MODULAR VOLUMETRICCONSTRUCTION

June 2009

The purpose of this document is to review the feasibility of using modular construction techniques for hotel, housing and worker accommodation developments.

We have highlighted the advantages and disadvantages of a modular method of construction. We believe that a volumetric modular construction has the potential to be one of the key solutions to rapidly construct hotel, housing and worker accommodation developments.

One big advantage is that the developer can be given a clear fixed construction budget for the majority of the building due to the modular factory process.

Other advantages are speed of construction, environmental impact and quality control.

Executive summary

Modular Construction - what is it?

• Factory production of a fitted out room.

• Pre-engineered building units.

• Delivered to site as modular units and assembled on site to form a building.

• It may comprise highly serviced rooms such as plant, bathrooms or kitchens or bedrooms, lounges, stairwells.

• It is a self supporting structure

Benefits include:

• Short construction time/programme• High early return on capital investment• Significant cash flow advantages over

traditional build• Reduced need for skilled workforce on

site• Less waste• High quality control• Reliable delivery timescale• Price certainty• Sustainable - can be relocated or recycled• Light weight gives foundation savings

Modular Construction - why use it?

Modular construction - when to use it?

• Short programming required

• Repetitive building type

• Skill shortage on site

• Certainty of delivery

• High quality

• Future relocation

• Weather conditions have limited effect

• Security issues

• Price certainty

Architectural aspects

• Rectangular or A high degree of repetition is required

• High quality factory finished rooms

• Fully serviced rooms "ready to plug in" via risers and corridor distribution routes

• 90 minutes fire rating available with double boards

• Outstanding sound attenuation• Low rise or high rise projects• Thermal insulation easily

upgraded• Maximum standard room width is

variable• Cladding choices• Variety of building shapes -

usually rectilinear but could be jutted out or with balconies

• Roofing – Variety of methods and products

• Rooms must have repetition and preferably be rectangular

• For transportation, room sizes are flexible

• Rooms wider than 5m may need to be subdivided into smaller width units

• Modules are lifted into place via a 4 or 6 point lifting frame

• Sequence of design, fit out and delivery to site to suit installation sequence to avoid double handling.

Logistical requirements

• Hot dip galvanised coated G275 g/m² steel

• Minimum 100 year design life expected for most buildings

• A design life over 200 years can be achieved with additional insulation

• In all cases normal building maintenance is required to fabric and cladding

Durability and design life of Modular units

Acoustic performance

This Modular building system can be super insulated with higher than usual building regulation requirements for both thermal and acoustic insulation.

In addition to this, the system incorporates a method of separating each individual module acoustically which means that noise cannot be transmitted easily through the structure.

The benefits of using the modular system for overseas construction

• The ability to “template” all designs and specifications for generic types of buildings

• Fast-track set-up and operation of assembly plants.

• Consistency of quality and build

• Cost benefits of design and specification consistency

• Reduction in design cost

• Plants can be utilised for other purposes

• Following the building design freeze the modules are fabricated in jigs made from galvanised LGS cages

• They have a design life in excess of 100 years

Module fabrication

• Following delivery of the modules to the fit-out plant assembly is commenced

• The modules are

fitted out in accordance with the building system standard processes

• Kitchens and bathrooms are installed along with plumbing and electrical systems

• Doors, windows and flooring are also installed to client’s requirements

Module fit out

Module fit out

• Following assembly, the modules are delivered to site

• Modules are lifted into position and connected together

• All modules are waterproof and weatherproof immediately

• System design satisfies Building Regulations progressive collapse requirements

Module placement

Once installed, the modules are plugged and plumbed in

Module services connection

Following placement of the modules:

• The cladding and roofing go on simultaneously

• Cladding could also be fitted in the factory reducing on site programme.

• Balconies can be fitted • External works are completed• Services are commissioned

Module cladding and roofing

Modular construction - summary

Volumetric systems

• Standard size units • Load bearing three dimensional frames• Prefabricated and fitted out under factory conditions• Each module self-contained• Ideal for re-locatable applications• Identical units, e.g. Villas, apartment units or hotel rooms• Room sized units may serve as main structural components of an

entire building

Modular construction - summary

Light gauge steel frames provide:

• Inherent rigidity• Can be built to strict tolerances• Advantages over timber frame systems• Dimensional stability• Durability • Modular systems are super-insulated• Walls and floors typically give 53dB reduction for sound• Typical u-values achieved for external walls are 0.21 W/m2k

Building type: Modular student accommodation

Located in the heart of Nottingham, this modular project consists of a 6-storey, 300 bedroom, student accommodation building, and the smaller 70 flats 4-storey Belgrave Suite..

Chaucer Street

Student accommodationLocated on the tight site in central Manchester is the 600 bedroom a hall of residence for the Royal Northern College of Music, comprising single and double bedrooms with en-suite bathrooms and kitchens for each flat and common rooms.

The nine-storey block was totally prefabricated off-site using the light gauge modular system.

Royal Northern College of Music, Manchester

This site was extremely confined, with the proposed construction filling the entire 12m wide by 100m long

North Pole Road, London

North Pole Road, London - key worker housing

This site lies directly between a mainline railway and a busy road and thus required high levels of sound insulation, this was easily provided with the modular framing solution. Offering very good acoustic performance both against external noise and also the transmittal of sound between units internally.

Rodney Road, Twickenham - social & private housing

Rodney Road, Twickenham - social & private housing

Rodney Road, Twickenham - social & private housing

RNCM, Manchester

Wilmslow, Manchester

Wilmslow, Manchester

South Chase, Harlow - social & private housing

South Chase, Harlow - social & private housing

Traditionally clad to resembles traditional housing

Modular & Volumetric LtdImage House72 Madison AveBirmingham, B36 8EQ, UK.Tel: 0044 (0) 7753 675716philwdm@aol.com