people to ask, "Just what is a pre-engineered building?"

A pre-engineered building is constructed from an exterior system created by a manufacturer. It comes complete with all components (unassembled) and is sometimes referred to as a shell system. There are many different system types: laminated wood-arch systems, prefabricated stud-wall systems, structural insulated-panel systems, truss systems, steel-frame systems, precast-concrete systems, and stressed-membrane systems, which can be set up and taken down several times.

Pre-engineered buildings are not the same as modular buildings. Modular construction has tighter parameters; modular buildings are more finished structures. In modular construction, units are put together, then shipped, and only the final assembly takes place on site.

Today thanks to increased customization, it can be difficult even to tell a pre-engineered building from a conventionally framed building, especially as more manufacturers use 3-d modeling techniques. Plus, the exterior of most pre-engineered buildings (the outside shell) can be finished just as you would finish a traditional building.

Finally, thanks to advancing technology, manufacturers are increasing quality, accuracy, and precision in materials and design. By reducing waste, companies are able to pass on cost savings to their clients without compromising quality.

The comparatively low cost of pre-engineered construction is just one reason why churches are interested in this type of building. Versatility is another major factor. Pre-engineered buildings can be used as sanctuaries, gymnasiums, fellowship halls, and education wings, or they can be used as all four under one roof. Because of their varied uses, these structures can be an economical solution for a young, growing church or a megachurch looking to add more education and recreation space.

The large spans and open interior shells typical of these buildings are what make them attractive, says architect David Case of Flint, Michigan. "They are great for activity centers, gymnasiums, and sanctuaries," he says. "The large amount of open space they offer makes them easily adaptable to different functions."

In most cases, pre-engineered structures are free-standing buildings that offer spans up to 300 feet, an attractive option for churches wanting worship space with unobstructed views. Many pre-engineered packages also offer high ceilings, perfect for recreation centers.

Pre-engineered structures, which can be up in a matter of weeks, also lend themselves to future growth. For instance, your church could use one to house a sanctuary with classrooms and offices all under one roof. Then, in the future, the classrooms and offices could be removed to expand sanctuary seating, and an education wing could be added as a second phase. Trinity Assembly of God in Flatrock, Michigan, was thinking along those lines when it built a 110-foot pre-engineered octagon to serve as a sanctuary and classroom space. The church presently seats 560 people in worship, but seating in the sanctuary could be expanded to 670 if four classrooms are removed.

Finally, pre-engineered buildings can easily blend in with other types of construction. It is becoming very common to see different types of construction methods used in one complex. For example, New Albany First Church of the Nazarene in New Albany, Ohio, incorporated three types of construction into its present complex. The education and office spaces are conventionally framed; the fellowship wing is a pre-engineered steel structure; and the sanctuary is a pre-engineered laminated-arch structure. Each phase was built at different times, but because care was taken in the planning stages, each unit fits with the others to form a perfectly functional complex.

Don Mathison, a member of Saint Stephen's Lutheran Church in Northglenn, Colorado, served as project manager for his church's building program. When asked why the church chose a pre-engineered system, he summed up its advantages this way: "the freedom of design, efficient use of quality materials, quicker onsite erection time, and less cost."

Most states and local municipalities require churches to have a complete set of sealed architectural drawings prepared for any building project, regardless of construction method. So, your church will need to hire an architect, if one is not provided by the manufacturer. Today more and more pre-engineered building companies are providing full architectural services in an attempt to become more service-oriented. Other companies have a network of design professionals throughout the country to whom they can refer church building committees.

Most architects are now very open to the idea of designing a pre-engineered structure, despite occasional space or shape limitations. Ten years ago it was not as common, but today some architects say a large percentage of their projects incorporate the use of pre-engineered buildings.

"The new buildings do not have as much of the 'off-the-shelf' feel as the older ones did," says architect David Case. "The manufacturers offer so many accessories. It is kind of like buying a car: you have the base model and many options beyond that."

If your church is using an outside architect, he or she will work closely with the company providing the building package in order to share technical information and engineering specifications. Their relationship should begin as early as the floor plan-design phase. The manufacturer does all of the structural engineering, and it is the manufacturer's responsibility to communicate that information to the architect.

In most cases, architects are responsible for customizing the design of the pre-engineered structure. Their creativity is crucial as they work with a virtually limitless variety of available floor-plan layouts. They are the ones who make sure a church's personality shines through in the building design. And they also ensure the building functions well and meets the liturgical needs of the congregation (baptistry, Communion, preaching, etc).

Once a church has approved drawings and has obtained a building permit, the manufacturer will start the actual fabrication process at its factory under controlled environmental conditions. At the construction site, prep work can begin, such as clearing the land, installing footings, installing underground utilities, and putting in a basement or a cement slab. This multitask method of construction is one way costs are kept low.

A pre-engineered structure is normally put in place after the slab or basement has had sufficient cure time. Communication between the onsite manager and the manufacturer is critical at this phase in order to ensure proper delivery times. The structural system normally goes up in a matter of weeks—an inspiring sight to churches.

A pre-engineered building can be finished by a general contractor or a construction manager. Or, the church can work as its own contractor by hiring subcontractors. It is common to have church members do some of the work.

Much like architectural firms, general contracting firms are increasingly working with pre-engineered construction. General contractors say that using a pre-engineered structure can save up to a month and a half of onsite labor when compared to conventional stick-frame construction.

Overall, the makers of pre-engineered buildings are striving to offer more customization while keeping costs low. Churches want the house of the Lord to be attractive and inviting, and most are not willing to compromise that, even for financial reasons. So, manufacturers are trying to offer the best of both worlds, providing versatility and expandability in a cost-effective, well-designed package.

If pre-engineered builders want to remain active they will continue to respond to the needs of churches and to gain support from architects and contractors. It looks like they're up to the challenge.

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