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Prefabricated Pump Systems Save You Time & Money

3 min read

Cut costs and site labour now! Prefabricated Skids, or “Prefab”, is a fantastic way to streamline the installation of your HVAC equipment. Imagine 3 months of drawn-out site activity being reduced to 3 days! 

Masterflow has earned a reputation for designing and delivering custom-designed HVAC systems to suit the unique requirements of the most demanding projects. This range covers prefabrication that can involve pumps, heat exchangers, headers, and more. 

Traditional installation methods onsite take time and money. In many cases, it’s easier and more cost-effective to choose a prefabricated package pump system. You’ll see benefits both in the organisation and installation stages of your project. These savings apply whether your prefabricated skid includes pumping equipment or not. 

Organisation Stage 

Improved System Efficiency 

Building a pump system onsite generally means sourcing parts from multiple suppliers and manufacturers, which can lead to several complications. 

A system composed of disparate parts is likely to be less efficient than a system for which each part was specifically designed to work as part of the finished whole. Prefabricated systems are therefore likely to be more energy efficient, giving you better, more consistent results at lower operating costs.  

Our prefabricated systems are built entirely in a controlled environment by in-house technicians using the latest tools and equipment, resulting in a higher level of quality control than would otherwise be possible. 

Greater Manageability 

Another issue with sourcing your system parts from multiple suppliers is that it complicates the maintenance and repair process. If a mechanical issue occurs, it can be difficult to establish which part – and therefore which manufacturer – is at fault. Our prefabricated systems are designed, built and tested in our workshop, so if an issue arises, you’ll know right away that Masterflow is the only one you have to contact for servicing. 

Installation Stage 

Faster Installation 

The fundamental difference between a prefab HVAC system and a non-prefab system is that non-prefab systems need to be assembled onsite, while a prefab system arrives already assembled. 

Onsite Safety 

A complex, non-prefabricated installation can take many hours or even days to complete onsite. There are safety issues to consider, as the use of heavy machinery required to build HVAC systems carries an inherent level of risk. The longer technicians spend working on complex pump systems at job sites, which are known for being chronically untidy and far from ideal as a technical workspace, the greater their risk of injury. 

Our prefabricated systems are built in our workshop in a tidy, controlled environment and are quick and easy to install when they arrive at the job site. 

Fewer Labour Costs 

Our prefab systems are mounted on a skid or platform that includes all the electrical and plumbing components. The only onsite work required in these areas is a simple connection of the skid’s plumbing and electricals to the building’s connection points. 

With traditional systems, after the pumps, chillers, and other components have been delivered, ALL the piping and wiring must be constructed onsite. This requires more onsite labour and installation time. Therefore, non-prefab systems tend to be more costly. 

Lower Overall Cost 

When you think about the cost of labour, last-minute parts and communication issues that come with a large installation team, prefabrication seems like the perfect solution.  

Then why aren’t we seeing more of it? 

  • Tradition sometimes prevents contractors from wanting to try prefabrication. 
  • The fear of going over budget arises when viewing a large lump cost as opposed to the smaller, more manageable amounts of each separate product. 
  • Prefabrication is relatively new to the HVAC industry, so not many manufacturers are trusted to do it correctly. 
  • At first glance the price for a Prefab may seem extremely high, so the traditional method is chosen in the mistaken belief it is more cost effective. When consideration is given to OHS, site hazards, induction times, lost time, parking fees and less personnel needed on site, the cost advantage becomes more apparent.  

The engineering team here at Masterflow have worked incredibly hard over the past 20 years to come up with new ideas on how to make prefab skids work to their highest potential. 

  

Is a prefab solution the best fit for my application? 

There are certainly situations in which a prefabricated system is not suitable – for instance, where unique space and sizing requirements mean such a system will not fit. In these instances, having a qualified team of technicians assemble your system onsite is your best option.  

Likewise, a building where a plantroom is being upgraded (not a new build) may have installation restrictions, including the fact that the roof is already in place. This means a large prefab unit cannot be lifted into a plantroom, unless it is a rooftop setup. 

If your project is not space-poor or a retrofit job, it’s a great idea to have a serious look at a prefabrication option. 

Get in touch here to tell us about your application and consult with our engineers.