3D Modular Volumetric Construction

CHAPTER – 01
INTRODUCTION

1. GENERAL

Modular building and modular homes are sectional prefabricated building or houses that consist of
multiple modules or section which are manufactured in a remote facility and the delivered to their site
of use. These modules are assembled into a single residential building using either by a crane or trucks.

Modular building has a wide variety of uses. They will either be used for long term temporary or
permanent facilities. Such uses include construction camps, schools and classroom, civilians and
military housing needs and industrial facilities. Modular buildings are a perfect solution in remote and
rural areas where conventional construction may not be reasonable or even possible. Other uses have
also been found for modular buildings include churches healthcare facilities and retail offices, fast
food restaurants and cruse ship constructions.

At this time modular home today can be built to any specification and any size from a simple one to a
complex one. One of the big advantages of modular construction is that it is very rapid and it tends to
be less expensive than a site-build structure. Manufactures are not limited by issues like inclement
weather and because they have a great deal of experience, they can put structure together quickly and
well. And they tend to be more earthquake and weather resistance than site build structure.

Modular construction concepts can be applied for all types of buildings such as offices, commercial,
residential, hotels and much more. Recently, modular construction was used in the UK for projects
such as Raines Diary, Murray Groove and the micro-flats concepts. As shown in the case studies,
modular construction can save time in the construction schedule and therefore may result in savings.
Also, the generation of construction waste is reduced on-site due to the off-site prefabricated modules
being transported to the site fully fitted out, hoisted and assembled

2. THEORY
There is an age-old analogy in construction circles regarding how building modules are much like the basic,
living cells found in nature. Take the brick for example. A brick is a man-made module of elegant simplicity
that has been used by home builders for thousands of years. Although it seems lifeless, assembled piles of bricks
stuck together with mortar develop into protective structures, just as cells labelled “skin” to combine and protect

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our bodies.
Recently, modular building modules have evolved into larger and more complex
cells born to encapsulate smaller functions. In modular design, these modules now incorporate many
of our life support systems: heating, ventilating, air-conditioning, waterdelivery, wastesystems,
electricity, security,and much more.
And, just as tiny organisms have evolved, so have the small brick modules formerly used in the
buildings of old. Now, sheets of plywood, glass & metal panels and floor joists (to name just a few)
are components that have become pieces of our sophisticated environment.

3. STANDARDS AND ZONING CONSIDERATIONS

Typically, modular dwellings are built to local state or council code, so dwellings built in a given
manufacturing facility will have differing construction standards depending on the final destination of
the modules. Steel and/or wood framing are common options for building a modular homes. Modular
home designs can be customized for local zoning codes. For example, homes built for final assembly
in a hurricane prone area can have additional bracing built-in to meet local building codes.

Some US courts have ruled that zoning restrictions applicable to mobile homes do not apply to modular
homes since modular homes are often assembled with a permanent foundation. Additionally, in the
US, the Uniform Standards of Professional Appraisal Practice allow site-built homes to be used as
comparators to modular homes in real estate appraisal; thus, modular homes can in some cities and
counties (depending on local ordinances) be evaluated the same way as traditionally built dwellings
of similar quality. In Australia Manufactured Home Parks are governed by additional legislation that
does not apply to permanent modular homes. Possible developments in equivalence between modular
and site-built housing types for the purposes of real estate apparels financing and zoning may increase
the sales of modular homes over time.

4. BUILDING STRENGTH

According to manufacturers, modular homes are generally designed to be initially stronger than
traditional homes by, for example, replacing nails with screws and adding glue to joints. This is
supposed to help the modules maintain their structural integrity as they are transported on trucks to
the construction site. Despite manufacturer claims that the modular home is initially built to be stronger
than a traditional home, it is difficult to predict the final building strength since it needs to endure
transportation stresses that traditional homes never experience.

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Typically, a modular home contains about 10% to 20% more lumber compared to traditional stick-
built homes. This is because modules need to be transported to the job site and the additional lumber
helps keep them stable.

5. CONSTRUCTION PROCESS

Modular components are typically constructed within a large indoor facility on assembly lines. Such
facilities use an assembly line track to move the modules from one workstation to the next.
Independent building inspectors are on site to supervise the construction and ensure that all building
codes are adhered to during assembly.

The modules that will combine to form the house are assembled off-site in a factory. These modules
can take one to three months to be constructed but often take as little as 10 days actually to construct
when they are first started. Then they are transported to the building site where a crane is brought in
to assemble the modules together. The placement of the modules together generally takes several hours
or days. Once assembled, modular buildings are essentially indistinguishable from typical site-built
homes.

