When Kaufmann Bausysteme (KBS) was awarded the contract to build a retirement home consisting of 136 modules in Hallein, Salzburg, in 2012, the company did not yet know where to manufacture them. Kaufmann finally found what he was looking for in Kalwang, Styria. There, he rented a hall which he later purchased. “We gradually adapted the hall for modular construction,” the managing director recalls, adding that the optimized and careful production of the modules is just one of the many factors in the success of his company. But let’s start from the beginning.
In 2008, Kaufmann won the contract for the BMW Hotel Ammerwald, a project that called for modular construction already during the tender phase and marked the beginning of a new era for the Vorarlberg-based company. “At the time, I had rejoined my father’s company and quickly recognized the potential of modular timber construction,” Kaufmann says, recalling his first project in this area. Just four years later, he was already generating 95% of his total revenue from modular buildings. Back then, projects involving 80 to 100 modules were considered large. Today, the company handles construction projects with 500 to 1,000 modules.
Then as now, Kaufmann uses cross-laminated timber for his projects. “Since over 90% of our walls remain visible, CLT is still the best choice for us,” the managing director emphasizes. The company’s demand for the product currently amounts to around 30,000 m³ a year.
Steep learning curve
When Kaufmann compares his modules from 2008 with those from 2025, he finds hardly any similarities, apart from the CLT: “The entire structure, the stacking of the modules, the structural aspects, the logistics – each project has taught us something in all areas and we improved as a result.” This is especially true for the planning process and the path towards becoming a general contractor. “Before, when we only delivered modules, we repeatedly had problems with connections and cables on the construction site, and that cost us a lot of time. So, we were more or less forced to consider becoming a general contractor,” Kaufmann says, describing an enlightening development phase that has opened many doors for him.
The entire structure, the stacking of the modules, the structural aspects, the logistics – each project has taught us something in all areas and we improved as a result. This is especially true for the planning process and the path towards becoming a general contractor.
© Angela Lamprecht
Today, at KBS, the construction process begins with the first customer consultation and extends over the entire project planning phase to the production and assembly of the modules: “It is important to keep an overview and to have an excellent project team that plans and coordinates the entire building services, piping, sanitary facilities, building physics, floor structures, and all the other relevant details.”
Digitalization to support production
Following major orders in Berlin and Rostock, Kaufmann has set up production sites in both cities in recent years. “In those cases, too, we received the orders first, and only then did we think about the production sites. Transporting thousands of modules from Kalwang to northern Germany would have simply been too expensive, so we rented large, empty halls,” Kaufmann tells us and adds that the equipment for a new production line fits into just a few trucks.
Kaufmann describes the personnel situation as particularly challenging: “In many areas, we have successfully relied on subcontractors from the very beginning. However, it was extremely difficult to find additional qualified experts in Germany.” In response, his company delved even deeper into the digitalization process and created production and logistics software in which all construction processes are documented in detail using descriptions and images. “The employee receives all this information – from the assembly of the CLT elements to quality control – on their iPad, which provides significant support,” Kaufmann says. He does believe, though, that the digitalization of his company is far from complete. Now that all processes and materials have been integrated into the software, the company is currently busy linking all this information to cost centers in order to further exploit any potential for optimization.
Up to 4,000 modules a year
Depending on the type of project, Kaufmann Bausysteme produces between 2,500 and 4,000 modules a year at three sites, and the order books are quite full at least until the end of 2026. “Modular timber construction is in a golden age. With educational buildings, student dormitories, hotels as well as government and office buildings, we have impressive references in many areas that we are proud of,” Kaufmann emphasizes, who is now in the fortunate position of having major project developers approach him specifically.
A good example of this is the so-called Luisenblock West in Berlin’s parliamentary district where Kaufmann, as general contractor, built 400 offices to meet the space requirements of the German Bundestag at short notice. Starting with an examination of the project by authorities in September 2019, it took a total of 27 months to complete the seven-story building consisting of 460 modules. Construction itself took less than 15 months. In Rostock, a €240 million student dormitory built with 1,000 modules is scheduled to be completed this year. Meanwhile, schools with a total value of €210 million are being built in Berlin.
Despite these enormous sums and project sizes, Kaufmann still sees KBS as a family business with short decision-making processes: “From the boss to the apprentice, we all stick together and complete projects together as a project team. This keeps us flexible and gives us enough energy for what matters most.”