Advancements in modular construction are revolutionizing the building industry, offering faster timelines, cost savings, and sustainability benefits. Prefabricating sections of a building off-site using a production line process streamlines a project’s delivery. Modular construction is broad term that captures a variety of prefabrication methods that each offer unique benefits for different types of projects. The three main types of modular construction are volumetric, panelized and hybrid and modules are typically built using wood and/or steel. Let’s explore each type to determine which prefabrication method is most suitable for your next construction project.
Volumetric Modular Construction
Volumetric modular construction involves prefabricating 3D modular units off-site and installation/completion on-site. Upon arrival on site, the module’s interior is nearly complete and resemble Lego blocks with typical dimensions varying between 10’-14’ wide to 30-60’ long. Once the modules arrive on site and placed on the foundation, the module’s seams are sealed and finished with either flooring, trim, siding or drywall to make the modules look as one.
Highlights:
- Reduced On-Site Construction – Volumetric construction can reduce construction schedules by 30% – 50%. Optimized manufacturing processes increase the rate of production and occurs concurrently with on-site preparation, allowing for a faster completion.
- Design Optimization – Pre-designed buildings can be customized to suit your specific needs and preferences. Most manufacturers offer a large selection of home finishes for clients to choose from. New custom designs can be optimized for prefabrication, but there are certain guidelines that limit volumetrics’ design flexibility.
- Reuseable – If designed properly, volumetric buildings can be disassembled and relocated. This is a significant advantage because it creates more options for how the building and property are used.
Applications:
Residential
Volumetric construction is a great solution for nearly all types of residential projects, including low- & mid-rise multi-family, single-family and tiny homes. Tiny homes and single-family homes can be built using one module that’s completely finished inside and out. Larger single-family homes can use up to 4 modules but require a little more on-site work to join the modules together. Volumetric is also ideal for multi-family because of the boxy design and repeatable floor plans that make stacking easy. Volumetric modular construction can be used for buildings that range between 6 – 10 storeys and anything greater than requires a hybrid system.
Institutional
Schools – Most of the large Ontario manufacturers offer modular classrooms (portables) that are cost effective, energy efficient and durable. Thanks to advanced manufacturing, modular construction can be stacked, turning a single portable into a complete school.
Medical – Some Ontario manufacturers specialize in advanced medical modules that are used in emergency situations, or temporarily while a hospital is being renovated. Modular dental offices are becoming a popular solution to bring dental care services to remote communities.
Commercial
Hotels – Due to a hotel’s repeatable floor design, modular construction is a great solution when building a hotel. The speed of installing and completing the modular hotel means less financing fees and faster revenue generation.
Retail – Modified shipping containers are an example of a trendy volumetric solution for pop up retail stores. The durable and secure design meet the retailer’s typical needs, and the ability to move and relocate the module makes the structure a very versatile asset.
Panelized Modular Construction
In panelized modular construction, a building’s design is segmented into wall, floor, and roof sections and prefabricated off-site. Panels are made from a wide variety of materials and the degree of off-site prefabrication varies depending on the type of material and the intended use of the panel. The assembled panels form the building’s structure, so depending on the degree of the panel’s prefabrication, there could be a decent amount of work to complete on-site. Prefabricated panels can arrive fully finished with siding and drywall or just bare studs and sheathing. The latter being less efficient overall. Although the panels are the least fabricated form of modular construction, panelized construction still offer advantages that volumetric cannot.
Highlights:
- Design Customization – Any building design can be optimized for panel construction.
- Installation Flexibility – Panels are versatile and ideal for challenging sites where a crane is not an option.
- Sustainability – Advancements in panelized construction has introduced a wide variety of energy efficient construction materials. Expanded polystyrene (EPS) offers great thermal performance and can now be integrated with a wide variety of structural material.
- Transportation Savings – Panels are delivered to site flat-packed, so more building can fit on one trailer.
Applications:
Residential/Commercial – Panels are now commonly used to build single family and mid-rise multifamily.
Deep Energy Retrofits – Deep energy retrofits of existing buildings require significant thermal upgrades to the foundation, walls and ceiling. Insulated panels clad the exterior of the building which means the tenants do not need to move out during the renovation.
Facades – In large commercial projects, the exterior façade of the building can get prefabricated off-site and delivered and attached to the building’s superstructure on-site.
Superstructures – Mass timber consists of individual pieces of lumber glued and fastened together to form posts, beams and floors. It’s rapidly gaining favor in Canada as a low carbon sustainable alternative to concrete and steel superstructures.
Hybrid Modular Construction
Hybrid modular construction combines volumetric and panelized methods, and traditional construction techniques. By combining construction methods, the project benefits from the element’s individual strengths, achieving greater cost and on-site efficiencies. Certain building components are easier to build on site using traditional construction methods. The combined methods offer the confidence and familiarity of traditional construction techniques, while keeping the building process evolving, finding better ways to build.
Highlights
- Combined Strengths –Hybrid construction utilizes the strengths of modular and traditional construction methods, making it easier to adopt into general building practice.
- Best Method Wins – Modular construction generates more sustainable and efficient alternatives to traditional methods, but some traditional methods still reign supreme.
- Greater Design Options – Modular buildings typically max out around 6-10 stories. Incorporating proven traditional construction methods into modular projects, allows modular projects to reach new heights.
Applications
Large Commercial Buildings – Hybrid construction lends itself well to large mixed-use buildings that offer larger retail space on the bottom and residential above.
Increased Capacity – Modular buildings can be added on to existing structures adding more space without demolishing the existing building.
High-rise Residential Buildings – Recent advancements in hybrid modular construction has made modular construction a viable option for high-rise towers. Encapsulating a prefabricated modules with concrete and rebar, satisfy the structural requirements of a high-rise tower, while offering the efficiencies of modular construction.
Conclusion
Modular construction introduces more efficient construction methods for builders and can be applied to a variety of building designs and on-site scenarios. From permanent and relocatable solutions to hybrid approaches that blend traditional and modular methods, there are new innovative ways to build. Whether you’re looking to speed up your construction timeline, reduce costs, or achieve a higher level of quality control, there’s likely a modular construction type that fits your needs. As modular construction continues to evolve, it promises to play an increasingly important role in shaping the future of the built environment.
At Sightline Building Solutions, we specialize in various types of modular construction, tailoring our approach to meet the unique needs of your project. Contact us to learn more about how we can help bring your vision to life with modular construction.