Individual Report on Modular Construction Methods for WSU Students

This report provides a comprehensive overview of modular construction methods, focusing on permanent and relocatable modular construction. It delves into the history of modular construction, tracing its evolution from early applications to modern practices. The report outlines various modular construction products, including four-sided modules, partially open-sided modules, and stair modules, detailing their characteristics and applications. A significant portion of the report is dedicated to comparing the advantages and disadvantages of modular construction against conventional methods, highlighting factors such as speed of construction, indoor manufacturing, adaptability to remote locations, waste reduction, environmental friendliness, flexibility, and quality. It also addresses the disadvantages, such as volumetric constraints and potential limitations in flexibility. Furthermore, the report provides an estimated cost analysis for modular home components and installation, including substructure, site works, frame, roof, stairs, external walls, and internal finishes. The report is aimed at providing an in-depth practical assessment of modular construction, offering insights into its technological improvements and environmental performance within larger-scale residential construction. The report is a student submission available on Desklib, a platform offering AI-based study tools for students.

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MODULAR CONSTRUCTION METHODS
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Table of Contents Page
Introduction 3
Modular Construction Types and Products 4
Advantages and disadvantages 6
Likely Products and Installation costs 8
Conclusion 9
References 10

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Modular Construction Methods
Introduction
For decades, the construction industry has lagged when it comes to product
performance in comparison to other sectors. However, there has been a recent change of tides
and a chance to step up, moving away from the traditional building activity of on-site
manufacturing to off-site construction style projects (Baldwin & MacDonald, 2012).
Prefabricated is a not so new idea although a fresh wave of interest and investment has stung
the industry concerning shifts in the environment and technological advancements.
Construction industries make one of the largest sectors in the global market and a profound
change like modular construction has a major impact. The current projects have accelerated
projected timelines by 20 to 50 per cent (Bernstein, et al., 2011).
Modular constructions entail a procedure where a building is constructed off-site,
utilizing materials and designing similar to conventionally build facilities as well as the same
codes and standards. This process is under controlled plant conditions and takes about half
the time used by conventionally build facilities (Blismas & Wakefield, 2009). The structures
are constructed in modules that when assembled on the plot area, showcase the same
specifications and similar design intended of the most advanced site build center.
Countries like Japan and Scandinavia have a sustainable foothold in modular
construction. The United States and United Kingdom markets have been in and out of favor
regarding prefabricated construction since the post-war era (Blismas & Wakefield, 2009).
Thus, multiple key factors determine whether modular construction is likely to be embraced
by the market or not. Among the key determinants, two stand out as the biggest determinants:
the relative costs of skilled construction labor and real estate demand. In areas like Australia's
East Coast, the southern part of the United Kingdom, Germany major cities and the United

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States west coast have unmet demands in the housing sector and labor shortages making this
model particularly relevant (Burleton, et al., 2015).
Capturing the productivity benefits and total cost of prefabricated housing is not a
straightforward task. Multiple considerations have to be made ranging from optimizing and
choosing the relevant materials; obtaining the preferred solution between 3D modules or 2D
panels, mastering the risks in design, hybrid designs, the technology, logistics and assembly
(Gambatese & Hallowell, 2010). Moreover, it depends whether the market can sustain
builders operation on large scale and repeatability. The regulators and public owners can
affect the industry structure too.
Historical Background of Modular Construction
Modular construction is among the oldest inventions in the construction industry. It
has since evolved from the 20th century to date (Gambatese & Hallowell, 2010). The
company that pioneered this invention is the Sears, Roebuck and Company, it started by
selling its catalogue to different construction companies. Housed constructed by this
catalogue where the very first to have a complete construction system (Gambatese &
Hallowell, 2011). A sears house had a complete house kit having almost 75 pages manual
containing instructions and a 3000 complete pieces. Henry Ford, who is a renowned
automotive pioneer, in the year 1913, introduces an assembly line in the automotive sector,
this helped minimize on production time and maintenance.
Almost a half century later, the invention was implemented in the construction sector
too. Sears, Roebuck and Company combined the technology to come up with a modular
construction. After World War II, after the much destruction of buildings and structures, there
was need to come up with more buildings within a very short time (Ghassemi & Becerik-
Gerber, 2011). Therefore, companies decided to construct buildings from factories. These
housed looked similar to the modern day mobile house, also known as HUD-code house.

