multifamily market on the rise - modular construction · construction schedule at his latest...

FOR THE COMMERCIAL MODULAR CONSTRUCTION INDUSTRY

MO

DU

LAR BU

ILDIN

G IN

STITUTE’S Q

UA

RTERLY PUBLIC

ATION

▪ FEB 2016 | 1Q

MULTIFAMILY MARKET ONTHE RISEPLUS▪ INDUSTRY NEWS

▪ MBI MEMBER CASE STUDIES

▪ INTERNATIONAL/ALLIANCES

▪ RESEARCH & INNOVATION

Emerald Ridge Apartments Phase I Watford City, North Dakota, USA

Guerdon Enterprises LLC

MODULAR.ORG

TM

http://www.modular.org

3MODULAR ADVANTAGE | FEB 2016 | 1Q -MODULAR.ORG/MODULARADVANTAGE.ASPX

Module setting of Pacific Park Apartment TowerLocation: Brooklyn, NYBuilding Height: 32-storiesCompany: FC Modular

Modular Advantage Sponsors:

TABLE OF CONTENTS

■ INDUSTRY NEWS Northeast Leads the Way with Multi-Story Modular Developments ............... 05 Modular Grows as Conventional Building Costs Climb ................................ 06 PacificParkReachesNewHeights! ..................................................................... 10 MBI & Company Updates ................................................................................... 11 Why Modular Building is More Than Just a Trend ....................................... 11 Wall Mount Air Conditioners ............................................................................... 12 Gerdau Ameristeel’s Two-Story Modular Scale House ................................. 14 MBIMembers,DirectorElectedasNationalBoardOfficers ...................... 15 MBI Welcomes Two New Staff Members ........................................................ 15 From Cottage Industry to Global Success ......................................................... 16 TopMarketsIndentifiedfor2016 ..................................................................... 17 Government Affairs .............................................................................................. 18 A Guide for Determining Code Compliance for Relocatable Buildings ........... 18 MBI Now a Preferred Provider of ICC CEUS ..................................................... 20 Upcoming Events & Reminders ......................................................................... 20

■ MBI MEMBER CASE STUDIES Multifamily Market ................................................................................................ 23 KirklandAvenueTownhomes......................................................................................24 Passive House - Vancouver Coastal Heath ............................................................. 26 Emerald Ridge Apartments Phase I .......................................................................... 28 West Campus Lofts ....................................................................................................... 30

■ INTERNATIONAL/ALLIANCES The Rise of Off-Site – A Global Perspective ...................................................... 32 KiwiPrefab:ALookatPrefabricationinNewZealand...............................34 Modular Construction Educational Foundations .............................................. 36

■ RESEARCH & INNOVATION “Expanding” The Use of Modular Construction ............................................... 37

■ ADVERTISER INDEX & MBI STAFF............................................................. 42

MODULAR.ORG

TM

Visitusatfacebook.com/ModularConstruction

Follow us on Twitter at@rethinkmodular

Modular Advantage™ is the quarterly publication of the Modular Building Institute.

MBI Executive DirectorTom Hardiman

MBI Board of DirectorsKelly WilliamsChristopher PetersonDevinDuvakMichael RhodesKate BaumannMarc BoilyPaul BonaccorsiTimothy BoswellRoland BrownJohn ErbBill HaliburtonJohn MorrisonChristoph NeufeldDrew Welborn

Subscriptions & SponsorshipsModular Advantagec/o Modular Building Institute944 Glenwood Station Ln., Ste. 204Charlottesville, VA 22901 USA

Phone: 888-811-3288Fax: 434-296-3361Email: [email protected]

Copyright © 2016

PostmasterSend address changes to:Modular Advantagec/o Modular Building Institute944 Glenwood Station Ln., Ste. 204Charlottesville, VA 22901 USA

TOC

http://www.modular.org/modularadvantage.aspx

http://modular.org/

https://www.mobilemodular.com/

http://www.modspace.com/

http://www.satelliteco.com/

https://www.facebook.com/ModularConstruction/

https://twitter.com/rethinkmodular

mailto:info%40modular.org?subject=


Climate Control Solutions

Bard Manufacturing has been the leading HVAC supplier for the modular manufacturing industry for the past 50 years. There are many reasons why manufacturers prefer Bard. Our wall-mount units are made for modular with the durability, flexibility and reliability the industry demands. Bard also has easy installation and serviceability that traditional HVAC or mini-split systems simply can’t match. What’s more, Bard units are available with a variety of comfort enhancement options that work together to control fresh air, humidity and sound, providing the ideal Indoor Air Comfort.

Visit us online to see our full line of wall-mount HVAC units with available comfort enhancement options. And discover why Bard is Made for Modular.

NO ONE DOES COMFORT

BETTER THAN BARD.

4 1 9 . 6 3 6 . 1 1 9 4Your tool to make HVAC selection simple!

M A D E F O R M O D U L A R . C O M

BRD11048_Modular_MBI_8.5x11_Ad_v1.indd 1 4/9/15 1:14 PM

INDUSTRY NEWS MODULAR ADVANTAGE FEB 2016 | 1Q

NORTHEAST LEADS THE WAY WITH MULTI-STORY MODULAR DEVELOPMENTSBy Modular Building Institute

While the headlines have been dominated by the PacificParkproject,severalothermulti-storymodu-larprojectshavebeensuccessfullydeliveredinthenortheast.

The recently completed 7-story apartment complex knownas“TheStack”,designedbyGluck+architec-turefirm,consistsofnearlysixtymodulesmanufac-tured by Deluxe Building Systems in Pennsylvania.

The modules were shipped to the site and hoisted intoplaceinjust19daysafterthefoundationandfirstfloorsupportswereconstructed.“Therewasademand for it, even though it didn’t exist yet, and so the modular played into that because it gave us the quality of construction and shortened the time frame,”saidarchitectThomasGluck.

AnotherNewYorkproject,MyMicroNY,designedby nArchitects, focused on smaller more affordable housing units. My Micro NY is a 55-unit, 9-story studio-only apartment building with units ranging from 260 to 360 square feet, constructed by Capsys CorporationofBrooklyn.

The three dimensional modular units – commonly used forhomes,apartmentsandoffices–arebuiltinaquality and climate controlled offsite factory, then transported to the site and installed using a crane. Butit’snotjustNewYorkthatisseeinganewwaveofmodularprojects.BostonMayorMartyWalshrecently announced a goal of adding 53,000 new housing units in the city over the next 15 years. Mod-ularprojectslikeChelseaPlace,developedbyTocciBuilding Co., opened in 2013 as a 4-story, 56-unit marketrateapartmentcomplex.In2010,Toccibuilta 54-unit residential complex in West Cambridge for AbodeZ,alsousingmodulardesignandconstruction.

Another recent announcement by Grossman Cos. Inc. of Quincy and the Wayside Cos. of Boston revealed that they purchased nearly an acre of Allston prop-erty permitted for an 80-unit, $26-million apartment complex. In a release, the companies boasted that the61-89BraintreeSt.projectwouldbethe“largestmodularconstructionprojectinthecityofBoston”anddesignedto“ensurequalitycontrol,tofast-trackthe construction schedule, to provide tighter construc-tionforgreaterenergyefficiencyandtoreduceexcess materials waste.”

Top images: The Stack, courtesy of Deluxe Building Systems.Bottom images: My Micro NY, courtesy of nArchitects.

“THE MULTIFAMILY MARKET HAS BEEN IDENTIFIED AS A STRONG

GROWTH OPPORTUNITY FOR MBI AND OUR MEMBERS. OUR INDUSTRY

IS IDEALLY SUITED TO DELIVER A HIGH QUALITY PRODUCT WITH GREATER COST AND SCHEDULE

PREDICTABILITY FOR MULTIFAMILY DEVELOPERS.”

-- Tom Hardiman,MBI Executive Director

54


6 7- MODULAR ADVANTAGE | FEB 2016 | 1Q MODULAR ADVANTAGE | FEB 2016 | 1Q -MODULAR.ORG/MODULARADVANTAGE.ASPXMODULAR.ORG/MODULARADVANTAGE.ASPX

MODULAR GROWS AS CONVENTIONAL BUILDING COSTS CLIMBAs the cycle matures, apartment pros cut time to marketwithprefabconstruction.

By Multifamily Executive

Eviva Midtown, a six-story, 118-unit mixed-use community in Sacramento, Calif., is scheduled for completion next spring, only 18 months after construction began. The modular “boxes” that make up the building measure 12 by 64 feet and weigh 35,000 pounds each. Photo Courtesy: Tricorp Hearn Construction via multifamilyexecutive.com

TonyMoayedmayhavefiguredouthowtobendtime. Or at least compress it by about 25%.

As CEO of Sacramento, Calif.–based Tricorp Hearn Construction, Moayed has been able to collapse the construction schedule at his latest multifamily build. EvivaMidtown,a118-unit,mixed-usecommunityjuststeps from the California State Capitol, will feature luxury amenities, 5,000 square feet of retail space, andanundergroundparkinggarage.Thecommunityisscheduledforcompletioninspringof2016,orjust18monthsafterMoayedturnedhisfirstshovelofdirt at the site, instead of the 24 months originally estimated.

“We should be able to cut it down by about six months,” Moayed says. “That time savings has been a bigselleronthisproject.”

Moayed’s time-collapsing weapon? Modular con-struction.AllofEviva’sunitswillbestacked,onebyone,atoptheproject’sground-floorretailspace.Measuring 12 by 64 feet, and weighing 35,000

poundseach,the“boxes,”asthey’reknowninmodu-lar parlance, will then be stitched together, with me-chanical, electrical, and plumbing (MEP) runs strung between them, until Eviva reaches its full, six-story height.

Aside from the building’s stucco façade, once the units are in place, there will be next to nothing left for Moayed’s subs to do. The units, supplied by Boise, Idaho–based Guerdon Modular Buildings, will arrive atthesitealmostcompletelyfinishedout.Paint,floor-ing, baseboards, cabinetry, counters, lighting, faucets, showerheads, tile, mirrors, windows, switch plates, thermostats, and even appliances, will all already be in place.

“We were up at the factory yesterday, and it was 100% done,” Moayed says. “There was electrical to each of the units, so you could turn on the lights and fans. Everything’s operational, everything’s complete. Including payment.”

Only the Beginning

While popular in Europe, modular construction is still in its infancy for multifamily in the United States and barely registers as a blip on the data screens of mostapartmenttrackingfirms.Indeed,modularonlyaccounted for 1.3% of all construction categories followed by the Charlottesville, Va.–based Modu-lar Building Institute in 2013. But the trade group’s lodging category, which includes multi-dwelling units (MDUs),showedanannualuptickinactivityof31%.Indeed, some notable apartment developers have brought communities out of the ground—and out of the factory—using modular construction in recent years.

Those who have used modular construction tout shorter cycle times and the elimination of material cost over-runs(sinceyouknowthepriceofeachunitupfront,there’s no fudging in the numbers once on site), as well asmoreconsistencyinthefinishedproduct.Becausemodular units are built in the controlled environment of a factory, spec drift and exposure to the elements can largelybetakenoutoftheequation.Withcompo-nents built in a factory, fewer union wage hours are workedonsite.Andthefinishedproductcanbemoreenergyefficientandhavemoresound-dampeningqualities than site-built apartments.

6 - MODULAR ADVANTAGE | FEB 2016 | 1Q

INDUSTRY NEWS

But those same vets who appreciate modular’s ad-vantages say putting up a factory-built structure isn’t really cheaper than on-site construction and may, in fact, cost more. Because each unit has its own struc-turalframing,walls,ceilings,andfloorsareessen-tially doubled up, and more material—as much as 50% more—is used in the process. Transportation coststogettheunitsonsiteaddup,too.Andfindingcompanieswiththecapacityandknow-howtobuildthe boxes for large-scale multifamily developments, as well as the tradespeople to stitch them together, poses another challenge.

