Up until 2008, Kaufmann Bausysteme was primarily active in traditional timber engineering. The BMW Hotel Ammerwald, the company’s first major modular timber construction project, marked the entry into this segment. At that time, the modules were jointly produced with carpentry firm Kaufmann Zimmerei, which is also based in Reuthe. “I had just joined the company and was already convinced of the potential of modular construction,” Managing Director Christian Kaufmann tells us. In the following years, they have been “canvassing” intensively to inform people and have them overcome reservations about this construction method, which was not yet widely accepted at the time. With the increasing size of projects, the opportunity arose to acquire the Mayr-Melnhof site in Kalwang and establish an independent module production facility there. In 2016, Kaufmann Bausysteme began operations in Kalwang.
Production close to the project site
“When we completed our first school project in Berlin, which involved more than 400 modules, it became clear that transporting them from Kalwang to Berlin was not economically viable,” explains Kaufmann. Consequently, Kaufmann decided to establish a production facility in Berlin. The balancing act between the logistical advantages and the uncertainty of finding enough local skilled workers paid off. “The beginning was challenging, but this strategy has proven successful. Today, we have extensive experience in setting up new production sites, and we also have a strong network of partner companies.” Sufficient space and high-performance cranes are the basic requirements for selecting suitable production halls.
After being awarded the contract for the customs school in Rostock, which has a volume of around 1,000 modules, the company decided to establish a third production site in the northern German city. When it comes to training new employees, Kaufmann Bausysteme relies on its in-house construction and project management teams who provide on-site support during the first few weeks. Should the rented halls no longer be needed after the completion of the project, the production facility can be dismantled within a week.
High degree of digitalization
Collaboration with subcontractors requires clearly defined work processes. “A few years ago, we developed a tool that describes all processes in detail. Thanks to this tool, even less qualified staff know exactly what to do,” Kaufmann explains. The production process is similar to that of an assembly line in the automotive industry. The modules move along rails through various stations where precisely defined work steps are carried out. This way, one finished module is produced per hour.
Each module is also equipped with a QR code containing all the information from planning and production. Furthermore, every production step is meticulously documented with photos, which are also stored in Kaufmann Bausysteme’s specially developed tool.
Becoming a general contractor
With the growing project volume, there was an increasing need to act as a general contractor. “The decision to become a general contractor wasn’t part of any deliberate strategy. However, we thought about this issue and recognize its importance,” Kaufmann emphasizes and adds that such projects are significantly more complex in terms of planning. “What distinguishes us and makes us successful is our reliability. The prices in our quotes are mostly the same as those on the final invoices. Together with the high quality of execution, this is what makes us successful,” Kaufmann says, whose company operates almost exclusively in modular construction these days.
Since the modular units are predominantly built with visible surfaces, the company uses CLT, which is delivered pre-assembled to the respective site. Kaufmann Bausysteme has an annual demand of around 40,000 m³.
Excellent order situation
Kaufmann reports a substantial increase in project volumes: “Ten years ago, 140 modules were considered a large-scale project. Today, we are carrying out construction projects with more than 1,000 modules.” The order books are full: “We are fully booked until the end of 2027 – and we already have the first projects lined up for 2028, too.” Kaufmann sees enormous potential in school construction in particular: “A lot has been neglected here. In the past six years, we have built 35 schools in Berlin alone.” A framework agreement for another ten schools over the next three years with a contract volume of €400 million has already been signed. Other projects include a student residence with 530 modules in the greater Cologne area, one with 450 modules in Regensburg, and a construction project for the German Federal Ministry of the Interior.
The situation is different in Austria: “Two years ago, I sent brochures with all our school construction reference projects to every municipality and building authority. The response was very poor, though,” Kaufmann notes.
Modular construction as a franchise model
A friend of Christian Kaufmann’s, an architect in the US, established initial contact with the United States. After a visit, Kaufmann’s friend returned home impressed by the modular way of building. One project has already been completed in the state of Montana: Kaufmann provided expertise and the digitalization tool, and employees of Kaufmann Bausysteme assisted with setting up the production facility. Similar inquiries have also been received from New Zealand.
Kaufmann envisions scaling the business model through a franchise system in the future, with license fees charged for each module. “At the moment, this represents a very small portion of our revenue, but we will definitely continue to develop this area,” Kaufmann announces.
