Grant: CCI Applied Research and Development Grants

The high costs of construction materials, along with a shortage of affordable housing and skilled labor, necessitate alternative construction methods to address Canada's housing crisis. Prefabricated housing offers a solution for residential and commercial structures, reducing material consumption, accelerating construction timelines, and offering greater flexibility and affordability compared to traditional materials. Prefabrication also reduces environmental impacts, making it a sustainable choice for future development. Prefabricated homes are designed using specialized software, manufactured in factories under strict quality control, and assembled on-site according to the design. This method ensures superior quality while reducing costs and production time. Prefabricated modular construction has a long history, dating back to the Gold Rush in the United States and post-World War II housing shortages in the United Kingdom. The United States has embraced prefabrication, as seen in the Structural Insulated Panel Association, which provides resources for design, installation, and sustainability. While other countries have embraced this market, further development and promotion are needed in Canada. Innovative Composite Products (I-C-P) has developed structural and insulating sandwich panels using 100% recycled polyethylene terephthalate (PE) core and fiberglass skin laminated in a thermoplastic polypropylene (PP) matrix. These panels offer high mechanical strength, lightness, insulation, durability, and long life. However, further development is needed to meet the CAN ULC 701 standard for thermal insulating systems and to improve water, air, and fire resistance properties. This project aims to enhance the product's performance for specific building applications, ensuring compliance with construction material regulations by optimising the skin reinforcement (the fiber glass and the coating) of the prefabricated panel and evaluating the performance of the newly developed product to ensure compliance with the National Building Code of Canada. Additionally, the assembly configuration will be defined and designed, including the development of joining systems such as brackets, I-joists, and lumber. The aim is to create a final product that not only meets the stringent requirements of the Canadian National Building Code but also offers superior performance and durability for habitation purposes.