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These houses were prefabricated and looked almost like modular houses. A perfect modular
building was constructed in 1958 where a housing manufacturer managed to come up with a
two sectioned modular building hence formally introducing the modular construction
technology (Girmscheid & Rinas, 2012).
The research paper below provides detailed research on Modular construction methods,
giving types and product options available in the marketplaces. Furthermore, it quantifies the
advantages and disadvantages of the system. Including a discussion of the likely cost of each
product together with the cost of installation.
Modular Construction methods and Products
Methods
Modular construction is categorized into two kinds, namely the permanent modular
construction and the relocatable modular construction. The Permanent modular construction
is a well-grounded and innovative way where the means of delivery is dependent on offsite
construction methods to prefabricate building sections to deliver module solutions (Ikuma &
Nahmens, 2012). These model can be integrated projects on the site orstand-alonee and
supplied with MEP features together with interior fixtures. The relocatable buildings Ares
one that is partially or fully assembled structure that conforms to the rules and procedures and
is manufactured in a factory using the modular construction action. RB is outlined for
multiple utilities or repurposed and can be conveyed to various locations (Girmscheid &
Rinas, 2012). They are mostly used to construct schools, site offices, and medical clinics
together with any area needing a temporary space. Relocatable buildings provide for
enormous flexibility, fast delivery, ease of relocation, the depression schedules are high and
their reconfiguration has minimal costs (Koroluk, 2013). Relocatable structures are installed
in consideration to the manufacturer installation guideline, and are not permanently affixed to

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real estate. They are necessary building in instances where space, is temporary, speed is
needed and the need to relocate is necessary.
Products
The modular construction products in the market are either completely modular or
mixed form of steel construction and include; special stair or lift module, four-sided modules,
open-sided modules, partially open-sided modules, and non-load bearing modules. In this
document the discussion is limited to three types of products (Ozerhorn, et al., 2011). The
first is the 4-2-sided module. This kind of module has four edges that are closed to make a
cellular space that is made to transfer the vertical and in-plane loads of the module via their
longitudinal walls. The height of such buildings is between six to ten storeys depending on
location and wind action. The modules are constructed from 2D panel’s series starting from
the floor cassette to the walls and ceilings (Schoenborn, 2012). It has steel angles at the
corners for lifting and stability.
The second module is the partially open-sided modules; the four-sided modules can
be constructed or redesigned with two sides that are partially open. It can be achieved through
initiating a corner, posts in the middle and an uninterrupted border beam at the floor. The
intermediate posts are hollow sections in square forms to fit within the wall width. The last
module is the stair module (Schoenborn, 2012). The modular stairs can be constructed as full
sections and have landings and half landing within two flights of stairs. They have
longitudinal walls to support this landing and half-landings and SHS to give local
strengthening.
Advantages and disadvantages
Modular construction has presented several pros over the conventional building and below
are some of the advantages;

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Advantages
The speed of construction is faster than conventional building, therefore, giving faster
returns on expenditure. The modular construction industry provides for the site work and the
building of the facility to be completed simultaneously. This has proven to reduce the
completion time of the project close to 50 per cent (Smith, 2010). In turn, reducing the labor
and supervision sector as well as the finance sector. Additionally, the design and engineering
disciplines are included in the manufacturing procedure saving more money. A unique
feature of this construction method is that the manufacturers can develop the building walls,
floors, ceilings, roofs and rafters at similar times (Touré-Tillery & Fishbach, 2011). In
conventional building, this is impossible as walls cannot be set without unit floors in position.
The second advantage of this construction process is that it allows for indoor manufacturing,
the fabrication method is thus independent of weather increasing the work proficiency and
reducing risks of damage on the building materials.
Another advantage is the ability to service remote locations. Australia is one
particular nation that the potential markets are located far from industrial centers. The cost of
on-site construction in these remote areas is high therefore, modular building s are necessary
for medical and sanitary services while addressing the money space and time predicament.
The fourth advantage of this construction method is a low waste (Touré-Tillery & Fishbach,
2011). Modular construction tends the same plans being constantly constructed so the
manufacturer has information on the exact amount and type of material needed. The materials
can be cut with efficiency and the required bulk ordered. On-site construction on the other
hand product waste on the construction site resulting in filing multiple dump sites. According
to WRAP, a group based in the UK, modular construction can reduce up to 90 per cent in the
material used in construction (Smith, 2010).

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The fifth advantage of this construction method is in its environmentally friendly
construction process. The waste distribution and site disturbance of modular construction are
low in comparison to conventional methods. The controlled environment provides for extra
construction materials to be recycled while at the same time allowing for more accurate
construction. Flexibility is another advantage (Smith, 2010). Modular construction gives
room for easier continuous addition to create high rises. In case there is change on the need of
the structure, the building can be disassembled easily the modules refurbished or relocated to
a different site minimizing the need for new raw materials and reducing the energy required
in construction and demolition of a building (Schoenborn, 2012).
The quality of the structure is also high in modular construction. Mixing the
traditional techniques of building with quality construction and third-party agencies, modular
construction structures have regular inspections, attestation and issuance of certificate
services. This offers quality control and the structures are constructed strictly and according
to the regulations relating to the state and local regulation codes (Ozerhorn, et al., 2011). The
module is furthermore built independent to withstand the travel and installation needs. The
final structure is an independent module to module assembly that is durable and stronger than
site-dependent structures. The structures use structural insulated panels that are advantageous
in comparison to traditional methods.
The final advantage of this construction module is that it improves air quality. Most of
the conventional building has indoor air quality problems that arise from inflated moisture
volumes in framing fabrics (Gambatese & Hallowell, 2011). Modular structures are
constructed indoors in a regulated environment utilizing dry mediums thus the likelihood for
trapping inflated moisture is eliminated.