All that said, several developers who’ve tapped modularconstructionfortheirmultifamilyprojectsareexperiencing unequivocal success.

Singled Out

TaketheDomaininSanJose,Calif.,a444-unit,lux-ury community developed by Equity Residential that opened in late 2013. The largest modular apartment projectcompletedinthecountrytodate,thebuild-ingrecentlytookbest-in-showhonorsintheModularBuilding Institute’s 2015 Awards of Distinction compe-tition.Aquicklookatsomeofthebuilding’sbeautyshotstellswhy:Nocookie-cutterdevelopmentofblocksuponblocks,Domainisvirtuallyindistinguish-able from a site-built community.

The courtyard at the Domain in San Jose, Calif. The 444-unit luxury community, developed by Equity Residential, is the largest modular apartment project completed in the United States to date. Photo Courtesy: Guerdon via multifamilyexecutive.com

The layout includes cascading, elongated windows lookingoutontothebuilding’ssunnycourtyardpool

deck,whileinteriorsboast9-footceilings,granitecountertops, casement windows, stainless steel appli-ances, and washers and dryers, which were already installed and in place when the modular units were delivered to the site. Each unit also offers patio space,andtop-floorapartmentshaveawalk-out,privaterooftopdeck.

Butit’snotjustDomain’sgoodlooksthathavebeenwinning it accolades. Started in 2011, the proper-tywenttomarketaboutninemonthssoonerthanwould normally be anticipated for a similar, site-built project—eventhoughitcostabout$2millionmoreto build—and reached full occupancy an entire year earlier than the underwriters’ pro forma esti-mates. With the historic growth of rents in the past fiveyears,andwhispersaboutthetopofthecycleemergingformultifamily,havingthatkindofjumpgettingtomarketcanmakeastaggeringdifference.

The living-room level of an apartment unit at the Domain. The building recently took best-in-show honors in the Modular Building Institute’s 2015 Awards of Distinction. Photo Courtesy: Guerdon via multifamilyexecutive.com

“Anytimeyoucangettomarketfasterandstartearning rents sooner, you’re going to have more moneyinyourpocket,”saysMarkTennison,Equity’sexecutive vice president of development. “Domain hasbeenagreatassetandarealjoytomanageinour portfolio.”

TheprojecthasalsogivenLadDawson,CEOofGuerdon, which supplied Domain’s units, an opportu-nity to press modular’s multifamily case.

“[Equity was] able to generate nearly $15 million

INDUSTRY NEWS

Article continues on next page.

76



http://www.multifamilyexecutive.com/


moreingrossrevenuesonthatprojectthantheywould have if they’d gone with site-built construc-tion,”saysDawson,whosefirmhasmanufacturedapproximately 8,000 modular apartment units since 2005.“That’saprettyremarkablereturnoninvest-ment for that extra $2 million they spent up front.”

Other modular multifamily buildings abound too.

InNewYorkCity,modulardevelopmentCarmelPlace (formerly My Micro NY) has been gaining attention as a solution to some of the city’s notorious housing shortages. Located at 335 E. 27th St., the building’s 55 units, manufactured by Capsys in the BrooklynNavyYard,startedstackingupinMay,andtheprojectisslatedforcompletionthisfall.Withunits that range from 260 to 360 square feet, the development was heralded by former mayor Mi-chael Bloomberg as a way to help combat the city’s housingcrisis.Butfirst,theBigApplehadtowaivezoning and density rules limiting apartments to no less than 400 square feet, a critical victory for hous-ing advocates. Rents will start at $2,000 a month, a bargain for Manhattan.

Similarly,TheStack,a28-unit,six-storymodularbuilding developed by Jeffrey M. Brown Associ-ates uptown in Manhattan’s Inwood neighborhood, wasassembledinjust19daysandopenedtoravereviewsin2014,offeringamixofmarket-rateandaffordable apartments.

Chelsea Place, in Chelsea, Mass., was delivered in less than nine months, 25% less time than it would have taken had the project been built conventionally, says its modular builder, Tocci Building Cos. Photo Courtesy: Tocci Building Cos. via multifamilyexecutive.com

Then, there’s the 56-unit Chelsea Place, in Chelsea, Mass. Developed by Federal Realty Investment Trust andbuiltwithOaktreeDevelopment’sGreenStaxxmodularsystem,thecommunitywasstackedintoplace by Woburn, Mass.–based Tocci Building Cos. injustninemonths,andwentfromconcepttooccu-pancyinjust14months,or25%morequicklythanasite-builtproject.Stackeduponavacantlotthathad been the source of neighborhood complaints, the building helped anchor Federal Realty’s 20-acre Chelsea Commons shopping center in the same area.

“There are a lot of reasons why multifamily modular isgainingmomentum,especiallyinurbanmarkets,”says John Tocci, Tocci’s CEO. “You’ve got the high cost of unionized labor in urban areas, and congested sites and restrictive lay-down space for conventional construction. At the same time, increasing rents are drivinguptheimportanceoftimetomarket.Ev-erybody’slookingforawaytoreduceconstructiontime.”

The Other Side of the Coin

Yet, for all of modular’s multifamily allure, it has its detractors. One of them looms, only partially com-pleted,overBrooklyn’sskylineandhasbecometheposterchildforwhatnottodoonyournextjointdevelopmentproject,modularorotherwise.

The 363-unit B2 BKLYN, which is being erected next to Barclay’s Center, will be the world’s tallest mod-ular building—when it’s completed. But Forest City

“IT’S A HIGH-PROFILE PROJECT IN A REAL ESTATE– AND CONSTRUCTION-

OBSESSED CITY. BESIDES THE SIZE OF THE UNITS, PEOPLE HAVE BEEN

DRAWN TO THE MODULAR ASPECT OF IT SINCE THE BEGINNING.”

-- Tobias Oriwol,

ProjectManagerforMonadnockDevelopment

INDUSTRY NEWS

Ratner,theproject’sdeveloper,hadanacrimoniousandverypublicfallingoutwithaU.S.unitofSkans-ka,theSwedishconstructiongiantitwasoriginallypartneredwithonthedeal.Costoverrunsandfingerpointing eventually led to lawsuits, and the whole sagamadeformonthsofdrama-soakedcopyinNewYork’sbusinesspress.

AfterSkanskasentalettersayingitcouldn’tguaran-tee that the building’s self-sealing exterior wouldn’t leak,ForestCityRatnerboughtoutSkanska’sinterestinitsjointmodularmanufacturingfacilitysoitcouldforge ahead on its own. In June, Forest City appoint-ed construction executive Susan Hayes as head of FCModular,thefirm’snewmanufacturingsubsidiary,andiscurrentlymovingaheadwiththeproject.

“It’s been hard. It’s not gone as planned. And it’s cost a lot more money,” said MaryAnne Gilmartin, CEO ofForestCityRatnerCos.,duringarecentBrook-lyn real estate summit, according to The Real Deal. “This model is still yet to be proven, but I am a deep believer.”

Indeed,whilemodular’sbuildingblocks,oncedeliv-ered,cansnapintoplaceonajobsitelikesomanyLegos,proswithexperiencesayplanningaprojectout can be cumbersome. At Eviva Midtown in Sac-ramento, for instance, while construction is slated to be 25% faster than a conventional build, getting thatconstructionstartedwasabear.OneofthefirstissuesMoayedencounteredwasfindingacompa-nywiththecapacitytomeethisneeds.Theprojectoriginally contracted with North Highlands, Calif.–basedmodularmanufacturerZetaCommunities.Butit eventually switched to Guerdon and Dawson when itbecameclearZeta’sscheduleanditsownwouldn’tline up.

Then, there’s been the ramp-up time.

“Thisismyfirstmodularproject,butI’vealreadygotthreeyearsofexpertexperience,”Moayedchuckles.Some of that time has been consumed addressing overlapping design issues—once with structural and architectural designers at Guerdon’s factory in Boise, Idaho and then again with structural and architectur-al designers on site. “We’re really trying to stream-line the process so we’ve got one cohesive team,” Moayed says.

Park87 in Cambridge, Mass., made up of 76 modular units on a tight, urban site, was erected in only five days. Photo Courtesy: Tocci Building Cos. via multifamilyexecutive.com

In fact, while modular’s time savings can come from a foundation being poured at the same time units are being manufactured, you’ve got to spend more time in the planning stages initially.

“Provided that adequate up-front design and man-ufacturing time is allowed, on-site construction can be cut by 15 to 40%,” Tocci says. “But your typical 200-unitprojectisgoingtorequireapproximatelyfour months’ more lead time, even with production split between two facilities.”

Andyou’lllikelyhavetoeducateyourbankeraboutconstruction draws, as well. Because multiple phases, such as foundation and unit manufacturing, can hap-pen simultaneously, you’ll need more cash sooner to fundtheproject.

Findingskilledtradeprofessionalswhounderstandthe different variables of assembling modular con-struction on site can be a pain point too. “Getting the subcontractors who really understand what it is we’re building has been a challenge,” Moayed says. “I’ve got 118 units, and 200-some modular units, which translates into more than a thousand mechanical, electrical, and plumbing chases. If you don’t do it efficientlythefirsttime,youmultiplyyourmistakesby1,000.”

On top of that, there’s the fact that in order for mod-ular to pencil out, you have to reach certain econo-mies of scale. That was certainly the case for Marcus Toconita, partner at Philadelphia-based Callahan

INDUSTRY NEWS


98




Ward Cos., when he ran the numbers for a recent infillproject.

Petr Vancura, director of communications at New York–basedengineeringandarchitecturalfirmGil-sanzMurraySteficek,deconstructsmodular’sbreak-even point thusly: “In order to offset the higher setup, material,andtransportationcosts,modularprojectsworkbestwithasingledesignprototype,”hesays.“Then, once you’ve got that single prototype, you have to have enough units to get the per-unit cost down and achieve economies of scale. You need a highernumberofunitsfortheprojecttoremaineco-nomically feasible.”

And yet, while modular’s challenges go far beyond what’sinsidethebox,itsbenefitsaremany,includ-ing reduced cycle time, increased production control, lowerlaborcosts,and,ultimately,aquickertimetomarket.

With an increasing number of developers starting tolookatmodulartechnologyformultifamily,andpressuremountingtobuildataquickerpaceandstart collecting rents as the cycle matures, don’t be surprisedifabunchofbigboxesstartstackingupinamarketnearyou.

Article source: multifamilyexecutive.com

PACIFIC PARK REACHES NEW HEIGHTS!By Modular Building Institute

The modular tower known as B2, nestled against Barclays Center at 461 Dean Street in the Pacific Park/Atlantic Yards development.Photo Courtesy: brownstoner.com

Despite its troubled past and vocal critics, FC ModularismovingfullsteamaheadwithitsPacificParkproject,slatedtobethetallest modular building in the world at 32 stories. The team recentlyinstalledthe25thfloorandhavebeensettingaboutoneflooreachweek.

To put this into perspective, the tallest modular building in North America was the 21-story Hilton HotelontheSanAntonioRiverwalk,builtin1968!A24-story student dormitory in Manchester, England currently holds the distinction of world’s tallest modular building, despite claims from China’s Broad Group about their recent 57-story“modular”projectbuiltinjust19days.WhiletheChineseprojectwas a phenomenal feat and highlights the speed of offsite construction practices in general, it used a combination of prefabricated wall panels and subassemblies and a seemingly unlimited supply of labor. In terms of volumetric, three dimensional modular construction, we still give the nod to the UK project.Nonetheless,BroadGrouphasquiteastorywith over 3 million views on YouTube.

