National Housing & Rehabilitation Association Spring ...€¦ · International Station Modular...

National Housing & Rehabilitation Association

Spring Developers ForumMay 6‐7, 2019 Marina del Rey, CA

Multifamily Hospitality CommercialMixed Use RestaurantRetail Parking IndustrialLandscape

For over four decades, using collaboration as our guiding force, Architects Orange (AO) has evolved into a successful

full‐service, integrated practice. Comprised of nine specialized studios with over 290 professionals and 9 Partners, AO

provides the multidisciplinary benefits of a large architectural company while retaining the accessibility of a boutique firm.

Multifamily Mixed Use Hospitality

Architects Orange

NH&RA Spring Developers Forum


Modular ConstructionWhat is Modular Construction?

484 du I 3.9 ac I 124.1 du/ac

Under Construction


International Station Modular Senior Affordable Project I Oakland, CA

Prototype Modular Project

633 du I 3.9 ac I 162.3 du/ac


El Cerrito, CA

On The Boards Modular Project

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NH&RA Spring Developers ForumMixed Use Modular with Charter School

On The Boards Mixed-Use Modular Project


General Design ConsiderationsThe process is very disciplined. If you are committed to modular you need to be all in. It can’t be half field built and half factory built.

Limitations on width and height that can be transported.

Double walls and floor / ceilings need to be accounted for. The building will be taller than a standard stick built building.

Utilities run through corridors.

Plan for variations in tolerances from the setting process.

Modules can cantilever over lower levels to add variety to the building facades.Revit is the preferred software to assist the factory in their shop drawings.

• Modular Design requires a disciplined approach.

• Grid Alignment is important for project efficiency.

• From a site planning standpoint pre‐planning crane logistics are important as it can dramatically affect the site layout.

Full length module includes corridor


Design Parameters

Short modules can be combined with other short modules of the same width for Optimization (Sawbox)

Cut‐away area of Sawbox

• Modular Height:• Overall module height: 12’‐4”• Ceiling Assembly is typically 12”• Floor Assembly is typically 12”

• Modular Length: Less than 72’‐0”

• Modular Width: • 11’‐6” min.• 14’‐10” max. recommended *

Sawbox section used elsewhere

• Use Sawboxes for shorter modules


Design Parameters

Typical Modular UnitsFactory Built

Utilityconnectionswithin corridorsSite Installation


Up to 4 Stories: Type V Construction I 5-stories: Type III Construction

Typical Modular Units

ExteriorSkinBalconiesAwningsSite Installation

Utilityconnectionswithin corridorsSite Installation


Up to 4 Stories: Type V Construction I 5-stories: Type III Construction

Factory Built

Typical Modular Units

RoofSite InstallationUtility

connectionswithin corridorsSite Installation

ExteriorSkinBalconiesAwningsSite Installation


Up to 4 Stories: Type V Construction I 5-stories: Type III Construction“Stitching” the modules together

Factory Built


Working with the modular manufacturer to define scope and achieve the design vision.

Factory built bathroom pods.

Standardized bathroom layouts.

Width less than 7’‐10” overall for shipping.

Plumbing stacks are pre‐installed in the void space between the pod and the corridor wall.


Modular Bathrooms

• Modular Elevators are factory, built self contained assemblies. The fire‐rated shaft contains the elevator cab, rails, and drive system. They are fully wired and ready for final hookup, testing and adjusting.

• The elevator and shaft assembly arrives on‐site and is craned into place. With power connected, the elevator will be fully functional and ready for inspection in less than one week.

• Modular elevators replace temporary construction elevators.


Modular Elevators


Work begins at the factory…


Process

Walls and Roof / Ceiling Utility Installation


Roofing and Parapets Tapered Insulation and Tie Backs

Process

Grading and Excavation


Demolition

Field Installation

Foundations and anchor bolts for major steel


Foundation, stem walls and below grade utilities for the Modules

Process


Logistics on Modules, Transportation and Storage

Field Installation

Stacking begins


Stacking continues Scaffolding starts for the exterior finishes

Field Installation


Lessons LearnedArchitectural:

Again… Discipline is important.

There is a tolerance to stacking modules. For this, pay close attention to mate lines and tolerances for stacking. Things won’t always align perfectly.

Review clearly with the local and state agencies and the inspection team so they understand modular, and what is in their perview/ scope.

Engage all consultants early. vertical construction starts early in the factory and information is needed earlier than in standard stack built construction.

Use the same architect and engineers for site built portion and factory portion of work, for state permit sets and local permit sets.


Lessons Learned

General Contractor:Coordinate closely between the field GC and the factory, and ensure all scope is covered by one of themThe stacking sequence has to be determined early with GC, Factory and Structural input, or it affects the structural engineeringLine up a staging yard early for module staging.Ensure the building is watertight at all times. The modules are finished and susceptible to damage right from the start.All shop drawings are needed early, including sprinkler drawings, elevator drawings, façade maintenance, Mechanical, etc.


Lessons Learned

OwnerOrder FF & E early, so it is ready for model modular review and can be shipped with modules.Ensure the developer and property management team sign off on the design before factory production starts. Changes after this point are expensive and hard to implement.Engage the Interior Designer early. Interior coordination with the factory must start early and be comprehensive.Ensure financing is on board early and is familiar with the modular approach and the schedule.

Note: Leasing office cabinets were not ready for factory installation


Benefits of Modular ConstructionQuality Control in the Factory

Speed of construction / speed to market – site work and lower levels are constructed simultaneously, with upper levels, not sequentially

Budget Certainty – costs are known and agreed to up front.

Reduced risk – weather, labor shortages, safe working conditions, reduced on site labor,

Reduced construction impact on neighbors and adjacent residents.

It’s a smart approach to construction.


RC Alley

Partner, Architects Orange

[email protected]

714.639.9860

National Housing & Rehabilitation Association Spring ...€¦ · International Station Modular...

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