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Modular construction system developed in Fremantle Western Australia.
Based in Fremantle, WABi Systems is developing a modular construction platform designed to address the logistical and environmental challenges associated with building in remote and regional locations. The company forms part of the wider WABi Group, which integrates design, manufacturing and construction capabilities developed through more than three decades of project delivery across Western Australia. (main image: Zambezi Lodge in Margaret River, Western Australia, built using the WABi Tourism system and originally developed from an eco-tent design. Credit all images WABiSystems.)
Founded by Karl Plunkett, Owner and Director of Eco Structures and WABi Systems, the company’s approach reflects lessons learned from building projects in remote parts of the state, where distance, labour availability and supply chains often complicate conventional construction methods.
“Over many years building in remote parts of Western Australia, we were constantly looking for simpler and smarter ways to deliver buildings,” said Plunkett. “That experience ultimately shaped the system we use today.”
The result is a prefabricated building system combining galvanised steel structural frames, insulated wall panels and modular components designed for transport and rapid installation. By shifting key elements of construction into controlled manufacturing environments, WABi aims to reduce site preparation, shorten build programs and improve consistency in project delivery.
Watch Karl Plunkett’s story
Building systems designed for remote environments
A defining feature of the WABi building system is its ability to operate in locations where conventional construction methods can be difficult or costly to implement.
Central to this approach is the company’s patented Eco Anchor system. Instead of relying on traditional concrete footings, the anchors are driven into the ground using pneumatic equipment and connected directly to the structural steel base of the building. This approach allows structures to be installed in uneven or environmentally sensitive locations while reducing the need for excavation or heavy earthworks.
The structural framework itself is manufactured from galvanised steel. The use of steel provides consistent structural performance while also offering resistance to termites, corrosion and moisture. The material can also be recycled at the end of its service life.
Wall assemblies are formed using WABi’s proprietary polyisocyanurate insulated panels, a type of structural insulated panel designed to deliver high thermal performance while remaining lightweight enough for transport to remote locations. According to the company, the panels contribute to improved energy efficiency and simplified installation on site.
Additional prefabricated elements are incorporated into the system, including bathroom pods manufactured offsite. These bathpods are produced in controlled environments before being delivered to projects as completed modules, allowing installation to occur within hours rather than requiring extended on-site finishing works.
Together these components form a building system based on prefabricated elements manufactured separately and assembled on site using detailed installation drawings.
Modular typologies supporting tourism, accommodation and housing
The WABi platform supports several building typologies depending on project requirements and site conditions.
Flat-pack structures are manufactured as individual components that can be transported in compact form and assembled on site. This approach can be particularly useful in locations where transport constraints limit the delivery of larger modules.
Transportable modular buildings are fully prefabricated in controlled manufacturing environments before being transported to site as completed units. Once delivered, the modules can be craned into position and connected, allowing buildings to be installed within relatively short timeframes.
For larger developments, the company also produces stackable modular structures. These units can be assembled or prefabricated before being craned into place to form multi-storey configurations.
The system has been applied across a range of project types including tourism accommodation, staff housing, residential projects and government housing.
Supporting these projects is the broader WABi Group, which includes design and architectural services, construction delivery and window manufacturing through WABi Windows. The glazing division manufactures doors and window systems using Vantage by AWC Window Systems, allowing glazing elements to be integrated into the prefabricated building workflow.
Modular housing project underway for Kununurra
WABi Systems is currently applying its modular construction approach to a regional housing project in Western Australia.
At the company’s Mosman Park fabrication facility, 18 modular units are currently in production. Once completed, the units will be transported to Kununurra where they will be assembled on site to form five Government Regional Officers Housing (GROH) homes.
The project demonstrates how modular construction can assist with housing delivery in regional locations where labour availability, transport logistics and environmental conditions can slow conventional construction programs.
By manufacturing the units in a controlled environment, sequencing, labour coordination and quality control can be managed before the modules are transported to site for installation.
“By controlling sequencing, labour and quality at the source, we can reduce risk upstream and shorten the time required on site in remote regions,” said Plunkett.
The development also coincides with the commissioning of WABi’s new assembly yard, which expands the company’s capacity to fabricate and prepare modular structures before delivery to regional projects.
Integrated design and construction capability
A central element of WABi Systems’ delivery model is the integration of design, manufacturing and construction within a single organisational structure. The group provides architectural design and planning services alongside fabrication and construction, allowing projects to move from concept through to installation within one coordinated process.
Early project stages typically include site analysis, concept design, master planning and approvals. Once design and engineering requirements are confirmed, manufacturing begins in controlled environments where structural steel components, insulated panels and prefabricated elements are produced before transport to site.
Installation follows a staged approach that includes Eco Anchor installation, placement of the structural frame, panel assembly and the integration of prefabricated components such as bathpods and window systems. This sequence allows much of the construction work to occur offsite before modules or components are transported for final assembly.
By shifting significant portions of the construction process into fabrication environments, the company aims to reduce on-site labour requirements and improve quality control, particularly in locations where workforce availability and site access can be challenging.
With projects spanning tourism accommodation, staff housing and government projects, WABi Systems continues to apply its modular building system to projects where remote logistics, site conditions and construction timelines require alternative delivery methods.
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