Modular Buildings

• Modular Buildings
• The modular construction process
• Wooden modular buildings
• Modular buildings benefits

Permanent modular construction is an alternative construction method that means doing more in advance of the building site. Sometimes called “Off-Site” construction, we build “Volumetric” building blocks to near completion with flooring, walls, ceilings, lighting and systems. We manufacture all of it indoors under controlled conditions. After completion, we transport it to the site. Modular buildings can be single or multi-story with a wooden frame structures with nearly limitless customization options.

Given that site work and fabrication run concurrently,  permanent modular projects save time compared to traditional forms of construction.

Advancements in design technology, Building Information Modeling (BIM), further enables collaboration between designers, engineers, modular fabricators and building installers. Moreover, Design-Build forms of project delivery, integrated approaches to construction, and owners’ willingness to depart from traditional Design Bid Build has helped pave the way for more successful modular projects around the World.

There are many advantages and benefits to using modular technology on commercial construction projects.  The controlled manufacturing environment, the ability for simultaneous construction operations and the shorter construction cycle are a few, but the main drivers for prefabrication and modular use are to improve productivity, attain a competitive advantage, and generate a greater ROI. Additionally, the ability to integrate sustainable design using green construction elements and Energy Star compliant building design easily and cost effectively into modular projects is an added benefit for many users.

When you consider the benefits, it just makes sense:

• Speed to Market
• Budget Certainty
• Consistent Quality
• Reduced Risk
• Quiet Construction
• Green by Design
• Safety
• Clean building site

These are the major areas where modular construction methods have been shown to be inherently advantageous on commercial construction projects:

Cost Savings – Streamlining the process does not only reduce the time it takes to complete a project. It also reduces the cost. Minimizing the teams, delays, and wasted materials typically associated with designing and constructing a building means choosing modular can cut costs by up to 20%.

Streamlined, Simultaneous Construction Activities – Unique to modular construction, while modules are being assembled in a controlled off-site setting, site work is occurring at the same time. Also, unique to modular is the ability to simultaneously construct a building’s floors, walls, ceilings, rafters, and roofs. During site-built construction, walls cannot be set until floors are in position, additional floors, ceilings and rafters cannot be added until walls are erected. This modular process often allows construction times of half that of conventional, stick-built construction and permits earlier building occupancy, reducing both financing and supervision costs.

Reduced Labor Costs – Modular buildings are constructed off-site by skilled, trained workers at a fixed price.  This reduces expensive onsite labor and supervision costs and eliminates other costs associated with conflicting trades scheduling delays.

Less Materials Waste – Pre-fabrication makes it possible to optimize construction material purchases and usage while minimizing on-site waste. Bulk materials are delivered to the manufacturing facility where they are stored in a protected environment safe from theft and exposure to the environmental conditions of a job site. The factory reuses or recycles scrap material at a higher level than on site, reducing the amount of waste in landfills.

Less Weather Related Schedule Delays – The work being completed in the factory is not delayed by weather issues that commonly delay on site construction activities, thus reducing the delays in the overall construction schedule.  Once on site, the structure is weather tight very quickly also reducing delays to the finish trades.

Less Material Exposure to Inclement Weather – Many of the indoor air quality issues identified in new construction result from high moisture levels in the framing materials. Because the modular structure is substantially completed in a factory-controlled setting using dry materials, the potential for high levels of moisture being trapped in the new construction and the resulting moisture related problems are eliminated.

Less Site Disturbance – The modular structure is constructed off–site simultaneous to foundation and other site work, thereby reducing the time and impact on the site and surrounding neighborhood environment, by reducing the number of vehicles, workers  and equipment needed at the site.

Safer Construction – Modular construction is a safer alternative. Conventional construction workers regularly work in less than ideal conditions dealing with temperature extremes, rain, wind, or any combination of natural conditions. This is a much more challenging environment to work safely in. Additionally, the potential for injury including falls, the most common work site risk, is much higher. In a factory controlled setting, each worker is typically assigned to a work station supplied with all the appropriate equipment needed to provide the safest work environment possible. Off-site modular construction also eliminates the hazards associated with materials, equipment and an incomplete construction processes typical of construction sites that can attract curious and unwelcome “visitors” (i.e. students on a school expansion project).

Flexibility – When the needs change, modular buildings can be disassembled and the modules relocated or refurbished for new use, reducing the demand for raw materials and minimizing the amount of energy expended to create a building to meet the new need. In essence, the entire
building can be recycled in some cases.

Adaptability – Modular buildings are frequently designed to quickly add or remove one or more “modules,” minimizing disruptions to adjacent buildings and surroundings.

Quality – With modular construction you can get a structure built to the same local codes with construction quality as good as or better than a comparable site built building in much less time. By combining traditional building techniques, quality manufacturing and third-party agencies who offer random inspections, testing, and certification services for quality control; modular buildings are built in strict accordance with appropriate local, state, and national regulations and codes. Due to the need to transport modules to the final site, each module must be built to independently withstand travel and installation requirements. Thus the final module-to-module assembly of independently durable components yields a final product more durable and structurally sound than conventional structures.

These practical time and money saving advantages of modular buildings effectively meet the specialized needs of many diverse industries and businesses. Modular construction offers compelling advantages in terms of quality, cost, durability, and environmental impact.

Efficiency – Constructing a building through onsite methods is notoriously inefficient. It typically involves the coordination of multiple, disjointed teams that all too often results in miscommunications, conflicts, and mistakes that require costly returns to the drawing board all before the ground is even broken.

Once plans are finally solidified, the construction process is no more efficient. Delays in material deliveries, difficulty organizing large teams and equipment, and inclement weather are just some of the factors that most commonly lead to delays.

Modular construction minimizes all of these issues by streamlining the entire preconstruction and construction process.

Selecting from existing, pre-engineered design templates, approved and scalable to fit a wide variety of needs cuts down on the time required to design a modular building. And the process of fabricating the units off-site while the site is prepared means that any delays experienced on-site do not impact the progress being made in the facility.

The efficiency continues into the final stage of the building. As the modular units have already been completed in the facility, right down to the finishes, they need only be assembled onsite – a task that can be accomplished in a matter of days, not months or years.

By the end of the project, choosing modular can save a property owner as much as 50% of the time, compared to traditional construction.

Strength  – Structurally, modular buildings are generally stronger than on-site built buildings because each module is engineered independently to withstand the rigors of transportation and craning onto the project platform. Once connected and sealed, the modules become a single integrated building. Building in the factory permits better construction quality management.

All these factors considered, modular construction delivers a building of superior quality in less time, at less cost, and with less waste than traditional construction methods, making it little surprise that the processes gaining popularity in Scandinavian and around the world.