“WE HAVEN’T PRICED OUT ANYTHING ON THE SCALE OF A 200-UNIT BUILDING, BUT WHEN

WE LOOKED AT IT ON THE SCALE OF A 10- OR 20-UNIT BUILDING, MODULAR DIDN’T MAKE SENSE

FOR US. WE BOTH DEVELOP AND MANAGE THE CONSTRUCTION OF

OUR PROJECTS, SO OUR COSTS CAN BE LOWER THAN OTHER

DEVELOPERS WHO HIRE A GENERAL CONTRACTOR TO DO THEIR BUILD.”

-- Marcus Toconita,

Partner, Callahan Ward Cos.

INDUSTRY NEWS

MBI & COMPANY UPDATES

WHY MODULAR BUILDING IS MORE THAN JUST A TREND

An interview with MBI’s Executive Director, Tom Hardiman, by PDH Contractors as part of their Expert Interview program.

Q: Why does modular building seem to be ev-erywhere now?

A: Modular construction is a building method in which homes may be constructed off-site in approximately half the time that it would other-wisetaketobuildahome.TomHardiman,whohas been the executive director of the Modular BuildingInstitutefor11years,spoketousaboutwhymodularbuildingismorethanjustatrend,the most rewarding part of building modular, and more.

Q: On the Modular Building Institute website, it claims that your business is “changing the way the world builds.” How do you accomplish this?

A: The construction industry for the most part still builds the same way it did 100 years ago. There have been a lot of studies regarding construction industryproductivityoverthepastfiftyyearsand the fact is that it has not improved much (if atall)comparedtosignificantgainsrealizedinother industries.

Modular construction is simply a process whereby larger components (or modules) are prefabri-cated at an offsite location in controlled settings, then transported to the site and installed. The endproductisthesame;it’sjustamoreefficientway to get there.

Q: Why should people build modular?

A: The primary advantage is speed (i.e., a re-duction in the overall construction schedule). This isaccomplishedbecausetheworkonthebuildingcanoccursimultaneouslytothesitework.Itisnot

unrealistic to cut 20 to 30 percent off the overall schedule.

Additional advantages include reduced site dis-turbance, which is critical for educational facili-ties or dense urban locations. Schedule predict-ability and cost certainty are other advantages as a result of early communication and collabo-ration.

Workersafetyisalsoabigadvantage,asthereis a much lower chance of accidents resulting from falls and from inclement weather. Addi-tionally, with modular construction there is less material wasted, again, as a result of the con-trolled building environment. Lastly, the quality is typically higher in a facility constructed in a controlledsettingversusatraditionalprojectexposed to the elements.

Q: What are some of the main things you’ve noticed about the modular building trends?

A: I wouldn’t refer to modular construction as a trend, rather an evolution of the construction industry.Itisinevitablethatmoreworkisgoingto be shifted “offsite” as owners and developers demandgreaterefficiencyfromcontractors.

Q: What is the most challenging part of building modular?

A: Early communication and collaboration is the keytoasuccessfulmodularproject.Itismuchmore challenging to bring a modular contractor inaftertheprojecthasbeendesigned,asthedesign may or may not optimize the modular/offsite construction process.

Q: What is the most rewarding part of building modular?

A:Attheendoftheday,ifthebuildinglookslikeabuildingconstructedconventionally,butdone in less time, with less material waste, and less disturbance to the surrounding neighborhood, that’sasuccessfulproject.

Article source: pdhcontractors.com

INDUSTRY NEWSMBI & COMPANY UPDATES

1110



http://www.multifamilyexecutive.com/

http://pdhcontractors.com/uncategorized/expert-interview-series-tom-hardiman-on-why-modular-building-is-more-than-just-a-trend/


WALL MOUNT AIR CONDITIONERSA Conclusion to the Infusion of Regulatory Confusion

By Paul Quigley, Bard Manufacturing Company, Inc.

Becausethisissuchanimportant,albeitaconfusingtopic,I’mgoingtoofferasummaryfirstandthengetintothe details. That should allow all readers to get the gist of this complex scenario that will affect all modular builders’ logistics planning.

The Confusion:Historically,ASHRAEstandardshavebeenusedtoestablishminimumefficienciesforaircondi-tioners, heat pumps and furnaces. These standards are normally accepted by the DOE (Department of Energy) and are thus adhered to on a national level. That has always made it easy for modular builders to select HVAC equipment, no matter what state they are shipping their buildings to. Unfortunately for modular builders, that’s no longer the case.

The Infusion:In2015,theDOEdidnotacceptASHRAE’srecommendationtomakeallwallmountaircondition-erssatisfyaminimumefficiencylevelof10.0EER(EnergyEfficiencyRatio),effectiveOctober2015.Forrefer-ence,thepreviousfederalEERminimumefficiencywas9.0EER.Instead,theDOEhasmandatedthat11.0EERbethenewminimumefficiencyforwallmountairconditioners,upto65,000BTUH,effectivenationallyinlate2019. Wall mounts exceeding 65,000 BTUH must now meet 10.0 EER minimum standards. That means that the old 9.0 EER minimum is still in effect as a national standard… but not necessarily on a state-by-state level, and only for wall mounts that produce 64,999 BTUH or less.

Thattakesusrightbackto“TheConfusion”foramoment:Asitstands,statescan,andwill,adopttheASHRAE90.1-2013(AmericanSocietyofHeatingRefrigerationAir-ConditioningEngineers)buildingefficiencystan-dard at a time independently determined by each state. Three of them have already done so. That means that certainstatesnowmandate10.0EERminimumefficienciesforwallmountairconditioners,whileotherswillstillpermit 9.0 EER units to be placed into service.

The Conclusion:Beefuponyourindividualstaterequirements,andletyourHVACwholesaledistributorknowif you plan to ship air conditioned buildings into states that mandate 10.0 EER. Certainly, it would be easiest to simply transition your entire Wall-Mount HVAC strategy into a 10.0 EER platform, but you’ll need to determine thecost-benefitscenariosinordertodetermineifthisisadoablestrategy.

Of course, the devil dwells in the details, so for those of you who are still willing to read on, the following is the nitty-gritty that you need to ensure that your logistics analyzers understand. ASHRAE 90.1-2013 is the most cur-rentbuildingcodestandardthatcoversacomprehensiveamountofbuildingefficiencytopics.HVACstandardsare some of the most important topics covered in ASHRAE building code standards. While ASHRAE standards are adopted on a state level, the federal government, through the Department of Energy, has always accepted theASHRAEstandardsforHVACminimumefficiencies,whichhasmeantthatallstateswererequiredtofollowthesameminimumefficiencyguidelines.Inanunprecedentedmove,theDOEoptedtomandatetheirownHVACminimumefficiencies,whichdiffersfromASHRAE90.1-2013buildingstandards.It’sinterestingtonotethatthecurrent administration’s DOE has enacted almost twice as many mandates as the DOE from the previous three administrationscombined.TheDOEmustgiveafour-yearwindowwhenmandatingnewefficiencies,sothenewstandardswilltakeeffectsometimeQ4-2019.Untilthattime,thefederalminimumefficiencywillremainat 9.00 EER, except for the states and countries (Canada?) that adopt ASHRAE 90.1-2013 standards. In those cases,theminimumallowableefficiencyfornewbuildingswillbe10.0EER,untilQ4-2019.

MBI & COMPANY UPDATESINDUSTRY NEWS



Here is the current breakdown of Wall Mount Air Conditioner efficiency requirements:

NationalMinimumEfficiencies:Theminimumefficiencyremainsat9.0EERforstatesthathavenotyetadoptedASHRAE90.1-2013.Nationalminimumallowableefficiencieswillmoveto11.0EERsometimeinQ4-2019forair conditioners up to 65,000 BTU (5.5 tons). 6-ton through 10-ton wall mount air conditioners must now meet 10.0EERminimumefficienciesandwillnotchangein2019.10.0tonthrough20-tonwallmountunitsmustmeet10.0EERminimumefficienciesbeginningOctober9th,2016andwillnotchangein2019.

StateMinimumEfficiencies: To-date (12-28-15), three states have already adopted ASHRAE 90.1-2013 stan-dards. Those states are New Jersey, Maryland, and Vermont. In all three of those states, you MUST utilize wall mountswithaminimumefficiencyof10.0EERinallnewbuildings,regardlessofsize.Inaddition,asweunder-standit,mostinspectorsinthosestatesarealsomandatingthesameminimumefficienciesforreplacementunits.ManymorestatesareexpectedtoadoptASHRAE90.1-2013asthecalendaradvances.Thefollowinglinkwillcome in handy when you are planning your immediate logistics strategies. Trying to anticipate which states will makethechangeinthenextmonthortwoisanentirelydifferentgamble.

Hereisthelink,andIsuggestforwardingittoyourdesignandlogisticsteams:www.energycodesocean.org/code-status-commercial

Insummary,wehavebeenlegislatedintoabitofanefficiencystandardsquagmire.MysuggestionisthatyouworkcloselywithyourHVACdistributortoplanforyourfutureequipmentneeds,asitseemshighlydoubtfulthatanydistributorisgoingtobewillingtostockallpossibleefficiencylevelsofequipmentwithoutstrategicplanning input from their clients.

Feelfreetocontactmeifyouhaveanyquestionsaswesortthroughthistogether,orifyou’dlikeanelectronicversionoftheflowchartI’veincludedwiththisarticle.Youcanreachmeatpaul.quigley@bardhvac.com.

Paul QuigleySeniorVicePresident:Sales&MarketingBard Manufacturing Company, Inc.

www.madeformodular.com | www.bardhvac.com

Use 10 EER equipment, or check with the local codes administrator to find out if they will accept

9.0 EER equipment for replacement projects.

This unit or the building the unit is being mounted on will be installed in a state that has adopted the ASHRAE 90.1-2013 energy code?

The state’s energy code requires 10 EER product to be installed on new construction applications*.

See below for Bard SPVU products that meet andexceed the 10 EER standard

All Bard SPVU products are approved for installation

Link to guide showing State’s current ASHRAE code level: www.energycodesocean.org/code-status-commercial

Specification calls for more than 65,000 Btu/h cooling?

The unit will be installed in a replacement application?

YES

NONO

NO

New federal efficiency minimum requires10 EER product after 10/09/2015.

Bard model prefixes that meet new standard:W72AA, W72LA, W6RV, W6LV

YES

YES

LESS THAN 10 EERW**A2-W**H2-

W**AA-W**HA-WG/WAG

TH/TSSHCH

I-TECQ-TEC

10 EER OR GREATER*Note: Some states may seek other/alternate status based upon Federal Efficiency laws.

DEPARTMENT OF ENERGY FINAL RULE REGARDING SPVU (Wall Mount Air Conditioner) ENERGY EFFICIENCY STANDARDS(BARD PRODUCTS AFFECTED: ALL WALL-MOUNTS, Q-TECS AND I-TECS)

December 2015

1312



http://www.bardhvac.com

http://energycodesocean.org/code-status-commercial

mailto:paul.quigley%40bardhvac.com?subject=

http://www.madeformodular.com/

http://www.bardhvac.com/

http://www.energycodesocean.org/code-status-commercial




In North Carolina, Gerdau Ameristeel Corporation is poised to open its new state-of-the-art perma-nent modular two-story scale house, located at their Charlotte mill facility. The steel and concrete mod-ular building totals only 1,300 square feet but is crammed-full with hi-tech security and data commu-nicationsystemstoensuresafeandefficientopera-tions. Gerdau decided to replace their existing, de-teriorated scale house with a new cutting-edge and high quality modular building that would be durable and meet the demands of its rigorous daily use.

This was a design-building permanent modular con-struction“PMC”thatrequiredprojectfeaturessuchasstemwallfoundationwithcrawlspace,ejectorpump, lightning protection, tempered glass for safe-ty,anobservationdeck,andacompletehi-ribsteelexterior for maximum longevity.

