Exploding The Myths Of Modular Construction. Find out the facts in this myth-busting report

Transcription

1 The Myths of modular Construction_Layout 1 08/08/ :06 Page 1 Exploding The Myths Of Modular Construction Find out the facts in this myth-busting report

2 Contents Introduction Myth 1 Modular means temporary Myth 2 Modular is all about ugly, grey boxes Myth 3 Modular construction is completely inflexible and restrictive in design Myth 4 Modular buildings have bouncy floors Myth 5 Modular is a cheap solution Myth 6 Modular means sub-standard accommodation Myth 7 Modular buildings are cold in winter and overheat in summer 2

3 1. Introduction Modular construction has changed radically over the past 60 years so it can be difficult to tell just what is fact or fiction when it comes to assessing the approach and whether it is suitable for your accommodation needs. Add to that the diversity of suppliers from sellers of low value second hand cabins to manufacturers of multi-storey purpose-designed landmark buildings and the ingrained perception issues that stem from the draughty, leaking prefabricated classrooms that were supposed to be temporary but had to be endured by schools across the country for too many years. It is easy to understand why the picture can be confusing. This report looks at the most common myths about modular buildings to help specifiers, contractors and occupiers separate the misconceptions from the facts. 3 Return to index

4 Myth 1 Modular means temporary It is completely correct to say that modular buildings can provide interim solutions but you may not be aware that if the interim accommodation is supplied from a leading manufacturer, it will actually be constructed to permanent building standards. But steel-framed modular construction also provides permanent facilities, as it has been doing for decades from superstores for leading food retailers to active nuclear laboratories, headquarters office schemes, airport buildings, health centres and hospital facilities, and self-contained classroom blocks through to complete purpose-designed schools. The applications are limitless and you will often never even know a building had been manufactured in a factory! You are Just Changing the Process The Building Materials Remain the Same! The reality is that you are just changing the process the building materials, such as the structural steel frame, remain the same but construction takes place off site in a more controlled factory environment. Think production rather than construction. This actually means better quality because the process is not subject to poor weather which can cause serious quality issues postcompletion, as well as a greater risk of delays and budget overruns. Modular buildings use the same materials as site-based construction you are just moving the process into a controlled factory environment And did you know that the very best modular building systems now have BBA approval for a design life of 100 years? That really is a permanent building! 4 Return to index

5 Do Modular Buildings Meet Building Regulations and Other Standards? Fact modular schemes generally have to meet the same Building Regulations requirements and standards as facilities constructed using site-based building methods. In fact, compliance can actually be easier with off-site construction. It is also hugely beneficial if your modular supplier has Local Authority Building Control (LABC) approval already in place. This is a fast-track route through the regulatory procedures for standardised buildings, modular buildings or building systems. All local authorities in England and Wales are members of LABC and this approval gives you firm assurance that the system meets rigorous, repeatable standards. If a project is a health scheme, the building should also be designed to meet the latest healthcare standards, which include: HTMs (Health Technical Memoranda) HBNs (Health Building Notes) SHTM (Scottish Health Technical Memoranda) HAI-SCRIBE (Healthcare Associated Infection System for Controlling Risk in the Built Environment) A paediatric unit built to permanent standards and in line with NHS requirements on a constrained site at Colchester Hospital Choosing a modular approach means you can have even greater peace of mind if there are structural warranties and independent certifications in place. Here are some to look out for: CE Marking to demonstrate that the system meets Europe-wide structural guidelines 30-year structural warranty for the load-bearing elements of the building 5-year product warranty for the external building fabric LPCB certification for fire assurance OHSAS for health and safety management ISO 9001 for quality assurance ISO the international standard for minimising impact on the environment Zurich supplier approval the biggest insurer in the education sector Government Procurement Service approval CHAS Contractors Health and Safety Assessment Scheme BBA approval for the design life of the building system. 5 Return to index

6 The Facts Permanent modular buildings are all around us and you will often never be able to tell the difference Modular buildings for permanent use need to comply with Building Regulations requirements Constructing a building off site actually means better quality and less risk of late completion and unforeseen costs A new school building at Martin High School build off site by Yorkon 6 Return to index

7 Hints and Tips: The best modular buildings win awards for design and architecture yes really! Make sure your modular building supplier fully complies with all relevant regulations and standards Check that your building system has BBA certification for a design life of 100 years When choosing a modular building specialist, consider what independent approvals and warranties are in place to give you even greater peace of mind about the quality of the system The final modules are craned into position at North Middlesex University Hospital. The project to construct a Women and Children s Centre is the UK s largest healthcare project to be built off site. 7 Return to index

8 Myth 2 Modular is all about ugly, grey boxes It is quite correct to say that the individual modules look like grey boxes but these units form the structure of the building and can easily be clad or combined with full height glazing and a pitched roof for a completely different appearance... if that is what you need! A steel or concrete frame that is assembled on site isn t attractive either but that shouldn t put you off the approach, and modular construction is no different. It is about finding a construction method that best suits your building requirements it may be more important to choose a modular solution because the programme time can be halved or because there is no access to your site for the plant and equipment needed for site-based building methods. A modular building under construction and the finished building. Proof that you would never know this is a modular building! 8 Return to index

