Permanent modular construction

Permanent Modular Construction (PMC) is a delivery method utilizing offsite, lean manufacturing techniques to prefabricate single or multi-story whole building solutions in deliverable module sections. PMC buildings are manufactured in a controlled setting and can be constructed of wood, steel, or concrete. PMC modules can be integrated into site built projects or stand alone as a turn-key solution and can be delivered with MEP, fixtures and interior finishes.

The buildings are 60% to 90% completed offsite in a factory-controlled environment, and transported and assembled at the final building site. This can comprise the entire building or be components or subassemblies of larger structures. In many cases, modular contractors work with traditional general contractors to leverage the resources and advantages of each type of construction.

Permanent modular buildings are built to meet or exceed the same building codes and standards as site-built structures and the same architect-specified materials used in conventionally constructed buildings are used in modular construction projects. PMC can have as many stories as building codes allow. Unlike relocatable buildings, PMC structures are intended to remain in one location for the duration of their useful life.

Benefits

Simultaneous site development and building construction at the plant reduces schedule by 30% to 50%

Accelerated Construction Process

Unique to modular construction, while modules are being assembled in a factory, site work is occurring at the same time or in some cases prior to construction.^[1] This can allow for much earlier building occupancy and contribute to a shorter overall construction period, reducing labor, financing and supervision costs. To save even more time and money, nearly all design and engineering disciplines are part of the manufacturing process.

Also unique to modular construction 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, and ceilings and rafters cannot be added until walls are erected. On the other hand, with modular construction, walls, floors, ceilings, and rafters are all built at the same time, and then brought together in the same factory to form a building. This process can allow modular construction times of half that of conventional, stick-built construction.

Quality Built

Combining traditional building techniques, quality manufacturing and third-party agencies who offer random inspections, testing, and certification services for quality control, commercial 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 can yield a final product that is more durable than site-built structures.

Modular buildings often use Structural Insulated Panels (SIPs) in construction, which offer a range of advantages over traditional building materials. SIPs panels are a light yet durable combination of panel board and either closed-cell polyurethane (PU) or expanded polystyrene (EPS) insulating foam. They are air-tight, and as such provide excellent thermal performance. They also offer superior damp and cold resistance when compared to timber and other materials, and are immune to both compression shrinking and cold bridging.^[2]

Modular units may also be designed to fit in with external aesthetics of any existing building and modular units once assembled can be virtually indistinguishable from a site-built structure.

Sustainable

• Less Material Waste - Modular construction makes it possible to optimize construction materials purchases and usage while minimizing on-site waste and offering a higher quality product to the buyer. 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.

According to the UK group WRAP, up to a 90% reduction in materials can be achieved through the use of modular construction. Materials minimized include: wood pallets, shrink wrap, cardboard, plasterboard, timber, concrete, bricks, and cement.^[3]

• 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 surrounding site environment, as well as reducing the number of vehicles and equipment needed at the site.
• Greater Flexibility and Reuse - When the needs change, modular buildings can be disassembled and the modules relocated or refurbished for their next 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.
• Improved Air Quality - 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 is eliminated.

Modular buildings can also contribute to LEED requirements in any category site-built construction can, and can even provide an advantage in the areas of Sustainable Sites, Energy and Atmosphere, Materials and Resources, and Indoor Environmental Quality.^[4] Modular construction can also provide an advantage in similar categories in the International Green Construction Code.

Key Markets

Permanent modular buildings can be utilized in any application where stick-built construction is used. The primary markets served are K-12 education, higher education student housing, office and administrative space, retail and hospitality, healthcare, and publicly funded facilities.

Research and Development

Modular construction is the subject of continued research and development worldwide as the technology is applied to taller and taller buildings. Research and development is carried out by modular building companies and also research institutes such as the Modular Building Institute ^[5] and the Steel Construction Institute,.^[6] An example of a recent research project is MODCONS.^[7]

See also

Commercial Modular Construction
Relocatable Buildings

References

External links

• Modular Building Institute - international trade association for commercial modular construction
• Triumph Modular - Traditional Construction vs Modular Construction