Gerdau Ameristeel Corporation is a large Brazilian owned multi-national business that produces steel products often used in the automotive, construction, andenergymarkets.Theyhavemorethan11,000employees in North America spread throughout their 140 locations. Gerdau contracted directly with Vanguard Modular Building Systems, LLC to pro-videthemodularbuildingfortheproject.VanguardModular coordinated closely with South East Modu-lar, which constructed the modular building, as well as Upside Innovation which delivered and installed the access systems for a successful completion. Edison Foard, a local but prominent general contractor in theCarolinas,alsoworkedcloselywithVanguardModularduringtheprojectandperformedallofthegeneralsite-workassociatedwiththeprojectandwell beyond the footprint of the modular building.

GERDAU AMERISTEEL’S TWO-STORY MODULAR SCALE HOUSEBy Vanguard Modular Building Systems, LLC

Gerdau Ameristeel’s two-story modular scale house. Photo Courtesy: Vanguard Modular Building Systems, LLC

MBI MEMBERS, DIRECTOR ELECTED AS NATIONAL COUNCIL BOARD OFFICERSBy Modular Building Institute

The National Institute of Building Science’s Off-Site Construction Council recently elected its board mem-bersandofficersfortheupcomingyear.Amongtheboard members voted in were Laurie Robert of NRB, Inc., elected as Secretary of the Council, Sue Kla-wans of Gilbane Building Company, elected as Chair of the Council, and Tom Hardiman, MBI Executive Director, elected as Vice Chair of the Council.

In 2013, MBI assisted the National Institute of Build-ing Sciences in establishing the Off-Site Construction Council (OSCC) to serve as a research, education, and outreach center for relevant and current infor-mation on off-site design and construction for com-mercial, institutional, and multifamily facilities.

The Council’s recent activities include holding a Rep-resentativeHearingonProductivityandtheWork-force. Based on oral and written testimony provid-ed by 18 representatives from a broad group of industry organizations during the hearing, the Insti-tutedevelopedaninfographictoidentifythemajorthemes that will help the industry address the pro-ductivity challenges. The main purpose of the hear-ing was to address productivity challenges, including the expansion of off-site construction techniques; development of enhanced tools and processes such as building information modeling (BIM); enhancing mid-tolong-termforecastsofworkforceneeds;and attracting new, technology-savvy entrants to the workforcethroughdevelopmentofscience,technol-ogy, engineering and mathematics (STEM) education programs.

Membership in the OSCC is open to all members of the National Institute of Building Sciences. If you arealreadyamemberoftheInstitute,youmayjointhe OSCC by emailing [email protected] with “JOIN OSCC”inthesubjectline.Non-membersmayjointhe Institute and the Council by completing the online membership application available at www.nibs.org.


MBI WELCOMES TWO NEW STAFF MEMBERSBy Modular Building Institute

Please welcome Kyle Phil-lips as our Canadian Busi-ness Development Manag-er.He’lldiligentlyworkinsupporting our Canadian member services. Kyle will travel extensively to meet

withmembers,prospects,andkeyindustrypartners to provide the professional service that MBI needs. With more than four years of experienceinmemberservice,Kyle’sskillsincustomer service and sales bring an entrepre-neurial mindset to the MBI team. He is excited tohitthegroundrunningin2016andlooksforwardtoenhancingtheCanadianmarket.

Contact information:Email:[email protected]: 888-811-3288 ext. 165

Join us in welcoming Kellie McDonnell, our Commu-nications Manager. She has more than 15 years of writing experience ranging from technical writing to journalism.Whileworking

inmarketingmanagement,Kelliegainedanunderstandingofconstruction-basedmarket-ingeffortsthroughalargearchitecturalfirmin Dallas, TX. She will play an integral part in ensuring that our members stay informed.

Contact information:Email:[email protected]: 888-811-3288 ext. 152

1514



http://vanguardmodular.com/

mailto:nibs%40nibs.org?subject=

http://www.nibs.org

mailto:kyle%40modular.org?subject=

mailto:kellie%40modular.org?subject=



FROM COTTAGE INDUSTRY TO GLOBAL SUCCESS By Paul Bonaccorsi, Intelligent Offsite

In the spring of 1995 I was fortunate enough to be presentwhenasingleeventtookplace,whichwouldturn what was a small, mainly localised industry into a dominant force in Offsite.

InterContinental Hotels Group (IHG) were on the fringe of introducing their Holiday Inn Express brand intoEuropein1995withthefirsthotelintheUK.Upon researching the fastest methods of construction theyidentifiedbathroompodsasanidealproductto use, and so mandated their use on all new build projects.Within12monthsthisactalonehadac-counted for 10,000 bathroom pods in a single year throughout Europe.

Thissingleactwasamajorstepforwardintheac-ceptance of pods as a viable alternative to tradi-tional methods of construction, and spawned a new erainturningacottageindustryintoamajorglobalindustry.Almosteverymajorhotelchainfollowedsuitin mandating bathroom pods for use on their new build developments and soon residential developers and student housing providers followed suit.

The main attraction for users of bathroom pods are they prove to be cost neutral, and are a repetitive product when used in hotels, student housing, and many forms of residential; therefore, minimizing design input and not reinventing the wheel on every project.Asacompletelyfinishedunitinternallyandfully tested before site installation, this saves the con-tractorandclientalikevaluablemanagementandorganizational time.

In many countries bathroom pods have played a majorpartinrevolutionizingtheconstructioncodesassociated with traditional methods, with many of the connections onto the pod on site now coming via side entryintothepodasopposedtofloorconnections,which are extremely prohibitive for future mainte-nance.

Bathroom pods have also encouraged the supply or vendor chain that feeds it to become more innovative to allow the manufacturers to speed up their manu-facturing processes. Simpler connections for bathtubs and more use of wall hung WC Pans are now com-mon.Modularwiringsystemsthelikeofwhicharemore commonly found on automobile production lines are now commonplace in Pod factories in Europe and Australia.Likewise,theintroductionofplumbingsys-temssuchasViega,UponorandSharkbiteallowasimplifiedwateranddrainageinstallation.Theseel-ements,combinedwithofflineproductiontechniques,have allowed the bathroom pod industry to embrace awholenewskillsetawayfromthetraditionaltradessuch as plumbers, electricians, carpenters, etc. into a specialistteamofthosewhocanmulti-taskinwhathasnowbecomeaverysimplifiedmanufacturingprocess.

It is also very refreshing that the Modular Building Institute has now embraced bathroom pods as a part of their growing membership and has now included a category in their prestigious Awards of Distinc-tion for permanent bathroom pods, won in 2015 by PivotekfortheirHealthCityCaymanIslandshospitalproject.Thishopefullywillencouragemorebathroompod manufacturers and their supply chain to become active partners in the Modular Building Institute and early indications prove that this is indeed the case.As a company we have noticed at Intelligent Offsite 8 out of 10 inquiries we receive from those wishing toentertheoffsitemarketarenowfocusedonman-ufacturing bathroom pods, and with more and more clientsandendusersutilizingthebenefitstheybring,and embracing their use, the capacity to expand this markethasmassivepotential.

Intelligent Offsite have various factsheets, brochures and cost comparisons on the bathroom pod industry and can be contacted at intelligent.offsite.com.

“FAST FORWARD THAT TO 2015 AND THE BATHROOM POD INDUSTRY HAS A VALUE OF US$2 BILLION A YEAR AND BATHROOM PODS ARE NOW FOUND ON EVERY CONTINENT. EU-ROPE BY FAR AND AWAY IS THE LARGEST PRO-

DUCER OF BATHROOM PODS WITH AN ESTI-MATED 130,000 BATHROOM PODS PRODUCED

EACH YEAR PURELY FOR CONSTRUCTION ALONE. THEY ARE ALSO USED FOR EXAMPLE IN

NEW BUILD CRUISE LINERS..”

TOP MARKETS IDENTIFIEDFOR 2016By Modular Building Institute

As part of MBI’s 5 in 5 Initiative to grow the modu-larmarket-shareto5%in5years,wehaveidentifiedthetopmarketsin2016bytotalforecasted expenditures. As afirststep,MBIdivided

North America into ten geographic regions as identifiedinour2015annualreports.Wethenlookedatthetopthreemarketsineachofthoseregions.

The multifamily and educationmarketsappearedinthetopthreemarketsforalltenregions,whileretail/commercialmarketsappearedinsixregionsand officesappearedinthetopthreemarketsintwo regions. The healthcaremarket,whileconsistent-lyinthetopfivemarketsacrosstheboard,ap-pearedinthetopthreemarketsonlyintheEasternCanadian region. As such, MBI plans to concentrate itsmarketingeffortsheavilyinthemultifamily,edu-cational,andretail/commercialmarkets,withstron-gereffortsintheofficeandhealthcaremarketsincertain regions.

This data helps to guide MBI’s PR committee in de-termining which publications to approach with stories and which events to attend. It also helps our events team determine when and where to plan modular summits and similar events. Lastly, it helps our busi-ness development committee identify potential mem-bers and partners.

Newfor2016,weareaskingourfleetowners,contractors, and associate members to help with this effort. Currently, the MBI’s Seals program provides the revenue to fund these types of outreach efforts, with the member manufacturers driving this revenue. Nothingwillchangeinthatregard,otherthanaskingthese other segments of our membership to support the 5 in 5 efforts directly.

MBI will be sending out more information about how you can help in early 2016, with more details at the annual convention. In the meantime, if you have any questions or concerns about the 5 in 5 Initiative or the Seals program, please contact MBI via email at [email protected].


TEN GEOGRAPHIC REGIONSOF NORTH AMERICA

2016 FOCUS

EDUCATION

HEALTHCARE

MULTIFAMILY

RETAIL &COMMERCIAL OFFICE

MBI plans to concentrate its

marketing efforts heavily in the multifamily,

educational, and retail/commercial

markets, with stronger efforts in the office

and healthcare markets in certain

regions.

NORTH CENTRALNORTH CENTRAL

NORTHWESTNORTHWEST

WESTERNWESTERN

SOUTH CENTRALSOUTH CENTRAL

CENTRALCENTRAL

SOUTHEASTSOUTHEAST

MID-ATLANTICMID-ATLANTIC

NORTHEASTNORTHEAST

EASTERN CANADAEASTERN CANADA

WESTERN CANADAWESTERN CANADA

1716



http://www.intelligentoffsite.com/

http://www.intelligentoffsite.com/

mailto:tom%40modular.org?subject=


GOVERNMENT AFFAIRS

A GUIDE FOR DETERMINING CODE COMPLIANCE FORRELOCATABLE BUILDINGSOverview: MBI estimates that there are approximately 500,000 code compliant relocatable buildings (RBs) currently in use in the United States. Public school systems own about 200,000 of these units, with theindustryowningandleasingabout300,000RBs.Educational,salesoffices,andconstructionsiteoffic-es are the primary uses of RBs. Definition: Relocatable Building (2015 IEBC) – a partially or completely assembled building constructed and designed to be reused multiple times and transported to different building sites.

Newly Constructed RBs: All newly constructed RBs must be constructed in accordance with the building codes that are in effect at the time of the building’s construction. These buildings are constructed off-site and many elements are concealed when the building arrives to the site (closed construction).

As such, most states (35) have a state-wide administrative program in place to determine if the building itself was constructed in accordance with all applicable codes. The terminology varies within state pro-grams with many referring to these buildings as “industrialized buildings”, or even “manufactured build-ings.” The latter term is not generally preferred as it tends to imply that these buildings are constructed to the same federal HUD code as manufactured housing products, which is not the case.

These state programs typically require manufacturers of relocatable buildings to be approved with the state agency, have a quality assurance program approved, and submit regular reports. Additionally, eachfloorplanthemanufacturerintendstobuildmustbereviewedandapprovedbythestateoralicensed third-party design professional acting on behalf of the state. These professionals are sometimes referred to as compliance assurance agencies (CAA) or third party inspection agencies (TPIA).

