Comparative explanation of construction method options for building a warehouse: conventional / prefabricated / system construction / tent

When building a new or additional warehouse, there are a variety of construction methods available, including custom-made conventional construction methods that take a long time to build, prefabrication, system construction, and tents that can realize a short construction period and still ensure a certain level of quality.

In order to help you understand the differences and how to choose the best method, this article provides an overview of the features, durability, cost, and time frame of each construction method, with comparisons made as a guide.

There are four main methods of warehouse construction!

First, we will give an overview of each of the four construction methods picked up in this article: conventional construction, prefabricated construction, system construction, and tent construction.

traditional construction

Conventional construction methods are, broadly speaking, the traditional construction methods that have existed in Japan since ancient times, mainly born after the technological revolution following World War II, and have continued to the present day.

Conventional construction methods, also called “wood-frame construction methods,” “conventional axis construction methods,” “conventional wooden construction methods,” or “wooden frame construction methods,” use mainly wooden materials to construct a framework consisting of posts and beams on a foundation, which is reinforced with braces and bearing walls to resist horizontal forces such as earthquakes and weather.

Although there are various differences among conventional construction methods in terms of details depending on the subject of construction and the building contractor, the following points are generally common to all conventional construction methods.

• A reinforced concrete “fabric foundation” (continuous footing foundation) is provided and anchor bolts are used to tie the foundation to the fabric foundation.
• Insert braces and stabilize the axis assembly by stopping with plates, etc.
• Use structural plywood or other materials for walls to provide strength to walls.
• Various hardware is used at wood joints to reinforce the framework.

The construction method has been handed down from generation to generation since ancient times, and is characterized by a variety of innovations and technologies that are used to construct buildings.

prefabricated construction method

The term “prefabricated” is a Japanese abbreviation, derived from the English word “prefabricated” (katakana: prefabricated).

Prefabricated is a word that means “assembled,” or a component that is designed to be assembled, i.e., in prefabricated construction, each component is made at a factory according to specifications, with the assumption that it will be assembled according to a predetermined procedure, and the actual construction site is where the components are assembled according to the predetermined procedure. The actual construction site is then assembled according to the predetermined procedures.

Because everything is a predetermined procedure, the dimensions of the finished building are completed according to the predetermined specifications for each product.
The materials used in the prefabricated construction method are not constant and range from heavy steel frame systems, light steel frame systems, wood systems, etc.

system architecture

The system construction method is based on the aforementioned prefabricated construction method with its predefined materials and procedures, but also offers design flexibility that is difficult to achieve with prefabricated construction methods, and further improves the quality of buildings in terms of durability, weather resistance, and seismic resistance.

Building materials and construction methods are thoroughly standardized by computer, and all processes, such as design, selection of building materials, and construction, are systematically streamlined to achieve significant cost reductions, shorter construction periods, and higher quality.

Tent construction method (tent warehouse)

As the name suggests, the tent construction method is a building construction method that covers the ceiling and wall areas with a membrane material.

This simple construction method is based on a lightweight steel framework, and the ceiling and wall sections are formed by covering them with special sheets.

In addition, to build a warehouse using the tent construction method, the Ministry of Land, Infrastructure, Transport and Tourism (MLIT) has notified the construction standards, which basically require a total floor area of less than 1,000 m2, an eave height of 5 m or less, and a flat roof, making it suitable for relatively small to medium-sized warehouses.

However, depending on the provider, mega-class tent warehouses with a maximum floor area of 3,000 m2 or less, which are classified as “general membrane structures” in compliance with the Building Standard Law Notification, can also be realized.

Comparison of conventional construction / prefabricated construction / system construction / tent construction features

When building a warehouse using each construction method, there are minor differences depending on the provider and product variations, but here is a general comparison of the features of each construction method for your reference.

Durability (building life)

The following is a rough estimate of the durability of a warehouse built using each construction method.

• Conventional construction method …… approx. 30 years or more (can be freely pursued at the time of designing, as it is custom-made)
• Prefabricated construction method …… approximately 20 years or more (exterior walls are more durable, but roofing materials are generally less durable)
• System architecture …… approximately 30 years or more (In recent years, many products are now available that use highly durable materials. (snow protection, high wind resistance, etc.)
• Tent construction method…… approximately 10 to 20 years or more (Generally, it is the most susceptible to deterioration. However, there are products with enhanced durability due to unique innovations such as the shape of the roof section)

Cost of construction

The relative costs of building a warehouse using each construction method are as follows

• Conventional construction methods …… standards
• Prefabricated construction method …… comparatively inexpensive
• System Building …… achieves a construction cost cut of 25% to 30% compared to conventional construction methods. Compared to prefabrication, it is equivalent or even slightly more expensive, but less expensive when the performance aspects that can be achieved are taken into account.
• Tent method …… least expensive. However, the cost of replacing the membrane material occurs during long-term operation.

construction period

The approximate construction time for building a warehouse using each construction method is as follows.

• Conventional construction …… approximately 6 months or more
• Prefabrication method: …… approximately 2 to 3 months approx.
• System architecture …… approximately 3 months approx.
• Tent construction method …… approximately 1-2 months approx.

Freedom of design

The following is a rough guide to the degree of freedom of design when building a warehouse using each construction method.

• Conventional construction method …… free for custom-made
• Prefabricated construction methods …… have almost no flexibility due to the fixed standard for each product.
• System architecture…… has more freedom compared to prefabricated buildings (various options within a certain range, such as a choice of wall materials, variations in specifications and colors, etc.)
• Tent construction method …… Generally not flexible due to almost constant framework standards (some businesses may be able to accommodate detailed requests as well as product variations)

Taiyo Kogyo's "Tent Warehouse" and "System Building Warehouse" realize smooth introduction and high durability.

The various construction methods for building warehouses described in this article all have their own unique characteristics.
It is advisable to make comparisons based on your needs, such as what is most important when building a new or additional warehouse, and what points should not be overlooked.

Tent warehouses and system building warehouses handled by Taiyo Kogyo have a wide range of products that take advantage of the features of each original construction method while at the same time incorporating innovations that further enhance performance.

Taiyo Kogyo's "Tent Warehouse

The fixed tent warehouses feature an arc-shaped roof that improves durability by widely distributing the load on the roof, and unique specifications that reduce the burden on the membrane material, resulting in tent warehouses that can be used with peace of mind for many years.

Understanding the differences between construction methods and selecting the best method for new warehouse construction

This article describes the main construction methods that are options for new warehouse construction, including the “conventional construction method,” “prefabricated construction method,” “system construction,” and “tent construction method” with detailed mechanisms, features and advantages of each, costs, construction period, and general life expectancy of the structures.
Both of these construction methods are widely adopted for building tents and can be the best option depending on your needs.

We urge you to select the optimal method of establishing a new warehouse depending on your company’s situation.
As described in the last section, Taiyo Kogyo’s tent warehouses and system building warehouses enable the construction of high quality, long-lasting warehouses at low cost and in a short construction period.
If you are interested, please visit our website for more details.

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