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Modular Construction Comes Into Its Own

A growing number of construction companies are choosing modular off-site construction over traditional on-site building, a trend that promises to continue thanks to modular construction’s cost benefits, better quality control, and quicker turn-around time. In addition, modular building requires less on-site space to complete, a bonus in areas where space is limited due to larger populations.

Modular construction is not a new method, having been around since the 1830s when London carpenter John Manning created a prefabricated home for his son who was moving from England to Australia. Manning designed the home in pieces so that it could be easily shipped and reassembled once it reached its destination. Modular construction made its way to the U.S. in the 1840s in order to fulfill the housing needs created by the California Gold Rush.

Later, between 1908 until the 1940s, Sears Roebuck and Company created and sold more than 500,000 prefabricated homes via its catalog, many of which still exist across the U.S. Prefab homes continued to fill a need created by a housing shortage after World War II, thanks to its efficient, low cost and quick construction. Today, the demand for modular construction has surged, and is being utilized in the construction of hotels, apartment buildings, offices, schools and hospitals across the U.S. and in many other countries. This growth is expected to continue.

Off-site is Where the Magic Happens
While all modular construction involves some on-site construction, such as excavation, footings and foundation, most of its components are assembled in a manufacturing facility. A modular building is composed of modular units supported by structural frames, each composed of six sides made of wood or steel. Exterior finishes, traditionally finished last, are completed earlier in the process, working from the outside in. Next, plumbing, electrical and HVAC are installed and sealed in each unit. Finally, a special wrapping is added to protect the exterior finishes during transport and installation.

The interior finishes, such as flooring, walls, counter tops and even furniture and appliances, are also present in each unit before it is put into place. Finally, marriage joints or mate lines ensure that each module remains fastened to those around it as the building is completed.

More Efficient and Easier to Build
Modular construction’s increasing popularity is due to a number of factors, all affecting the bottom line of construction jobs. According to FMI, the largest provider of management consulting, investment banking and research to the engineering and construction industries, 40 percent of contractors it surveyed stated that modular construction is a growing part their businesses. Quality control is one of the top reasons why, thanks to modular buildings being constructed in controlled environments where building materials are protected from the elements.

These controlled environments also allow builders to work in a contained space that provides all the tools and equipment needed at their disposal, leading to better build structures and higher quality standards. In addition, construction teams are able to use repetitive techniques and convenient equipment that result in faster build times. And since weather delays are no longer an issue, it is easier for contractors to reach building goals and avoid setback issues often associated with on-site construction.

Cost benefits are also a top reason for modular construction’s growing popularity. The decrease in build times, as mentioned, is one factor, resulting in a reduction in labor costs. The building process is also less wasteful since each modular structure uses exact amounts of lumber or steel and other building materials.

Finally, there are environmental benefits to modular construction since modular construction facilities have the full advantage of production repetition common with assembly line manufacturing, thus using less energy associated with traditional construction. In addition, waste in modular construction is used rather than discarded, with unused materials recycled for other projects, reducing millions of tons of waste that wind up at landfills each year from on-site construction projects.

While off-site modular construction cannot replace every on-site building project, its shorter construction schedules, greater ability to predict costs, reduction in material wastes, reduced carbon emissions that result from transportation to and from construction sites, reduction in construction site disturbances, and increased safety and security of employees and equipment while lowering safety risks, make modular construction an attractive alternative to traditional on-site building projects.

Imburgia Consulting is fully engaged in and knowledgeable about off-site modular building construction and is available to discuss how this innovative process may be applicable and beneficial to your next project. It is important to note that modular construction must be designed and developed from the start, either as fully modular or with modular components such as bathrooms, head walls, piping or duct work systems, etc. President Steven Imburgia and his team of experts can help your company to navigate and streamline this process from start to finish.

Imburgia Consulting, LLC is located at 1177 West Loop South in Houston. Contact us at 713-829-4044 to learn more about whether modular construction is a good fit for your next construction project.

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