Challenges Faced By Modular Industry

In a recent report the MBI points out that almost every U.S. industry hasexperienced growth over the last few decades except the construction industry. TheNational Institute of Standards and Technology (NIST) recently formed a committee of experts to investigate ways of improving productivity and competitiveness in theconstruction industry. The committee identifed the increased use of BIM and modularization as keys to increases in productivity. The U.S. Department of Housingand Development (HUD) has one of its mandates to support manufactured housing, and at a May 2012 meeting of experts in Washington D.C. organized by the HUD’sOffice of Policy Development and Research, development of multi-story modularconstruction was identified as one approach toward creating affordable and energyefficient housing. The primary benefit of using modular methods is the gains inconstruction productivity. Additional benefits are as follows:

• Factory-built products benefit from the controlled environment of an indoorfacility, which can be managed more efficiently than an outdoor jobsite.
• Productivity increases can be recognized in time or cost savings for thedeveloper. Lawson and Ogden (2008) estimate 10%-20% cost savings may beavailable and 30% - 40% time savings may be achievable in larger constructionprojects. Cost and time saving items include:

1. Fabrication of modules concurrent with site improvement activities.
2. Simultaneous module erection and site remediation efforts.
3. Reduced individual building subsystem construction.
4. “Just in Time Deliveries”.
5. Reduced need for equipment, labor and stockpiling space.

The benefits achieved through the construction process lead to an overallreduction in site and community disturbance. This can be advantageous forstudent housing projects or those in dense urban settings.

A benefit of modularization is the recyclable nature of the modules or panels.3D volumetric modules can be deconstructed offsite and recyled or reusedwhole if possible.

The implementation of modular methods can benefit both the project owner and thefuture dwelling occupant. The owner realizes the cost saving through productivityincreases and the shortening of the construction schedule can lead to early occupancyof the structure. The owner can gain a competitive edge in the market by providingmuch needed affordable housing to the occupant without sacrificing quality.Additionally occupants benefit from reduced utility bills and maintenancerequirements that result from a high quality factory produced unit.

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The most significant challenge facing the modular industry is the social acceptance of modular products. McGraw-Hill points out that the primary reason cited by industryfor not using modularization in their projects was that the architect did not specify it. Architects will be instrumental in initiating a strong modular integration effort in the main stream construction market. If they accept and adopt modular technology, architects have the opportunity to influenceclients when developing potential design options for a project. Additional Challenges facing the industry are listed below.

Modular construction projects have physical constraints that apply and limitthe ability to modularize some projects. Consider the feasibility ofmodularization at the conception stage of planning:

1. Will the dimensional constraints of using 3D modules be acceptable?
2. Is there site access for crane assemblage and delivery of the modules?
3. Can the modules be successfully transported and staged at the site?
4. Is there a modular facility within a reasonable distance of the project?

Standardization across the industry seems to be essential. In order tosuccessfully implement cost-effective design, standard dimensions andstandard communication protocols should be established.

Drafting systems used by designers are outdated. Once drafting systems areupdated and BIM is incorporated into the discussion, the benefits ofmodularization will become more apparent to both owners and architects.

The assemblage of interdisciplinary, colloborative, model based design teamsalong with increased design time allotment in the project schedule is needed toimprove the productivity of the design process and construction managementof projects that use modular methods.

Building codes are slow to develop and could hinder the integration ofmodular methods. Restrictive codes may hamper new ideas and make itdifficult to integrate much needed new building design philosophies intosociety.