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Disadvantages
The disadvantages of this module include one it is volumetric. The transfer and
placing of the complete module system on the site take a lot of space. The second
disadvantage is the flexibility; the module size can be limited due to several issues such as the
ability to transport and occasionally because of the construction regulations (Blismas &
Wakefield, 2009). The last disadvantage is that some financial establishments are hesitant to
offer loans for a modular home.
Likely Products and Installation costs
Modular homes prices vary depending on quality, standards. Materials used, and the
basic builder finishes. Below is a rough estimation of the likely costs for installation and
products:
The shell and core work substructure at £887, 970 which may be 58.22 pounds per
square meter. The site works at 2,136m³ @ £13/m³. The Frame and upper floors at 684,800.
Note that the modular construction does not need a traditional frame and upper floors
arrangement. Room for reinforced concrete cores which comprise 150mm thick walls at
1,412m² @ £180/m². The Roof at 315, 89£ and Stairs at 21,000£ (Bernstein, et al., 2011).
External walls, windows, doors and balconies all amounting to £2,128,142. The Internal
walls, partitions and doors at £107,700. .Floor finishes at £115,600 and the Ceiling
finishes at £24,000 (Bernstein, et al., 2011). Fittings, the furnishing plus the equipment at
£7,602,500. Allowance core elements room for the modules shell apart from those items
mentioned elsewhere. The disposal installations cost ranging from £267,949 to £324,768.
Drainage from bin stores and other drainage systems to the floor at £20,000). The Water
installations at £220,850. The residential fit-out works from the internal walls to the partitions
and doors at £396,100. The Wall finishes at £515,944.

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Conclusion
In most countries, modular construction is still at the beginning steps and not fully
embraced. Although there are high chances and signs that there is a boost in its application in
the market. The new competition is already drawn in and technological advancements have
created new winners and losers across the real estate and construction industry. The above
document has presented a complete explanation of the practical assessment of this
technological improvement and its performance on the large scale residential construction.
References
Baldwin, J. R., GU, W., & MacDonald, R. 2012. Intangible capital and productivity growth
in Australia. Retrieved from http://www.statcan.gc.ca/pub/15-206-x/15-206-x2012029-
eng.pdf
Bernstein, H.M., Gudgel, J.E., & Laquidara-Carr, D. 2011. Prefabrication and
modularization: increasing productivity in the construction industry. Retrieved from
http://www.nist.gov/el/economics/upload/Prefabrication-Modularization-in-the-Construction-
Industry-SMR-2011R.pdf
Blismas, N. and Wakefield, R., 2009. Drivers, constraints and the future of offsite
manufacture in Australia. Construction innovation, 9(1), pp.72-83.
Burleton, D., Ignjatovic, D., & Fillier, N. 2015.Canada’s non-residential construction
outlook. Retrieved from

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https://www.td.com/document/PDF/economics/special/Non_Residential_Construction_Outlo
ok.pdf
Gambatese, J.A., & Hallowell, M. 2010. Enabling and measuring innovation in the
construction industry. Construction Management and Economics, 29(6), 553-567.
Gambatese, J.A., & Hallowell, M. 2011. Factors that influence the development and diffusion
of technological innovation in construction industry. Construction Management and
Economics, 29(6), 507-517.
Ghassemi, R., & Becerik-Gerber, B. 2011. Transitioning to integrated project delivery:
potential barriers and lessons learned. Lean Construction Journal, 11(4), 32-52.
Girmscheid, G., & Rinas, T. 2012. Business design modeling for industrialization in
construction: a cooperative approach. Journal of Architectural Engineering, 18(2), 164-175.
Ikuma, L.H., & Nahmens, I. 2012. Effects of lean construction on sustainability of modular
homebuilding. Journal of Architectural Engineering, 18(2), 6-12.
Koroluk, K. 2013. Construction must answer innovation call. Journal of Commerce, 88(11),
1-2.
Ozerhorn, B., Abbott, C., Aouad, G., & Powell, J. 2010. Innovation in construction: a project
life cycle approach. Salford (UK): Salford Centre for Research and Innovation.
Schoenborn, J.M. 2012. A case study approach to identifying the constraints and barriers to
design innovation for modular construction. Blacksburg, VA: Virginia Polytechnic Institute
Press.
Rahman, M.M., 2013. Barriers of implementing modern methods of construction. Journal of
Management in Engineering, 30(1), pp.69-77.

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Smith, R.E. 2010. Prefab architecture: a guide to modular design and construction. Hoboken,
N.J.: John Wiley & Sons.
Touré-Tillery, M, & Fishbach, A. 2011. The end justifies the means, but only in the middle.
Journal of Experimental Psychology: General. Advance online publication. Doi:
10.1037/a0025928.
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