The smarter way to build
Off-site or prefab construction isn’t new, but it’s definitely having a moment as contractors and clients alike seek ways to make projects more environmentally friendly and manage costs. One company that’s been using the practice for a long time is Bensonwood. We asked Seth Clarke, the builder’s director of business development, to walk us through the benefits and opportunities.
— Interview by Margot Lester, edited by Bianca Prieto
What prompted you to invest more in off-site construction?
Our company has embraced off-site construction since its founding over 50 years ago as a timber frame builder, driven by the belief that better outcomes come from working in a controlled environment. Building outdoors in unpredictable weather introduces risks—especially moisture-related issues like mold and air infiltration—that homeowners often struggle with long after construction ends. We've also prioritized leveraging advanced 3D modeling and CNC machinery, which naturally aligns with off-site production. For Bensonwood, off-site isn’t just a preference—it’s a strategic commitment to quality, precision, and building science.
What's the most significant change it's produced?
Off-site construction has allowed us to take control of the most complex challenges facing the industry today. While manufacturing productivity has soared over the last century, construction efficiency has stagnated. At the same time, skilled labor is dwindling—especially in remote areas—and energy codes are becoming more demanding. High-performance building is hard to get right on the jobsite, but our off-site system enables us to consistently meet those standards, including achieving passive-house level airtightness on every project. It’s transformed our business from reactive to proactive, with predictable, repeatable success. And I think it's because of all these factors that we're seeing a big increase in interest and demand for what we do.
What do most people misunderstand about off-site construction?
Many people underestimate the full impact that off-site construction can have—not just on budget and lifecycle costs, but on health, comfort, and long-term sustainability. Building better has real consequences for families and future generations.
One major blind spot is the environmental footprint of homes. Everyone talks about getting polluting cars off the road, but few realize that fossil fuel-heated homes are among the largest contributors to carbon emissions in the U.S. Unlike cars, which are replaced every few years, the systems we build into homes can lock in decades of energy use. With new technologies, building off-site reduces waste, improves performance, and delivers higher quality results compared to traditional onsite methods. It’s catching on quickly, as people recognize that the precision and efficiency of off-site construction outpace what’s possible with conventional building. That’s why early design decisions, materials and methods matter so much—and why the superior outcomes enabled by off-site construction are so game-changing.
How can off-site construction support contractors’ bottom lines?
The key is risk reduction. Off-site and other sustainable construction methods bring predictability, which helps de-risk projects and lower costs. On top of that, reduced material waste directly improves margins. The combination of efficiency, performance and waste reduction creates measurable near-term savings for contractors.
What else should we know about off-site construction?
Education remains the biggest barrier across clients, contractors and trades. Many are unfamiliar with new methods that differ from traditional approaches. Upfront costs can also appear higher, but that often reflects the long-term investment value these projects deliver. Inconsistent building codes across states and municipalities also make adoption harder. Despite these challenges, Bensonwood is optimistic. The industry is ripe for disruption, and momentum is building toward innovation.
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The Level is curated and written by Margot Lester and edited by Bianca Prieto.