Once a potential homeowner has decided to go with a modular home, there are a few steps to take that
are relatively consistent regardless of which modular home building company one is working with.
First a homeowner must select a modular home factory. The majority of manufacturers are located on
the East Coast, and some are very specific as to what states they will ship their homes.

Fig .1: Bulk material used for modular building

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Fig .2: Wall attached to floor

Fig .3: Assembly of the building—exploded view showing the individual modules

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Fig.4 Construction of each module by crane in the site

Fig .5: Modular home after construction

6. SURFACES AND FINISHES

Modular buildings can be assembled on top of multiple foundation surfaces, such as a crawl space,
stilts (for areas that are prone to flooding), full basement or standard slab at grade. They can also be
built to multi-story heights. Motels and other multi-family structures have been built using modular
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construction techniques. The height that a modular structure can be built to depends on jurisdiction
but a number of countries, especially in Asia, allow them to be built to 24 floors and possibly even
more.

Exterior wall surfaces can be finalized in the plant production process or in the case of brick/stone
veneers field applications may be the builder’s choice. Roof systems also can be apart of - separate
from - applied in the field after the basic installation is completed.

7. EXAMPLES OF MODULAR CONSTRUCTION

7.1. MARRIOTT COURTYARD HOTELS

The USA’s Marriott Corporation shows offsite fabricated modular units from manufactured Kaplan
for its courtyard hotel chain. The units comprise two bedrooms separated by a corridor and measured
18.5m by 4.1m, using a rectangular hollow steel section frame with steel/gypsum board walls. Even
on the first prototype hotel, the offsite prefabrication approach saved 60 days on the construction
programmed, which Marriott considers in worth around US dollar 1 million

Fig.7: Marriott Courtyard hotel

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7.2 ABN/AMRO BANK EXTENSION, AMSTERDAM

This bank needed 600 to 700 people space. Today the bank occupies 100,000 sq. ft. class A corporate
office space, constructed from prefabricated modular units. The four storied building has a total GFA
of about 1, 15,000 sq. ft. The building was constructed using 675prefabricated modules to create 710
workspaces the floor was made of concrete and the ceiling height was about 9 ft. In future it is intended
that the manufacturer De Meevw will purchase back and remove the building after a minimum of 5
years should the bank want to sell it. The building was designed to a last period of 10 to 25 years or
more with proper maintenance. The total project cost were 31% lower than leasing conventional office
space

Fig.8: ABN/AMRO Bank extension

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CHAPTER – 02
ADVANTAGES AND DISADVANTAGES OF 3D MODULAR
VOLUMETRIC CONSTRUCTION

2.1. ADVANTAGES

Modular buildings are very affordable because of the factory construction of these buildings. They are
a very cost effective compared to conventional construction. These units are typically constructed in
an enclosed facility; therefore weather is not a factor in the construction time line. Material delivery
fees are also out of the equation because an ample amount of material will always be available at the
facility, as opposed to being delivered in limited quantities to the job site, nearly eliminating
construction delays, and theft of building materials from the site.

Such dwellings are often priced lower than their site-built counterparts and are typically more cost-
effective to builders and consumers. These new homes can be constructed in less time than it takes to
build a home on-site. Manufacturers cite the following reasons for the typically lower cost/price of
these dwellings:

• Speed of Construction/Faster Return on Investment - modular construction allows for the

building AND the site work to be completed simultaneously, reducing the overall completion
schedule by as much as 50%.
• Indoor construction. Assembly is independent of weather which increases work efficiency and
avoids damaged building material.
• Favourable pricing from suppliers. Large-scale manufacturers can effectively bargain with
suppliers for discounts on materials.
• Ability to service remote locations. Particularly in countries such as Australia there can be
much higher costs to build a site-built house in a remote area or an area experiencing a
construction boom such as mining towns. Modular homes can be built in major towns and sold
to regional areas.
• Low waste. With the same plans being constantly built, the manufacturer has records of exactly
what quantities of materials are needed for a given job. While waste from a site-built dwelling
may typically fill several large dumpsters, waste from a modular dwelling generates much less
waste.

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• More environmentally friendly construction process - modular construction generates less
materials waste and less site disturbances than comparable site built structures.

2.2. DIS ADVANTAGES

• TRANSPORTATION COST
➢ Need of modular shipment to the project site for permanent installation.
➢ Increased shipping cost for the project.
➢ Requirement of double handling as equipment and materials are shipped to the site.
• MODULE SIZE LIMITATION
➢ Different restriction for each mode of transport trucks, train.
➢ Design must consider dividing modules according to transportation constrains.
• TRANSPORTATION ACCESSIBILITY
➢ Modules must be shipped to the site
➢ Access site constrains should be carefully considered, especially in dense urban areas.