Once the manufacturer and plans are approved, every manufactured section or module of an industrial-izedbuildingshallbemarkedwithalabelsuppliedbytheagencyorthirdpartythatincludesthenameandaddressoftheagencyandthecertificationlabelnumber.

The relocatable building will also have a manufacturer’s data plate that is permanently attached on or adjacent to the electrical panel posted in the location as noted on the drawings, and includes information such as:

1. Occupancy group

2. Manufacturer’s name and address

3. Date of manufacture

4. Serial number of module

5. Design roof live load, design floor live load, snow load, wind and seismic design

6. Approved quality assurance agency or approved inspection agency

7. Codes, and standards of construction

8. Envelope thermal resistance values

9. Electrical service size

10. Fuel burning equipment and size

11. Special limitations if any

GOVERNMENT AFFAIRSINDUSTRY NEWS

Followingthisprocess,thebuildingisreadytobepermittedandplacedonitsfirstlocationandisconsid-ered approved or “registered” in the state. Registered buildings should be accepted in all localities as meetingtherequirementsofthecodesforthebuildingitself.Thelabelaffixedbythethirdpartyistheindicationforthelocalbuildingcodeofficialthattheunitdoesinfactcomplywithcodes.Therefore,thelocalauthoritygenerallyhasnojurisdictionover“whatisinsidethebox.”However,localrequirementsaf-fectingbuildings,suchaslocalland-useandzoning,localfirezones,sitedevelopment,buildingsetback,side and rear yard requirements, property line requirements, subdivision regulations, are within the scope ofthelocalauthorityhavingjurisdiction(AHJ).

Existing RBs: But what happens when you relocate one of these buildings?

Unique to RBs is that they are designed and constructed with the primary purpose of being relocated and used multiple times possibly at multiple locations, including in other states. The ability to be relocat-ed is where the value of the building rests, as this aspect is critical to its functionality.

Once relocated from its original permitted site, the building is now considered an “existing building” (per IBC2015,oneforwhichalegalbuildingpermithasbeenissued).Bydefinition,it’snotnewandthere-fore does not have to meet the new building codes at its subsequent locations. A very important note – existing RBs that have been placed on a subsequent location beyond their originally permitted locations ARENOTMOVEDSTRUCTURESperIBC3410.1.Itdoesnotmatterifthebuildingis“new”toajurisdic-tion,it’sanexistingbuildingasdefinedinthebuildingcode.

Prior to 2015, Chapter 34 of the IBC contained compliance information for existing buildings, which is wheretheconfusionoriginated.Chapter34oftheIBCconflictedwithChapter13oftheIEBC.Beginningwith the 2015 IBC, Chapter 34 has been removed in its entirety and replaced with a “pointer” to the International Existing Building Code or IEBC (IBC 2015 Section 101.4.7).

In Chapter 13 of the 2015 IEBC, “Relocated or Moved Buildings,” Section 1301.1 Scope states that “this chapterprovidesrequirementsforrelocatedormovedstructures,includingRBsasdefinedinChapter2.” Those requirements address various life safety issues such as the wind loads, seismic loads, and snow loads.AnyexistingRBplacedinajurisdictionmustmeettheselocalconditions.Thelocalcodeofficialcanfindthisinformationfromthemanufacturer’sdataplateaffixedtothebuilding.Asidefromthespecificsiteandzoningissues,alocalbuildingcodeofficialneedsonlytolocatethethird-partylabelandthemanufacturer’s data plate on the RB to determine compliance. If the building is missing either the label or thedataplate,thebuildingissubjecttoapprovalbythelocalcodeofficial.

Summary: RBs,unlikeHUD-codemanufacturedhousing,areconstructedinaccordancewiththesamebuilding codes as traditionally built commercial structures (typically the International Building Code). The code treats a newly constructed RB differently than an existing RB. Newly constructed (from the factory) RBsaresubjecttotheprovisionsoftheIBC,whileexistingRBs(oneforwhichalegalpermithasbeenpulled) are covered under the International Existing Building Code. Certainly the local AHJ can visually inspect the building to see if any obvious damage was caused during transport and to see if any noticeable repairs need to be made that could impact the safety of the building. AHJ’s have this authority on any buildings per IBC 116.1 UNSAFE STRUCTURES AND EQUIP-MENT.Butthissectionofthecodeappliestoallbuildingsinthejurisdiction,notjustRBs.

GOVERNMENT AFFAIRSINDUSTRY NEWS

1918



20 - MODULAR ADVANTAGE | FEB 2016 | 1Q MODULAR.ORG/MODULARADVANTAGE.ASPX

MBI NOW A PREFERRED PROVIDER OF ICC CEUS

MBI is now a Preferred Provider of continuing education units for the In-ternationalCodeCouncil,workingtoeducatecodeofficialsonthebenefitsand processes of modular construc-tion:TheICCcertificationprogram

certifiesover14,000codeofficials,inspectors,planreviewers, permit technicians, special inspectors, and students every year in over 40 national exam-ination categories.

MBI was approved for the following education courses:

• ProjectStakeholderIntegrationinOff- Site Construction: Challenges and Opportunities

• How a Leading General Contractor Utilizes Modular Construction to Deliver SuccessfulProjects

• Permanent Modular Construction: Process, Practice, Performance

For more information, contact MBI Executive Director, Tom Hardiman: [email protected].

GOVERNMENT AFFAIRS / UPCOMING EVENTS & REMINDERS

UPCOMING EVENTS

2016 World of ModularMarch 17 - 20, 2016Manchester Grand Hyatt, San Diego, California

Modular Construction SummitsDetails Coming Soon!

Offsite Construction Expo 2016 [Partner Event]September 21 - 22, 2016Walter E. Washington Convention Center, Washington, D.C.

Visit the events calendar throughout the year to stay informed of upcoming MBI events and also industry events that we have partnered in.

www.modular.org/events_calendar.aspx

INDUSTRY NEWS

REMINDERS:

As a way to promote and maintain high standards of professional service and ethical business conduct among its members and the industry, MBI requires one represen-tative from each member company to complete the MBI Code of Conduct.

Notsureifyourcompanyhastakenthecourse?Findouthere: www.modular.org/code_companies.aspx.

In 2015 MBI created two new membership catego-ries, Architects & Engineers and Owners/Developers (AECOs), to advance and grow the modular construction industry.We look forward towelcomingmoreAECOsintoMBIin2016!

Contact MBI Business Development Director, Dave Sikoratolearnmoreaboutthebenefits&resourcesMBI membership provides. Email: [email protected].

WE WANT TO HEAR FROM OUR MEMBERS!

Does your company have a new product, innovative project,recenthire,achangeinyourofficelocation,or a revamped website? Please share it with us so we canletothersintheindustryknowyourlatestnews.

Please send your stories and high resolution photos to the MBI’s communications department via email:[email protected]. Don’t miss the op-portunity to let others in the industry hear about the excitingdevelopmentsinyourcompany!

WORLDOFMODULAR.ORG

MARCH17 - 20, 2016

SAN DIEGO,CALIFORNIA

MANCHESTER GRAND HYATT HOTEL

WORLDOFMODULAR.ORG

REGISTER TO ATTEND OR EXHIBIT TODAY!

REASONS TO ATTEND:

▪ Our 33rd annual meeting

▪ The largest conference and tradeshow on modular construction anywhere

▪ International attendancefrom 20 countries

▪ Expert architect, engineer,modular, and traditional building speakers

▪ Inspiring keynote speakers

▪ Reporting on permanent modular and relocatable buildings

▪ Networking events, receptions, and a golf tournament

▪ Awards ceremony for the best modular building projects

▪ Entertainment and prizes

▪ Free mobile app and participant lists

▪ Low registration costs & discounted hotel rooms

MODULAR.ORG

20



http://www.worldofmodular.org

http://www.offsiteconstructionexpo.com

http://www.modular.org/events_calendar.aspx

http://www.modular.org/code_companies.aspx

mailto:dave%40modular.org?subject=

mailto:communications%40modular.org?subject=

http://www.worldofmodular.org


Module setting of West Campus LoftsLocation: Waco, TXBuilding Size: 51,768 Sq. Ft.Company: Hayes Modular Group, Inc.Affiliate: Clayton Manufacturing

MULTIFAMILY MARKETFrom single dormitories to complete campuses, permanent modular construction offers public, private, and char-terschoolswhatotherconstructionmethodscannot:acceleratedprojecttimelines,moreeconomicalpricing,andless disruption. Permanent, modular student housing is indistinguishable from other school buildings and can be constructedtoanyarchitecturalandcustomerspecifications.MBImembersdesignandbuildstudentdormsofalltypesandsizesusingtraditionalbuildingmaterialslikewood,steel,andconcrete.Virtuallyanysizepermanentstudent housing facility can be built, installed, and ready for occupancy, some in as little as 90 days.

MBI MEMBER CASE STUDIES

MODULAR ADVANTAGE FEB 2016 | 1Q

Kirkland Avenue Townhomes

Emerald Ridge Apartments Phase I

Passive House - Vancouver Coastal Health

West Campus Lofts

23



MBI MEMBER CASE STUDIESMULTIFAMILY MARKET

KIRKLAND AVENUE TOWNHOMES

Architectural Excellence

AvanguardprojectinWashingtonformodularconstruction,theKirklandAvenueTownhomesarethelargestpubliclyfundedaffordablehousingprojectin Washington to be built using modular construction and won the 2015 Governor’s Smart Communities Award. The 2-story townhomes provide (14) 2-bed-roomtownhomesand(4)3-bedroomflatsforlowincome families and veterans. The interior layout featuresanopenplanforkitchen,livinganddining– offering ample daylight and cross ventilation. The exterior design celebrates modular construction by featuring a split gable at the 14’ module width. The townhomes are offset 4’ to create a contemporary interpretation of the archetypal house. The buildings arenestledamongmaturetreesmakingtheprojectfeellikeithasbeentherealongtime,butthefresharchitecturaldesignclearlymarksitasanewde-velopment. The cost-conscious design incorporates a

high level of sustainable features. All stormwater is managed onsite.

Technical Innovation and Sustainability

Workingcloselywithcivilengineersandlandscapearchitects, innovative stormwater solutions were developed into attractive rain gardens and pervious paving as opposed to traditional below grade water detention vaults. These gardens serve the functional requirements of stormwater retention, while provid-ing additional landscaping at no additional cost. Specificsitestrategiesinclude:Allstormwaterisman-aged through Low Impact Development – drought tolerant plantings, porous pavements and bioret-entionswales;75%perviouspavingforwalkways;100%perviouspavingforparkinglot;allbuildingroof runoff is directed to bio-retention swales and retentiongalleriesunderthepreviousparkinglot;run-off from public roadway which was previously untreated is cleaned in the bio-retention swales and; native drought tolerant plants/no permanent irriga-tion.

Company: Champion Commercial Structures | Location: Renton, Washington | Project Size: 15,996 Square Feet | Days to Complete: 233

Cost Effectiveness

The bold but simple design is cost conscious and incorporates a high level of sustainable features, providing a home that is attractive and healthy for both residents and the planet. Nestled into a residential neighborhood, thesemodular,energy-efficienthomesareappropriatelyscaledtofitwithinthecharacteranddensityoftheneighborhood. The design was focused on creating equality for all tenants by providing similar daylighting and natural ventilation through its massing strategy. This allowed the heating and ventilation system to be simple electric cove heaters with a whole house exhaust fan–eliminating costly duct runs and expensive furnaces. The buying power of a national modular vendor allowed the client to purchase higher quality materials (which are ultimately more durable and will not require as frequent replacement) such as solid core doors, solid surface countertops,marmoleumflooringandallplywoodcabinetconstructionresultinginlong-termmaintenanceandoperations savings.


