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Modular Construction

Modular construction is an industrialized approach to building. Unlike conventional site-built construction, where thousands of elemental parts (e.g., lumber, nails, plywood, plumbing components, electrical components, windows, doors, shingles, siding, insulation, drywall, flooring) are delivered to each construction site, modular construction utilizes large, three-dimensional, factory-built modules for building. Each prefabricated module contains a floor, walls, and a ceiling and roof with plumbing and electrical systems installed and interior and exterior finishes applied. Modular construction is relevant to the discussion of housing because it promises the benefits of industrialization, such as higher quality, faster construction, and lower cost.

Modular Home Design

Modular home design options are wide ranging, offering a variety of architectural styles, sizes, levels of finish, and cost. A modular factory generally offers a large portfolio of standard house plans. Most factories will customize their standard plans, within limits. Some factories will also produce modules for unique home designs. The design for a typical modular home starts with a standard house plan and then is customized to meet the unique needs of the home buyer. The character of a standard house plan can be creatively transformed by changing room sizes and shapes, adding or deleting rooms, adding a bump-out addition or a wing, increasing roof pitch, changing from a gable to a hip roof, adding dormers, changing type and location of windows, and adding other major design elements such as a porch, garage, or fireplace. The transformation can be enhanced by selecting personal preferences for finish components (e.g., exterior siding, shingles, flooring, and kitchen and bath components).

When construction is complete, a modular home looks and performs like a conventional site-built home. It is built with the same construction materials using the same construction details as a conventional site-built home, with minor changes to accommodate transport and installation. Like most site-built homes, nearly all modular homes are produced using wood frame construction. Steel framing, structural insulated panels (SIPs), and precast concrete panels are also used in modular construction. A modular home complies with state and local building codes that are similar or identical to those that apply to conventional site-built homes. Most modular homes are located in states that have adopted a preemptive state modular building code that is based on a major model building code (International Building Code).

The Modular Construction Process

The primary difference between modular construction and conventional site-built construction is that 85% to 95% of modular construction occurs in the factory. The modular construction process begins by designing the home and ordering the modules needed to build it. The home builder works closely with the factory sales and engineering staff throughout the design effort. When the design is finalized and the order is placed, the factory orders needed parts from suppliers and schedules the modules for production. Scheduling depends on the home builder's schedule, the factory production backlog, and the expected delivery dates for needed parts. When production starts, the factory typically manufactures the modules in 3 to 6 days. Completed modules are loaded onto carriers and transported to the home site. At the home site, a specialized set crew uses a construction crane to lift modules off their carriers and set them on a permanent foundation, which has already been prepared by the home builder. The crew then attaches the modules to the foundation and to each other, raises any folding roof elements and seals the home so that it is weather tight. A home is usually made weather tight in 1 to 2 days. The remaining on-site construction tasks are completed by the home builder. In addition to the site and foundation work that is completed before the modules are set, the home builder must finish the home and add amenities such as a porch, deck, garage, and landscaping. Finish tasks include finishing the interior and exterior marriage joints (between modules) on the floors, walls, and ceilings; connecting utilities; installing heating, ventilation, and air conditioning (HVAC) systems; and installing fragile specialty items such as ceramic tile. These remaining on-site construction tasks can take another 4 to 12 weeks.

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