Faster, Smarter, More Cost-Effective
A quick look around the internet confirms that modular construction is a growing topic in all areas of the building industry.
But what does ‘modular’ mean?
OK, you could say that a single brick is a building ‘module’.
Though we’re talking about modules that are a bit bigger. In fact the only constraint on the size of a ‘module’ is the ability to transport it safely between the manufacturer and the construction site.
Many are the size of containers, with interior features already built in. They are put together in a factory, then taken to the site and slotted together.
You can imagine this is a quick way to assemble a building, and indeed, speed is one of the acknowledged benefits of modular construction. The individual pieces can be built at the same time as the site preparations and foundations are put in place.
The modules can be delivered once the site is ready, and swiftly put together, saving up to 50% of the time normally required.
When Did Modular Building Start?
The roots of modular construction stretch back centuries, and it has evolved hugely, with advancements in materials, manufacturing techniques, and changing societal needs.
Modular building, or prefabrication, dates back to the 17th century, which takes a good number of people by surprise.
Prefabrication—assembling parts of a structure off-site for on-site installation—was a solution to the challenges of transporting materials and labour. One of the earliest examples was the Portland Prefab Cottage, which was shipped from England to Australia in 1837 to meet the demands of a growing population during colonisation.
In the United States, prefabricated homes became popular during the 19th and 20th centuries. Companies like Sears Roebuck & Co. sold ‘kit homes’ that could be delivered and assembled by buyers themselves. The homes offered affordability and convenience to people who might otherwise struggle to buy a house.
Post-War Era: Prefab’s Expansion
Following World War II, modular construction became a vital part of rebuilding efforts in the UK. Prefabricated housing, or ‘prefabs’ provided a quick, cost-effective solution to the housing crisis caused by the extensive bombing of London.
Thousands were left homeless during the Blitz, and the government needed to find a quick solution to putting a roof back over the heads of families across the city. However, while functional, these structures often faced criticism for their lack of aesthetic appeal – they weren’t pretty. Somehow we suspect this criticism wasn’t coming from the people who lived in them, grateful for a home after losing theirs to bombs and fires.
Their durability was questioned too, with critics questioning how long would they be fit for use.
Their doubts were unfounded, with 16 prefabs in Moseley, Birmingham being listed at Grade II in 1995, and six surviving prefabs at the Excalibur Estate, Catford, in the London borough of Lewisham, following suit in 2009.
Many authorities looked to demolish the prefabs after the housing stock began to recover, but they were faced with vociferous opposition. Basic and unattractive as they might have been, they had become loved homes to the people who lived in them, and they weren’t keen to move. Instead they fought to keep their prefab houses intact.
Concerns around the use of lead-based paint and asbestos needed to be addressed, as both can pose serious health risks. These materials did tarnish the reputation of this form of construction for a while. There was still a great deal going for these structures that were only supposed to last a decade.
There are those who believe prefabs could be part of the solution to our housing crisis, but does the political will to make it happen exist?
And Now? A Modern Revival
Interest in modular construction has reignited in the 21st century. Advances in technology, materials and design principles mean the old objections can be overcome. Today, it encompasses not only housing but offices, hospitals, hotels, and schools.
What advances do we mean?
First we have more high-performance materials, such as:
- Engineered wood products like cross-laminated timber (CLT). These are lightweight, strong, and sustainable.
- Advanced composites and lightweight steel. Delivers improved durability and reduces environmental impact.
- Improved insulation and energy-efficient glazing. Smart and improved glass enhances comfort and sustainability.
Then precision manufacturing steps up.
Factories now use computer-aided design (CAD) and robotics to fabricate components with extreme precision. This ensures that parts fit together seamlessly, creating solid, weather-proof structures. It also minimises waste during the manufacture.
Emerging technologies like 3D concrete printing are becoming viable. It allows for the creation of modular components in complex shapes, opening up a wealth of design possibilities.
What are the advantages of Modular Construction?
Speed as an advantage we’ve mentioned already. It’s very definitely one of the major benefits. Modular construction can reduce project timelines by 30% to 50% compared to traditional methods. Manufacturing and on-site preparation work occur simultaneously, streamlining the process.
Cost-effectiveness is another big factor. Labour costs are reduced by factory-controlled production, and material waste is cut to a minimum. With faster build times come fewer overhead costs. A well-organised and run project can lead to substantial savings.
Sustainability is a constant topic in the industry, and modular construction can make a contribution to this. As previously mentioned, precision manufacturing minimises waste, and many modular companies prioritise sustainable materials and energy-efficient designs.
Quality control is made simpler as factory settings enable stricter measures and monitoring. The result is consistent and durable outputs, which is great for the site managers as the modules then fit together cleanly and can be swiftly assembled.
Flexibility is something modular units are fabulous for. They can be designed for disassembly and relocation, making them adaptable for changing needs. This is especially useful for public buildings such as schools and hospitals. New circumstances can change what is needed from the space and modular structures can be expanded or reconfigured with minimal effort.
Reduced disruption is a big benefit for people living and working close to a project site. Construction using modular units allows for a controlled environment. This significantly reduces noise, pollution, and disturbance and makes us a much better neighbour.
So are there disadvantages?
There are a number of disadvantages that arise from modular construction.
Upfront costs – while overall project costs may be lower, the initial investment in factory setup and transportation can be significant.
Design limitations really only apply to the maximum size of the modules. Dimensions are constrained by transportation regulations – they need to fit on the back of a lorry, and not cause too much disruption to traffic during transportation.
Perception – there is some amount of misunderstanding and prejudice around the idea of modular building. Stakeholders may still associate them with the lower-quality structures of the past, creating resistance to adoption.
Logistics can be an issue. Transporting large modules requires careful planning and can incur additional costs.
Material constraints crop up when certain modular designs rely heavily on specific materials. This can give rise to the threat of supply chain disruptions.
The Future of Modular Construction
The future of modular construction is poised to be bright. Advancements are allowing us to overcome limitations, and are constantly opening up new possibilities.
For example:
Smart modules which incorporate the Internet of Things (IoT) devices are a coming development. Future modular buildings could feature smart systems for lighting, HVAC, and security.
Greater Sustainability – advances in biodegradable materials and carbon-negative manufacturing could make modular construction even more eco-friendly.
Fully automated factories, equipped with advanced robotics and AI, could produce modules with minimal human intervention, further reducing costs and eliminating errors.
Hybrid modular designs can combine modular methods with traditional techniques. This could create bespoke buildings that leverage the best of both worlds.
Mars and beyond – could modular construction reach for the stars? Space agencies like NASA and private companies like SpaceX are exploring modular construction for building habitats on Mars and the Moon. Versatility will be critical to them, and surely they will advance the engineering further to the benefit of those of us remaining on Earth.
Looking to the future
Modular construction has come a long way from its humble beginnings. It has evolved into a sophisticated and sustainable solution for modern building challenges. While it’s not without its drawbacks, the benefits—speed, cost-effectiveness, and adaptability—make it an attractive option for commercial projects.
As technology continues to advance, the possibilities for modular construction are endless.
By embracing modular techniques, the industry can build faster, smarter, and more cost-effectively, paving the way for a more sustainable and innovative future in construction. Whether you’re planning a retail space, healthcare facility, or office building, modular construction offers the tools to bring your vision to life with efficiency and style.
Contact BHR Commercial Construction Ltd to discuss any projects you have coming up – especially if you’re looking for a reliable, trustworthy construction partner.
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