2.3. MODULAR HOMES VS. MOBILE HOMES

1) The codes that govern the construction of modular homes are the exact same codes that govern
the construction of any site constructed home. In the United States, all modular homes are
constructed according the International Building Code (IBC), IRC, BOCA or the code that has
been adopted by the local jurisdiction. Mobile homes (manufactured homes) are constructed
according to the HUD Code and are generally considered lesser quality.
2) The materials are the same as site constructed homes. Wood frame floors, walls and roof is
the most typical. Some modular even included brick or stone exteriors, granite counters and
steeply pitched roofs. All modular are designed to sit on a perimeter foundation or basement.
Mobile homes are constructed with a steel chassis that is integral to the integrity of the floor
system.
3) Lending institutions and appraisers consider as they consider a site built home, with the same
life expectancy and modular home the same as value. Mobile homes often require special
lenders.

Most companies have standard plans. However, all modular buildings can be custom built to client’s
specifications. Today's designs include multi-story units, multi-family units and entire apartment

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complexes. The negative stereotype commonly associated with mobile homes and has prompted some
manufacturers to start using the term Off-Site Construction.

2.4. ENVIRONMENTAL BENEFITS DURING THE CONSTRUCTION

The main environmental benefits during the construction operation are derived from the shorter
construction period,which lessens the impact on the local environments. Waste is
drastically reduced because of efficient factory production, and the reduced damage or use of
packaging materials on-site.There are other local environmental benefits of the
construction operation, which are identified as follows:

• Site installation of the modular units is a rapid and quiet operation that can be done ‘just in
time’, with no requirement for site storage or additional noisy equipment.
• The delivery and installation of the modular units can be timed to observe any site working or
road traffic constraints.
• The delivery of a large number of relatively small amounts of site materials is much reduced.
• Less waste is created so dumping of material waste from site is much reduced to less than 30%
of a conventional project.Foundation excavation is minimised and there are fewer potentially
wasteful site activities.
• Materials are used more efficiently, with considerable economy of use in production than is
achievable on site.
• The main construction operations are less disruptive to adjacent or connected properties in
terms of pollution and associated nuisance, etc.

2.4.1 ENVIRONMENTAL BENEFITS IN USE

The environmental benefits in use concern the high level of performance that can be achieved
economically, as follows:
• Good acoustic insulation is provided due to the separation between the modules.
• Good thermal insulation can be provided easily in light steel framing by creating a ‘warm
frame’.These buildings are very efficient thermally, leading to reductions in energy use and
consequent CO2 emission.
• Modular units are very stiff and strong, due largely to requirements for lifting and
transportation, and therefore have a solid ‘feel’.
• All light steel framed structures require minimal maintenance and no call-backs for shrinkage,
etc.

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2.4.2 ENVIRONMENTAL BENEFITS IN REUSE

The benefits in terms of re-use are:

• Modular buildings can be extended easily (or reduced insize) as demand changes.
• Modular units are fully relocatable at modest cost, withconsequent reduced energy cost in
dismantling, and nowastage of materials.
• Long-term use of scarce resources is reduced.

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CHAPTER – 03
CONCLUSION

Modular buildings are a perfect solution in remote and rural area where conventional construction may
not be reasonable or even possible. Other uses have also been found for modular buildings include
churches healthcare facilities and retail offices, fast food restaurants and cure ship constructions.
According to manufactures, modular homes are generally designed to be initially stronger than
traditional home by, for example, replacing nails with screws and adding glue to joint. The generation
of construction waste is reduced on-site due to the off-site prefabricated modules being transported to
the site fully fitted out, hoisted and assembled. Therefore modular buildings are good for construction
nowadays.

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REFERENCES

1) Automated post simulation visualization of modular buildings production assembly

line,Automation in construction,Science Direct
2) Hybrid light steel panel and modular systems,R.M.LAWSON,Thin walled structures,Science
Direct
3) The benefits of modular construction,by DEVIN M.REFFIT,renal Business today,October 2007
4) DonShulman”Reality Development Associates Announces Expansion” Easton Journal
5) Osama M Mohson, Paul J Knytl, Basel Addulaal, Jack Olearezyk and Mohammed Ali Hussein,
“Simulation Of Modular Building Construction”,University Of Alberta Edmonton Journal.
6) Chehayeb.N And Abourizk.S, 1998,”Simulation-Based Scheduling With Contours Activity
Relationships,”Journal Of Construction Engineering And Management, ASCE Civil Engineering
Journal.

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