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As the construction industry deals with a number of converging challenges, modular construction is emerging as a forward-thinking and highly technical solution to streamline the building process.

Modular construction is the process of building modules in a manufacturing facility, which are then shipped to job sites and constructed. Although the construction industry has used modular construction for many years, modern technological advancements like BIM have broadened its use cases.

Modular construction puts an intense focus on early planning, putting more risk on the preconstruction and design teams, in hopes to make construction faster, smoother and safer. Since manufacturers create and ship all modules before construction, any incorrect or damaged designs can lead to longer and more costly delays.

The benefits of Modular Construction

Modular construction has been popular at different times in US history, and is currently enjoying favor in other parts of the world, like China, but has yet to find its stride in modern North America. Builders aren’t accustomed to working with prefabrication – after all, it’s an entirely different way of building. If given a chance, and with the right set of circumstances, modular construction can offer a lot of benefits for both owners and contractors.

Reduced Timelines

Modular construction offers contracting teams the ability to work on two fronts at once: while ground preparation and foundation work is happening on site, the rest of the building can be in-process in a manufacturing facility. This dual approach can lead to drastically reduced timelines – some estimates claim a time savings of – for a project’s construction phase and ensures that the two phases don’t depend heavily on one another.

Risk Management

Owners and contractors can control many of the variables that introduce risk into construction projects. Constructing modules in controlled settings significantly reduces the impact of weather, materials delays, and worker shortages. This approach enhances predictability and consistency, minimizing the variability often encountered in on-site projects.

Heavy preconstruction planning allows for more efficient use of materials and workforce. Manufacturing teams can plan out which cuts of materials to use so that there’s less waste. Factory assembly makes efficient use of employee skill sets and time on the floor, while fitting together premade modules on site is often quicker and simpler than traditional on-site construction, requiring fewer labor hours.

Safer Working Conditions

Manufacturing facilities offer the benefits of carefully controlled workspaces, saving laborers from changing conditions like heat, wind, and rain. Indoor settings present the opportunity to use robotics elements to help complete some of the most dangerous tasks, and there’s significantly less risk for falls within factory walls. Work in this setting also prevents workers from having to work on top of one another or fighting for space to work on their trades.

Integrating modular construction into existing project frameworks

Some projects use modular elements into a traditional on-site build. The integration of modular construction into existing project frameworks requires careful planning and coordination.

Take for example a hospital construction, where space constraints necessitated the use of a prefabricated mechanical penthouse built off-site and later assembled on location. This approach not only addressed spatial limitations but also ensured that the project adhered to tight schedules without compromising quality.

However, fitting modular units into traditional job sites can come with its own unique challenges. For instance, storing modular units may require a significant amount of safe storage space. Without a storage area for the units, the manufacturer and project managers may find it daunting to coordinate the delivery of the right units at the right time.

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The challenges of modular construction

Despite its benefits, modular construction presents certain logistical and operational challenges. Some of the hurdles occur because modular construction isn’t all that familiar or popular in the US, so developers and contractors haven’t learned how to optimize the method just yet.

Planning and Logistics

Shipping and transporting prefabricated components can be complex. Inaccurate labels can make it difficult to determine where each piece belongs, especially if transportation becomes jumbled and modules arrive out of order. If this occurs, teams must ensure there is adequate landing space on or near the site to store the modules while awaiting installation.

Finally, although the manufacturing team avoids weather complications, the transportation team does not have the same advantage. Even bad weather can complicate the movement of large modules and make installation more difficult, especially when the modular unit must be placed on top of another finished piece without a roof.

Dealing With Two Building “Sites”

Modular construction creates two separate building "sites": one where the structure will be erected and another at the manufacturing facility where the modules are built. Teams permitted to work at one site may not have access to the other, and the distance between the two sites might make travel inconvenient.

Moreover, regulatory considerations and union stipulations can affect the scope of off-site work, requiring construction managers to be adaptable and well-informed. In the hospital construction project mentioned previously, the regulations prevented manufacturing teams from installing any safety or fire alarm or suppression components in advance; instead, local technicians installed those elements on-site.

The future of Modular Construction

The success of modular construction largely depends on designers, but technology also plays a crucial role in addressing its challenges and increasing industry acceptance. Software solutions provide essential tools for intricate planning, coordination, and real-time tracking, which are vital for successful prefabrication and improved project management.

Building Information Modeling (BIM), in particular, enables detailed 3D modeling of projects. This capability allows architects and engineers to visualize designs and make necessary adjustments before construction begins, enhancing accuracy and reducing the risk of costly errors. Additionally, BIM's ability to detect design clashes early on helps resolve issues before they escalate, minimizing expensive changes and delays.

These technological advancements ensure that prefabricated components fit together seamlessly during on-site assembly, making the construction process more efficient and streamlined. As technology continues to evolve, it will further support the growth and acceptance of modular construction methods, potentially reshaping the future of the industry.

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