2524




PASSIVE HOUSE – VANCOUVER COASTAL HEALTH

Britco,aVancouver-basedmodularbuilder,hasdesigned,builtanddeliveredCanada’sfirstmulti-unitmodularbuilding adhering to Passive House standards. International Passive House standards are currently considered oneofthehighestlevelsofenergyefficiencyforbuildings.InorderforabuildingtobecertifiedtoPassiveHouse standards, it must pass a rigorous quality assurance process that meets a criteria that includes space heat demand, primary energy demand and pressurization testing.

“TheBellaBellaPassiveHousewasdesignedtorequireamaximumofjust600wattsofheatperunit,evenonthecoldestdayoftheyear,”saidMontePaulsen,theCertifiedPassiveHouseConsultantwhoadvisedtheproj-ectonbehalfofRedDoorEnergyDesignLtd.“Certificationtothestandardwillensurethatthesedesigncriteriawillbeachieved,andthattheresidentswillbecomfortableforyearstocome.”AlthoughPassiveHouseprojectsarefairlywell-knowninEurope,theseconceptsarequitenewtoNorthAmerica.“We’reproudtobeamongCanada’sleadersinmodularPassiveHouseprojects,”saidBritco’spresident,ObieErickson.“It’sveryexcitingthat we were able to deliver Vancouver Coastal Health Authority a building that was both cost effective and extremelyenergyefficient–andwithinatighttimeline.”ThisprojectforVancouverCoastalHealthAuthorityconsisted of six, two-story townhomes designed to house hospital employees in this remote area of BC’s Central Coast.


Each module was pre-fabricated at Britco’s Agassiz facility. The modules were approximately 32-feet long and 14-feetwide.BritcoisveryproudthattheVancouverCoastalHealthPassiveHouseisthefirstmodularbuiltPassive House in North America.

Company: Britco | Location: Bella Bella, British Columbia | Project Size: 5,376 Square Feet | Days to Complete: 107



In order to meet rigid Passive House standards, each modulespecificationincluded:

• Efficientbuildingshape–usingaratioknownasthe‘ShapeFactor’(theratioof the buildings surface area divided by its volume) the heat loss from a building envelope is minimized.

• Superinsulation – incorporation of the correct levels of insulation performance depending on the climate zone.

• Advanced windows – using triple glazed units, with two low-e coatings, argon gas fillandinsulatedframesandspacers.

• Airtightness – prevention of air infiltrationandprotectionagainstmoisture damage.

• Thermal bridge-free construction preventing an area of the building which hasasignificantlyhigherheattransferthan the surrounding materials, resulting in an overall reduction in thermal insulation of the building..

Cost Effectiveness

Withspecialtransportpermitstothedock,Britcowas able to install the trussed roof in the factory, which made the building water tight for shipping by barge, but also much more cost effective to install. The site was in a very remote area on the coast, dif-ficulttogettoanddifficulttogetsub-contractorstoworkandstayat.Modularwastheperfectsolutionminimizingtheamountofworkrequiredonsite.


2726




EMERALD RIDGE APARTMENTS PHASE I


As part of a master planned community, the family–friendly development offers spacious, high-quality studios, and 2 and 3 bedroom apartments. Each unit includes one oversized (site built) garage stall per bedroom, full bathperbedroom,patio,centralairconditioning,andcommunitycenterparkfacilities.Situatedon230acresin a quiet country location one mile from main street in Watford City, ND, the slogan of the Emerald Ridge apartmentsstatesthattheyaretheplaceto“LeaseaLifestyle.”PeoplemovetoNorthDakotaforgreatworkopportunities in oil country, but they stay for the recreation, comfort, lush rich hills and beautiful sunset views fromthebalcony,allofwhichwereamajorfactorinthedesignofthebuildings.


Developerschosemodulartechnologytobringthisprojecttomarketasquicklyaspossible,curbrisinglaborcostsintheregion,andtakeadvantageoftheincreasedcontrolmodularmanufacturingoffers.Inadditiontothesebenefits,theirchosenmanufactureralsoprovidedincreasedefficienciesinadesignrequiringfewermod-ules for the same square footage. The original design called for 54 modules per building but the design team was able to modify the module layout, allowing for the same number of apartment units to be built using only

Company: Guerdon Enterprises LLC | Location:WatfordCity,NorthDakota| Project Size: 140,000 Square Feet | Days to Complete: 299


45modulesperbuilding.Twoobviousplacestheefficiencyeffectswerefeltwereinreducedcraningcostsandareducedcostofshipping,as27fewertruckswererequiredtotransporttheproject.Thefinishedprojectfea-tures 3, 3-story buildings with 36 units in each building. Construction began in the fall of 2014. Modules were transportedtothesitethroughoutthewinter.Cranesettingoftheunitsbeganthefirstweekof2015.

Cost Effectiveness

Thereductionofmodulesperbuildingwasthebiggestcostreducingaspectofthisproject.Beyondthetypicalcostsavingsassociatedwithmodularconstruction,(i.e.,reducedcostoflabor,productionefficiencies,buyingpower,etc.)thiscost-reductioncameaboutbytransitioningfromonemodulardesigntoamoreefficientmod-ulardesign.Anexperiencedmodulardesignerinconjunctionwithafactorycapableofbuildinglarger,moreefficientmoduleswerethetwoingredientsthatmadethisefficiencypossible.


2928




WEST CAMPUS LOFTS


Thechallengewasdifficultbutnecessary.IfHayesModularGroupwantedtodevelopanew51,000sq.ft.studenthousingprojectatBaylorUniversity,ithadtodosobypreservingthehistoricalsignificanceofanadja-centMiltonScottdesignedstructure.Thechallenge:Use21stcenturybuildingtechniquesthatfocusonefficiencyand connectivity and have it properly complement a local historical masterpiece that has endured the test of time through its strength of design and the beauty of simplicity. We started by using the thought process that a modular solution is a method of construction, not a function of design. The interior was designed as a Class A Student Living project.Itincludedstainlesssteelappliances,vinylhardwoods,granitecounters,privatebathroomsandaland-scapeandpoolpackageworthyofresortliving.Resultofthechallenge?WestCampusLoftsisahighlyefficientstructure that blended in practically and gracefully with the character of the century old community.


The use of offsite modular construction greatly reduced the impact on the community that is inevitable on a constructionprojectofthismagnitude.WorkingwiththeCityofWaco,weimplementedatightlycontrolledmodular delivery process that was designed to function without burdening the community. The foundation design forthisprojectallowedforinnovativethoughtsfortheinstallationandspeedoftheMEPinfrastructure.Wewere able to install almost all infrastructures above grade in a crawl space that is typically required to be installedundergroundonslabbuiltstructures.Thisinnovativethinkinganddesignallowedforseveralweeksto

Company: Hayes Modular Group, Inc. | Affiliate: Clayton Manuf. | Location: Waco, Texas | Project Size: 51,768 Square Feet | Days to Complete: 457


be reduced off the typical foundation installation. We not only saved thousands of dollars, but we also have access to the crawlspace for future repairs and maintenance. The ventless and pressurized crawl space was also designed to allow us to create grade and drainage around our building to give the appearance of a slab on grade structure.

Cost Effectiveness

The long-term practicality of West Campus Lofts has already started to pay off for our investment. We have averyhighoccupancyratethatisbeingdrivenbythesuperiorlocation,high-endfinishes,energyefficiencyinherent to modular construction and the serenity created by the 10-inch wall systems between all living spac-es.HayesModularwasabletoworkwiththeCityofWaco’sTaxIncrementFinancingprogramthatmadethisprojectaneconomichomerun.ThisTIFprogramisdesignedtomotivatedeveloperstoimproveaneighborhoodandstrengthenthelocaltaxbase.The51,000sq.ft.structurewasissuedaCertificateofOccupancy10monthsafter the building permit was issued. This rapid speed of construction allowed Hayes Modular to collect revenue ontheprojectfor10monthsduringthe18monthinterestonlyconstructionperiod.


3130




As an industry, we often focus our attention only on thefewhighprofilevolumetricmodularprojectsinour home countries. We hang our hopes, reputations, our futures, and companies’ successes on these highly visibleendeavorsforgettingthattheseprojects’successesandpotentialfailuresareonlyareflectionofthatproject’scapabilitiesandcircumstances.Weoftenoverlooktheeverydaysuccessesofoff-siteelements being successfully implemented on many projectsacrossmanyindustriesandmanycontinentsfrom companies not in the spotlight but steadily moving our industry forward. These successes are happening using many elements from the Off-Site Continuum including intelligent materials, components, subassemblies and modules. As an off-site program managerandconsultantworkinginmanycountries,we are seeing clients incorporate more elements holistically across multiple building systems in many formsincludingsingle-tradeprefabricatedfinishedcomponents, multi-trade MEP subassemblies, struc-tural panels and systems, as well as wood, steel and concrete pods and modules.

We often forget that aside from off-site manufactur-ers, many of these elements are coming from the tra-ditional subcontracting community as they have been the trusted partners of builders and have recognized thebenefitsofprefabricationandarenowimprov-inganddiversifyingtheirofferings.Theyareflexibleand willing to participate in various execution strat-egiesincludingadjacentfactoriesset-upbybuilders,investing in their own prefabrication facilities and partnering with other trade partners for multi-trade elements. This creates less disruption to the tradition-al supply chain and many manufacturers now have to competeforprojectsusingoff-siteelementsagainsttheir traditional subcontractor counterparts. This is good for the industry as it allows for builders to experienceoff-sitewithknownpartnersandenablesoff-site manufacturers the opportunity to compete for

moreprojectsasawhole.Itcreatesalargersupplychain base for off-site elements as many subcontrac-tors, after seeing the productivity and safety bene-fits,transitiontomanufacturers.

As these elements are used more frequently, the product improvement cycle moves faster and results in improved cost, quality and the ability to customize elements.Alongwiththesebenefits,iflocalmanufac-turers aren’t improving and adapting, we are see-ing off-site elements shipped not only across larger countries but also around the world. Modules are being shipped from Europe to North America, and large elements and modules are shipped from Asia to the UK and from Asia to Australia. We are truly becoming a global industry.

As this is happening, governments are recognizing the true costs of unsafe and less productive con-structionpractices.GovernmentslikeSingaporeand the UK are giving large sums of monies to both manufacturers and developers utilizing off-site and other modern methods of construction (MMC). These countries are even changing their permitting and approval processes to enable these practices. Other monies in endowments and grants to study and quan-tifythebenefitsandbarrierstoentryforoff-siteandMMC are coming from large universities, sometimes partnering with industry, in these countries and others likeCanadaandIndia.Someevencreatingoff-siteeducationalschools,liketheBCAAcademyinSin-gapore, the Offsite School in the UK and the R&D Center recently created in India.

In the last few years, Fortune 100 companies have focused on waste reduction for their businesses including implementing lean practices and MMC into their building processes. They are recognizing the need for change in their contracting, design, procurement and construction methodologies. Large

INTERNATIONAL /ALLIANCES


THE RISE OF OFF-SITE – A GLOBAL PERSPECTIVE By Amy Marks, XSite Modular Consulting

designersworkingfortheseend users have recognized the potentialgapintheirknowl-edge and experience in using Design for Manufacturing and Assembly (DfMA) principles, and are engaging with experts tochangetheirdesignthinkingand process to enable more off-site elements requested by clients.

Asownersaskforamorecollaborative and productive process, large construction companies are responding and recognizing the need to invest in expanding their institutional knowledgebasebyworkingwith off-site consultants and program managers while others investinself-performanceofoff-siteelementssettinguptheirownfactorieslikeLang-O’RourkeandLendLease.

From within the off-site industry, I often hear the outcry that traditional construction companies need to change andrecognizeourindustrybenefitsasweseethem.However,it’snotaboutthetraditionalindustryadaptingto use more off-site, it’s about the off-site community adapting to these new opportunities and challenges and understandingthekeydriversforthesecompanies,governmentsandinitiatives.Trulyrecognizingwhateachcompany’sactualvalueistoclientsandendusers,notwhatweasanindustrythinkitshouldbe.Thosethatcanunderstand this and articulate it well will prosper, and those that cannot will cease to exist as we have seen especiallyintheUS.It’sanexcitingtimeinourindustry,wehavetojustrecognizetheopportunitiesandbecomean integral part of it.

