The Prefab Revolution: Modularization Reshaping the Laboratory Landscape

2025 Lab Design Conference speaker—Ellen Sisle, global director of science & research, Jacobs

Laboratory construction is moving off-site—and into factories. That was the central takeaway from the 2025 Lab Design Conference session, “The Impact of Modularization and Prefabrication on Laboratory Design and Construction,” presented by Jacobs’ Ellen Sisle, global director of science & research, and Tejoon Jung, design principal. The session detailed how off-site fabrication has expanded well beyond casework to include structural elements, multi-trade utility racks, and even entire pre-assembled rooms.

According to Sisle and Jung, the shift is driven by the demand for speed, safety, and efficiency in an industry where accelerating research timelines can translate into billions of dollars and lives saved.

Accelerating schedules: a competitive edge

The most compelling benefit of modular construction is schedule compression. By moving critical work off-site, traditional construction and fit-out can occur concurrently. Sisle noted that accelerated timelines create significant cost savings—not only by reducing labor, but also by minimizing the need for extended temporary facilities or swing space.

Jung shared a case study of a 210,000-gsf lab, office, and pilot plant project in northern New Jersey. From design start to occupancy, the project took just two and a half years, including a 20-month construction period that relied heavily on modular components.

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He highlighted the importance of prefabrication in rapid enclosure: “We utilize a unitized curtain wall system… and that's going to allow us to close up the building, at least in enclosure, in about three months time.” This fast weather-proofing enabled interior fit-out to start much earlier. On a second urban project, the steel frame, typically erected in 20 weeks, was assembled in six winter weeks using a modular connection system: “This was done in six weeks during the winter months.”

A four-story lab project further demonstrated this speed. Two stair towers, prefabricated in Texas, were reassembled on-site in just hours. Jung explained, “Some seven, eight hours later, the whole stair tower is complete. And you know, if this stair had to be stick, built in two, you'd have taken four weeks.”

Safety and quality: beyond the jobsite

Modularization also improves health and safety. Sisle explained to the Lab Design Conference audience that controlled warehouse environments inherently reduce risk: “This is because a lot of the work is taking place in a warehouse environment, it's not elevated. So, you know, first of all, the workers are working at grade, essentially.”

On-site safety benefits as well. Jung described a large lab project where nine vertical utility racks—including ductwork and piping—were pre-assembled off-site into a “shark cage” structure and lowered into place. The result: “It only took 96 hours on the site, so about 10,000 hours were then shifted off site with the construction of this vertical shaft.”

For labs on dense university or pharmaceutical campuses, modular construction reduces disruption. Sisle noted, “Clients typically appreciate the fact that on the campus... there's a lot less disruption associated with noise and, even more importantly, vibration.”

Design challenges: planning is key

2025 Lab Design Conference speaker—Tejoon Jung, design principal, Jacobs

Despite its advantages, modular construction requires early coordination and careful planning. Sisle emphasized spatial considerations: prefabricated multi-trade racks can create tighter floor-to-floor constraints. “Maintaining a tight floor to floor space can be a challenge,” she said. Jung confirmed the trend, noting that 18-foot floor-to-floor heights are becoming the norm, up from 14–16 feet, to accommodate prefabricated utility systems.

Uniformity expectations can also challenge designers. Sisle recalled client frustration with overhead utility panels: “I don’t understand. We’re using overhead modular panels. Everything’s supposed to be repetitive. Why do you have 32 different panel types?” Differences in power, mass spectrometer requirements, and utility needs mean that repetition must guide design principles rather than dictate rigid rules.

Sustainability and the next phase

Modularization supports sustainability goals. Sisle shared a carbon analysis showing that using prefab panels over stick-built exteriors yielded a 14 percent reduction in carbon emissions, largely from less material waste and reduced worker commuting. Jung added, “We didn’t have to sacrifice any of our sustainability goals as we push for the prefabrication and modular and modular construction of these buildings.”

Looking ahead, prefabrication is moving into core and shell design. Jung highlighted a recent project where shafts and stairs were moved to the exterior for pre-fabrication, freeing interior floor plates for maximum flexibility.

Sisle concluded with advice for designers: “You really have to think ahead and have the end in mind so you can realize the maximum benefits around schedule, around sustainability and around the cost efficiencies.” Modularization, she emphasized, is no longer a niche approach—it is becoming a foundational methodology for building faster, safer, and more efficient laboratories.

The 2026 Lab Design Conference is heading to Orlando, FL, on May 11–14! Explore how objective decision-making tools and integrated project delivery models are shaping the future of lab planning. Be sure to register by December 31, 2025, to get the early bird discount. Read more about the agenda, networking events, workshops, and lab tours at https://www.labdesignconference.com/.