Off-site and modular construction are no longer niche approaches in the UK. From housing developments to education buildings, more projects are shifting towards factory-based assembly to deliver faster build times, improved quality control, and reduced on-site disruption.
Sheathing boards form an essential part of these builds, providing structural stability, racking resistance, and weather protection in the panelised wall systems. Choosing the right board is crucial to ensure the off-site process runs efficiently while meeting all safety and performance requirements.
Designing for Off-Site Manufacture
Precision is key in modular construction. Factory-built panels are designed to millimetre tolerances, meaning the materials chosen must remain stable and consistent from production to installation.
Klasse G-board – a lightweight, gypsum sheathing board – is engineered for reliability, ensuring sections fit seamlessly on site. Its high stability reduces the risk of gaps or misalignment when modules are assembled, helping maintain airtightness and weatherproofing without costly remedial work.
Transport & Handling Constraints
Once modules are complete, they must be transported to site without damage. Sheathing boards are exposed to vibration, stacking pressure, and changing weather conditions during transit.
With its robust composition, Klasse G-board offers strong durability, reducing the risk of breakage in transport. For added protection, simple corner guards or edge sealing can be applied before loading.
Speed of Assembly
Time savings in modular builds are achieved through efficient workflows in the factory. Sheathing boards that are quick to cut, fix, and finish can significantly improve production line output.
Klasse G-board’s score-and-snap capability means panels can be cut without specialised saws, reducing dust and noise while speeding up processing. It is also lightweight and easy to handle, saving additional time during the installation process. Paired with Klasse Sheathing Board Fasteners, panels can be secured rapidly with consistent fixing patterns, maintaining racking strength and compliance with UK building standards.
Achieving Weather Protection & Compliance
For off-site projects, maintaining product performance from manufacture to final installation is non-negotiable. Sheathing boards must withstand moisture exposure during construction, meet stringent fire ratings, and integrate effectively with the rest of the building envelope.
Klasse G-board is A1 non-combustible, and thoroughly tested by 3rd party test houses. Combined with Klasse FireFend Sealant, panels can be pre-sealed in the factory for airtightness and water resistance, reducing the need for additional sealing work on site.
Off-site and modular construction depend on efficiency, precision, and product reliability. By selecting materials like Klasse G-board, supported with compatible fasteners, sealants, or tapes, manufacturers can produce modules that are easier to assemble and built for long-term durability.
For projects where time, quality, and compliance are critical, Klasse provides proven sheathing board solutions designed to work seamlessly with modern construction methods. Contact our technical team today to discuss how our solutions can integrate into your next modular project.