INTERNATIONAL / ALLIANCESTHE RISE OF OFF-SITE – A GLOBAL PERSPECTIVE

ABOUT AMY MARKS

Amy Marks is the President/Owner of XSite Modular Con-sulting. XSite is a Modern Methods of Construction (MMC) consulting firm focused on enabling and optimizing the use of off-site and prefabrication in large, complex, technol-ogy-embedded buildings as an off-site program manager and factory start-up consultant. XSite has some of the larg-est global companies as their clients working on projects including high-rise, hi-tech industrial, healthcare and data

centers. Ms. Marks is an alumna of the prestigious Harvard Business School and a graduate of the University of Florida. She is an industry thought leader and a highly sought after keynote speaker for international conferences on con-struction. Recently, Amy was appointed by the Government of Singapore to a two-year position on an International Panel of Experts focused on Construction and Productivity. Amy is the founder and moderator of the Modern Methods of Construction (MMC) Group on LinkedIn and is trained in CoreClarity to deliver personal development and team dynamics workshops. She can be contacted at [email protected].

MBI HAS GREAT SPONSORSHIPOPPORTUNITIES THROUGHOUTTHE YEAR:■ MODULAR ADVANTAGE PUBLICATION■ MEMBER CONNECTION NOW (E-NEWS)■ MODUAR.ORG■ MODULAR CONSTRUCTION SUMMITS■ TOWN HALL MEETINGS■ WORLD OF MODULAR

3332



http://www.xsitemodular.com/

mailto:amy.marks%40xsitemodular.com?subject=

http://www.modular.org/documents/Media_Kit/MBI_2016MediaKit.pdf




INTERNATIONAL / ALLIANCES

KIWI PREFAB: A LOOK AT PREFABRICATION IN NEW ZEALAND By Pamela Bell,PrefabNZ

ABOUT PREFABNZ

PrefabNZ is the hub for prebuilt and innovative con-struction – a non-profit mem-ber-based organisation much

like MBI – comprised of architects, engineers, manufacturers, distributors, builders, researchers and other building professionals. Take a quick look at PrefabNZ here (www.prefabnz.com) or a closer look at the CoLab event April 6-8 in Auck-land, New Zealand (www.prefabnz.com/Events/Upcoming-Events/CoLab2016/).

LikeMBI,PrefabNZ is focused on delivering timely relevant information, education and advocacy for increaseduptakeofprefabricationoroffsitecon-struction.

PrefabNZstartedin2010andhasgrowntosup-port 4 part-time staff members, 9 hands-on board members and over 200 member organizations. For thosethatdon’tknow,NewZealandhasapopulationofalmost5million,soitisatight-knitdesignandconstructioncommunity!

In recent years, a sister organization, PrefabAUS, has been developed in Australia where the popula-tionis23million(2013).Thetwoorganizationsworktogether to improve understanding of the quality, time, cost, design, sustainability and health & safety advantages of using prebuilt components, panels, volumes, hybrid technologies, and complete build-ings.

NewZealandhasbeenhometoMaoripeopleformany centuries with Europeans settling relatively recently in the 1800s. Our prefab roots can be seen inboththebundlingof‘raupo’(bulrush)attheedgesof wetlands into wall panels by Maori, as well as English colonials bringing their homes with them from EnglandtoNewZealandaspre-cuttimberpieces.

NewZealanders,orKiwis,areknownfortheirinno-vation (as those who have seen The Lord of the Rings orTheHobbittrilogieswillattest)soitdidn’ttakelong to move from importing prebuilt dwellings to ex-porting them to the California gold rush communities in the late 1800s.

Our history of prefab mirrors other industrialized na-tions with a surge of activity post World War II and theinfluenceofnewmaterialsandtechnologiesinthe 1960s and 70s. See the image of the De Geest Construction factory started in a small rural settle-ment by a Dutch emigre – producing hundreds of houses for the hydro-power dam construction towns in the 1970s.

1974 De Geest factory. Photo Courtesy: PrefabNZ

The new millennium has witnessed a resurgence of in-terest in architect-designed offsite construction made deliverable by digital technologies such as BIM and factory-to-filemanufacture.Theseareexcitingtimesbutthereismuchmoreprogressthatcanbemade!

In 2013, the construction industry was estimated to createNZD2.95billionworthofprefabrication,mostly in the form of wall framing, roof trusses, win-dowsandjoinery.Thisisequalto25%ofthevalueofallconsentedbuildingprojectsandindicatesthemarketisalreadyrelativelysubstantial,butlimitedtoasmallnumberofcomponents(BRANZSR312,Norman+Page,2014).

Check out the infographic for a quick rundown on New Zealand’s current construction industry situation. The first infographic shows the state of play of prefab in New Zealand – almost all our new residential buildings use pre-nail timber roof trusses and wall frames. Many of our rural secondary dwellings (we have a lot of dairy and sheep farms!) and coastline holiday homes are transportable or complete prefab buildings.

We have growing interest in panelized and volumet-ric production, with several factories established in the last two years that manufacture timber-based panels, either as pre-cut custom frames using Ger-man machinery technology or as cross-laminated timber panels. Structural insulated panel use is also growing, particularly in the South Island where the colder climate reigns supreme, but these are mainly imported at this stage.

The second infographic shows the growing residential buildingshortageinourmajorcity,Auckland,duetorapidimmigration,urbanizationandinflatedhousingprices.Thegoodnewsisthattheearthquakerav-aged region of Canterbury is recovering well from the events in 2010-11.

The third infographic shows that our affordable housingissuesarelargelyinfluencedbylargelandcosts–upto50%inourmostpressuredmarketssuchasAuckland.OffsiteconstructioncanremoveNZD25,000 – 40,000 off each home. Prefabrication can reduce up to 60% of time at site through limiting weatherdamage,reducingfinancingcosts,enablingcompletion earlier and increasing client satisfaction (PrefabNZValueCase2014).

ThefourthinfographicshowsthatNewZealand’sbuilding industry is mainly made up of construction businesseswithfiveorfeweremployees–soourprefab future is in smaller distributed open-source components,andinjointventurefactory-shareenter-prises.

INTERNATIONAL / ALLIANCESKIWIPREFAB:ALOOKATPREFABRICATIONINNEWZEALAND


3534



http://www.prefabnz.com


INTERNATIONAL / ALLIANCESKIWIPREFAB:ALOOKATPREFABRICATIONINNEWZEALAND

PrefabNZworkscloselywiththebuildingresearchassociation(BRANZ)andtheMinistryforBusiness,Innovationand Employment (MBIE) to produce reports such as Levers for Prefab (available at www.prefabnz.com/About/). LeversforPrefabinvestigatedmedium-scalebuildersandidentifiedthethreeareasholdingbacktheiruptakeofoffsite were:

▪ Scale–collaboratingtoimproveconsistencyofworkflow ▪ Liability – clarifying the regulatory compliance process ▪ Show & Tell–communicatingprefabbenefitstochangeperceptions

Showing-and-tellingisastrengthofPrefabNZ.AftertheCanterburyearthquakes,wesetupthefirstHIVEHome Innovation Village to demonstrate ten different prefabricated residences side-by-side for over two years. OverthenextfewyearswewillbedevelopinganonlineinteractiveHIVEsothatinnovativeprojectscanbeexperienced online through video.

TheLeversforPrefabresearchledtoanactionplanprojectwithBRANZandMBIEthathaslookedcloselyatthe opportunity for more offsite in retirement village development and social housing – especially important with a forecasted 30,000 unit shortage by 2030. See attached Pipeline of Social and Retirement Housing re-port summary.

The continued growth of retirement villages and the high need for cost-effective social housing mean more innovativepre-packageddesignandconstructionsolutionsareneeded.PrefabNZrecentlylaunchedadesigncompetition for a UniPod, an open-source universal bathroom pod that can be made nationwide anywhere by anyone for multi-unit developments.

The winning UniPod will be announced in February 2016 and a prototype will be built for the annual CoLab eventinAuckland(April6-8).ComejoinusinNewZealandfortheCoLab–athree-dayeventwithhands-onsitevisits,presentationsonlocalandglobalinnovations,andintimateconversationswithkeynotesinaworldcafé-stylesetting.ComeadayearlierandjoinintheCoLabGlobalMeetup–aninternationalgatheringofprefabminds–allwelcome!

Pleasegetintouch–PrefabNZCEO,PamelaBell,[email protected].

TheMBIEducationalFoundationandtheMBICanadianFoundationwereestablishedspecificallyto provide educational opportunities in the form of training, research, and scholarships to indi-viduals with an interest in commercial modular construction. The foundation began in 2001 with a generous $100,000 gift from Barry & Mary Gossett. Mr. Gossett is an industry veteran, member of the MBI Hall of Fame, recipient of the MBI Outstanding Achievement Award, and esteemed friend to many modular building professionals. Since their beginning, the foundations have trained thousands of industry professionals, awarded several student scholarships, and spear-headed invaluable industry research.The foundations are registered nonprofits/charities in the US and Canada. All gifts are tax deductible. If you have any questions about MBI, the Educational Foundations, or how to donate, please contact us via email: [email protected] or call 888-811-3288.

YOU CAN HELP!Support the

scholarships witha financial gift.

mbifoundation.org

DONATENOW!

The MBI U.S. and Canadian

MODULAR CONSTRUCTIONE D U C A T I O N A L F O U N D A T I O N S

RESEARCH &INNOVATION

Verticalexpansionwasidentifiedrecently(Jellen2015)asapotentialappropriateuseformulti-storymodularconstruction in some situations, in particular for metropolitan areas. A conceptual expansion is shown in Figures 1a and 1b. Modular construction has been used by developers in the European Union (E.U.) to construct large-lysingle-storyresidentialadditions,suchastheoneshowninFigure1c.Theexpansionsareidentifiedintheliterature as “roof-top extensions.” It was suggested in an E.U. technical report (Lawson et al., 2013) that the economy of these roof-top extensions is improved by combining the extension with any required cladding (roof or wall) update or building energy performance enhancement.

Modular construction can be used to vertically expand existing buildings, adding valuable residential units. Foraverticalexpansionproject,itwasdeterminedthatmodularconstructioncanhaveadvantagesovermoresite-intensive forms of construction in some situations (Jellen and Memari 2014). Modular construction can be attractivetoanownerorcontractorinthisinstancebecauseprojectdeliverytimeandcommunity/businessdisturbancecanbesignificantlyreducedandlaborcostsavingscouldbeachievedduetooff-siteconstruction.Theseattributesoftheconstructionmethodarehelpfulwhentryingtodeliveraprojectlocatedinacongest-ed urban or remote area, maintaining an operating business simultaneous with a renovation or attempting to obtain an early return-on-investment. Light-weight cold-formed steel (CFS) or wood framed modules can also offer weight advantages over heavier forms of construction in some situations.

Verticalexpansionofanexistingbuildingcanbeadauntingengineeringtask.Thereareprocesses,deci-sions and inputs within the design process, many of which are not directly related to modular construction, that require detailed consideration. In the study reported here (Jellen 2015), the design process for a modular ver-ticalexpansionwasmappedtodeterminethosefactorsthatcouldaffectprojectfeasibility.Acasestudywasperformed on the building shown in Figure 2a to validate the mapped design process and identify those factors that are more easily recognized during engineering design.

Thefront-endpartoftheengineeringdesignprocesswasfoundtohavemanyfactorsthatcouldaffectprojectfeasibility. Analytical models of one- and two-story modular expansions using both structural wall-bearing and corner-post bearing modules were created to explore the feasibility of the design process. Finite element mod-els using thin shell elements illustrated in Figure 2b and 2c were developed to represent the general module behavior. Such modeling could be useful in developing optimized preliminary structural designs that could be collaborativelyrefinedanddetailedbyboththeengineerandthemodularmanufactureragents.Thefollowingare some of the results of the study:

“EXPANDING” THE USE OF MODULAR CONSTRUCTIONBy Anthony C. Jellen, Dawood Engineering, Enola, PA and Ali M. Memari, PennStateUniversity,UniversityPark,PA


Figure 1. (a) Existing building concept (b) Expanded building concept (c) The University of Plymouth used modular construction to add 28 roof-top study bedrooms to an existing four-story steel framed building (SCI, 2001)


3736



http://www.prefabnz.com/About/

mailto:pam%40prefabnz.com?subject=

mailto:steven%40modular.org?subject=

http://mbifoundation.org

http://modular.org/HtmlPage.aspx?name=foundation_donate


1. Existing building geometry and existing structuralconnection points are important considerations. In the case study considered, the existing roof structure had convenient tie-in locations. The 60' long trusses shown in Figure 3a and 3b were arranged at 15'-6" spacing, which were feasible modular dimensions. The simple struc-tural steel grid shown in Figure 2f was used totransfertheloadsfromtheconceptualfloorplan shown in 2d.

2. Roof-top equipment must be able to be relocatedorincorporatedintothefloorplan.Inthiscase, the modules shown in Figure 2e were envisioned to house relocated existing building equipment such as roof-top HVAC, communica-tionorfire-protectionequipment.

3. In this case, it appears that it would be possibleto detail the transfer grid such that it acts compositely with the existing roof trusses. The study showed that by engaging composite

action and removing the existing roof-top cin-derfill,theeffectsofthesingle-storymodularexpansions on the existing roof trusses were minimal. Internal load-effects and mid-span deflectionswerecomparabletothoseoftheoriginal structure.

4. As noted previously, combining an expansion witharequiredenergyorcladdingretrofitmayimproveprojectfeasibility.

5. For this case, total required square footage for a two-story expansion would be 8,580 ft2. A single-story expansion would be roughly half of this area. From discussions with sev-eralmodularmanufacturers,factorybreak-even points could be in the upward range of 20,000-50,000 ft2 for structural steel mod-ules. Wood-framed wall-bearing modules appearedlikelytohavelowerbreak-evenpoints, but the allowable height of construction

RESEARCH & INNOVATION “EXPANDING“ THE USE OF MODULAR CONSTRUCTION

Figure 2. (a) Case study building (b) Conceptual one-story expansion using shell model (c) Conceptual two-story expansion (d) Conceptual module arrangement (e) Proposed maintenance modules (f) Transfer grid

is limited due to the combustible nature. In this instance it might be possible (if acceptable to an owner) to install a wood-framed module single-story expansion if ceiling height were limited to 7'-1".

6. Due to the six-sided nature of the modules, theredundantstructuralwallandceiling/floorassembliescouldbelimitingwherefloorspaceand story-height is valuable. Preliminary IBC review for this building shows that it may be difficulttoconsiderwall-bearingmodulescon-taining any combustible structural components for a 2-story expansion with ceiling heights greater than 7'-11".Duetothehighbreak-even points, modular construction may not be an option if structural steel corner-post bear-ing modules are required.

7. The study shows that a two-story corner-post bearing modular expansion increases the demand-capacity ratio to 0.903 in some truss members and increases soil bearing pressure to greater than 4 KSF under some footings. The use of lighter wall-bearing modules would reduce soil bearing pressure.

8. The expansion must be scrutinized for compliancewith the IBC. Important aspects are:

a. Requirementsforautomaticfiresprinklers with even one-story of expansion.

b. Requirements for accessible dwelling units.

c. Requirements for access and egress to expansion. Due to accessibility regulations itislikelythatanelevatorwillberequired.Elevator shaft planning should be considered for compatibility for modular construction.

Figure 3. (a) Case study building roof plan showing truss plan (b) Image of in-service roof trusses (c) Conceptual composite transfer structure connection.



3938




Allowingforsufficientfront-endplanningtimeisimportanttoanyproject,butmoresoforprojectsinvolving higher levels of prefabricated components. There are many factors within the design process that couldaffectprojectfeasibility;therefore,ensuringthatmodularconstructionisappropriatefortheproj-ectiscritical.Poorexecutionofplanningtasks,notdirectly related to modular construction, could neg-atively offset any productivity gains obtained from the use of modular construction. The use of front-end

planning tools and appropriate preliminary design techniquescouldincreaseprojectfeasibility.Itisnotalways necessary to excessively detail the struc-ture in the preliminary design stages to extract the information necessary for front-end planning. Some-times simpler models can provide all the information required and allow time for iterative design, which ultimately could lead to better design and improved projectdelivery.


REFERENCES

Lawson,R.M.,Badoo,N.R.,Vannier,G.,Doering,B.,Kuhnhenne,M.,Nieminen,J.,…Kozlowski,A.(2013). Renovation of Buildings Using Steel Technologies (Robust) (No. Eur 25335 en). European Commission.

SCI. (2001). Value Benefits of Modular Construction in Building Extensions(No.P284).SilverwoodPark: The Steel Construction Institute (SCI).

Jellen, Anthony C. (2015). “Vertical Expansion of Existing Buildings Using Multi-Modular Construction Methods.” MasterofScienceThesis,PennStateUniversity,UniversityPark,PA.

Jellen, A. C. and Memari, A. M., (2014). “Residential Vertical Expansion of Existing Commercial Buildings Using Modular Construction Methods,” Proceedings of the 2nd Residential Building Design and Construction Conference, PennStateUniversity,UniversityPark,PA,February19-20,2014,pp.216-229.

FAST FORWARD ►►In the next issue of Modular Advantage:

“And the Winners Are . . .” Annually, in the second issue of Modular Advantage, the Modular Building Institute honorswinnersofitsAwardsofDistinctionContest.Modularbuildingsin20+categoriesarejudgedinthear-easofarchitecturalexcellence,technicalinnovation,costeffectiveness/energyefficiency,aswellastotaldaystocomplete.Inournextissue,we’llfeaturepageafterpageofinteriorandexteriorphotographs,floorplans,and building details of temporary, permanent, renovated, and green modular buildings. Plus the winners in the “multimedia” category will also be recognized.

The second issue of Modular Advantage willalsofeaturemodularcasestudiesfromtheeducationmarketanda hefty MBI member directory/buyer’s guide section. It will be an issue that you don’t want to miss!

The Offsite Construction Expo will feature exhibits from offsite construction contractors, traditional contractors that have integrated offsite methods, offsite factories, transportation companies, architects, engineers, BIM suppliers, materials suppliers, and offsite construction consultants. Educational case studies will be presented each hour on the expo floor.

Offsite systems and processes are ideal for the following markets:

▪ Healthcare

▪ Multi-family/Commercial Housing

▪ Publicly funded projects: schools, barracks, medical clinics, administrative buildings

▪ Quick service restaurants/franchisees

Event brought to you by

EXHIBITS NETWORKING EDUCATION

$99* FOR QUALIFIED ATTENDEES!*Visit offsiteconstructionexpo.com for details.

SEPTEMBER 21 & 22Walter E. Washington Convention Center in Washington, D.C.

DISCOVER

What is Offsite Construction Expo?

OFFSITE

REGISTER TO ATTEND or EXHIBIT NOW!www.offsiteconstructionexpo.comContact us at [email protected] or call 434-202-8180.

REACH KEY PARTNERS IN THE OFFSITE CONSTRUCTION INDUSTRY

93% of respondents implemented some form of offsite constructionin the 2014.93%

Results based on survey conducted by the National Institute of Building Science’s Offsite Construction Council.

EXHIBITS FROM:

▪ Offsite construction contractors▪ Traditional contractors that have integrated offsite methods▪ Offsite factories▪ Transportation companies▪ Architects▪ Engineers▪ BIM suppliers▪ Materials suppliers▪ Consultants of all types of offsite construction processes

4140




INTERESTED IN ADVERTISING?

A printed copy of the publication is mailed to all MBI members, while the digital version is emailed though Building Design + Con-struction Magazine (BD+C) to more than 40,000 architects, engi-neers, developers and general contractors. Don’t miss your chance to advertise in the next Modular Advantage. If interested in adver-tising,contactourBusinessDevelopmentDirector,[email protected].

For editoral details, ad specs and rates, visitmodular.org/modularadvantage.aspxand download MBI’s 2016 Media Kit.

ADVERTISER INDEX

ADVERTISER WEBSITE PAGE

Bard Manufacturing Company www.bardhvac.com 4

Contact: 419-636-1194

Offsite Construction Expo www.offsiteconstructionexpo.com 41

Contact: 434-202-8180 or [email protected]

Modular Building Institute www.modular.org Insideback

Contact: 888-811-3288 or [email protected]

Mule-Hide Products Co., Inc. www.mulehide.com Backcover

Contact: 800-786-1492

MBI STAFFExecutive DirectorTom [email protected]

Operations DirectorSteven [email protected]

Business Development [email protected]

Canadian Business Development ManagerKyle Phillips [email protected]

Graphic Design ManagerChandl’ [email protected]

Communications ManagerKellie [email protected]

Member Services/Event CoordinatorSharon [email protected]

BookkeeperSuzi [email protected]

General Inquiries:[email protected]

www.modular.org

ADVERTISER INDEX& MBI STAFF

MODULAR ADVANTAGE FEB 2016 | 1Q COMMERCIAL MODULAR CONSTRUCTION IS THE

PAST, PRESENT, AND FUTURE.

CHANGING THE WAY THE WORLD BUILDS. GREENER. FASTER. SMARTER.

The Modular Building Institute works to expand the demand for commercial modular buildings, provide the industry with a single voice, and altogether make things happen for our members. MBI manufacturers, dealers, and associates are professional, experienced, subscribe to a code of ethics, employ established practices, and study new methods. Contact us to-day to find out how you can become a member and take advantage of an industry united. It’s all about how things come together.

To locate a member in your area, call us toll-free at 888-811-3288, visit us online at www.modular.org or email us at [email protected].

TM

42







mailto:info%40hardimanwilliams.com?subject=



http://www.mulehide.com


mailto:steven%40modular.org?subject=


mailto:kyle%40modular.org?subject=

mailto:chandl%40modular.org?subject=

mailto:kellie%40modular.org?subject=

mailto:sharon%40modular.org?subject=

mailto:suzi%40modular.org?subject=




Acrylic Water Base Bonding AdhesiveExcellent for fully adhered EPDM systems with its single-side wet application.

Walkable PVC MembraneWaterproof, durable, high UV and saltwater resistant systems.

Roof Deck Panel Save time and labor with this industry exclusive, easy to install fire-resistant deck panel (Class C or A).

exactlywhat you need.

(800) 786-1492 | www.mulehide.com | [email protected]

Self-Bridging Mate-LineTM This pre-taped product offers consistent thickness and provides for fast installation or dismantles.

Elastomeric Acrylic Coatings Metal Roof Coating System and EPDM Restoration SystemTM both extend a roof’s life.

Just-in-time and custom cut, the Mule-Hide nationwide distribution network offers ready to install new or retrofit single-ply modular roofing systems that are exactly what you need.

• Custom cut EPDM (Black or White-On-Black), TPO and Pre-fabricated PVC membranes keeps factory lines moving

• Fast installation products designed for in-plant manufacturing or retrofit bay reroofing

• Crew retention with easy to learn, low VOC applications

• Available through the nation’s largest distribution channel

• Membranes custom cut locally and delivered with expert handling

• Code compliant assemblies available

44

http://www.mulehide.com/

multifamily market on the rise - modular construction · construction schedule at his latest...

Documents