9 Combine the Best Modular Solution with Great Design to get Exactly What You Want It is really important to combine the best modular building system with great design if that is what you are looking for. You may have a need for a more functional building if the facility is to be located on an industrial site; a landmark building to make a design statement on a prominent site, or a building that will blend in with the surrounding architecture. All of these projects can be successfully delivered using an off-site building solution and a reputable modular manufacturer will be able to offer a design service and should be willing to work with your own project architect if you prefer. And if you think it would still feel like you would be working in a grey box a good modular building system will create unrestricted internal spans of up to 12m and buildings up to six storeys high. This gives you the freedom to create an environment that is comfortable, welcoming, productive, and that facilitates space planning for your organisation. The Facts: You can create award-winning architecture using modular construction Technological advancements in modular construction have responded to architects calls for even more design flexibility to suit almost any building footprint and using a vast range of module lengths up to 18.75m and variable heights and widths You can create clear internal spans of up to 12m and multi-storey buildings Hints and Tips: Your modular supplier should be sufficiently flexible to provide a design service or to work closely with your own design team to deliver your precise brief You can combine the best modular building system with high quality design and effective space planning to get exactly what you need A multi-award winning school building in the Brecon Beacons National Park built using modular construction 9 Return to index

10 Myth 3 Modular construction is completely inflexible and restrictive in design and aesthetics One of the biggest criticisms of modular construction is that these building systems lack flexibility, particularly in terms of design and appearance. This is simply not the case and you may even be surprised by just what s possible! Restrictive layouts have been replaced by inspirational and stimulating architecture with complete flexibility in design and use. A technically advanced modular solution can easily deliver more architectural and bespoke buildings with a much greater degree of design freedom. This means an off-site building system can realise architects design aspirations and create landmark buildings or buildings that complement existing architecture. Traditionally-constructed Buildings can Easily be Extended with a Modular Building Specifiers may not be aware that a traditionally-constructed building can easily be extended with roof-top modular accommodation, in completely enclosed courtyards, and on raised platforms a particularly useful benefit for city centre projects or highly constrained sites such as hospitals. And a wider range of module height options will facilitate the linking of new modular accommodation to existing buildings. And the system can be fully future-proof to meet an organisation s changing needs. The space in all new buildings should be designed to allow for different uses, and in the public sector, the future needs of the local community or demographic changes. Non-load bearing partitions and clear unrestricted internal spans of up to 12m allow modular buildings to be completely reconfigured if required. A modular building with a full height atrium outstanding design for a visionary client Modular Schemes can be Expanded without Decanting A new office building installed on to the roof of an existing building at Harrogate District Hospital Modular buildings can be expanded vertically or horizontally, without the need for decanting, and installation can be timed to take place at the quietest periods such as weekends or during holiday periods. You can also increase or reduce the floor area very quickly in line with local needs and revised capacity requirements. And despite the speed of modular construction, a reputable manufacturer should be able to accommodate design changes at any stage. You just need to be aware that it is far more time efficient and cost effective to make design decisions at an earlier stage in the programme however, the modular system you specify should be sufficiently flexible to allow unavoidable late specification changes if required. 10 Return to index

11 Can Architects Really Work with Modular Construction? Fact leading architects have been working with the best modular building systems for many years! Twenty years ago, these architects were pioneers. They had become increasingly frustrated by poor construction quality and were keen to embrace modern methods of construction. They recognised the efficiency benefits of moving construction into a more tightly controlled factory environment and worked closely with ground-breaking modular manufacturers to develop innovative, award-winning designs that optimised the clear advantages of the approach and created really exciting, inspiring architecture. What are the Latest Advancements in Modular Technology? Today, modular technology has continued to evolve and the latest advancements respond to architects calls for even more design flexibility. These include: Columns that are no longer visible either internally or externally, for a seamless façade that can be specified with or without cladding The facility to accommodate almost any building footprint, including those designed for site-based construction reducing design time and resources A much wider range of module length, height and width options for unprecedented flexibility and literally thousands of configurations, permutations and layouts The option of using larger but fewer modules to reduce cranage, transport costs and site works The option of angled corners for further architectural variety An even wider choice of window and fenestration options, including full height glazing, as well as cladding and roofing specifications Sustainability features and low carbon technology such as green roofs, ground and air source heat pumps, solar panels, solar shading and rainwater harvesting A seamless façade with no visible external columns A host of cladding and glazing options are now available for modular buildings 11 Return to index

12 The Facts: Technically advanced modular solutions can deliver buildings with a much greater degree of design flexibility Modular buildings can fit almost any building footprint, site or layout and there are literally thousands of design possibilities and configurations Columns do not have to be visible either externally or internally There is a fantastic range of glazing, cladding and roofing options to realise architects ambitious designs and create high quality contemporary architecture Variations in module heights can facilitate linking to existing buildings Non-load bearing partitions and clear unrestricted spans allow modular buildings to be completely reconfigured to meet changing needs Modular facilities can easily be installed on roof tops and raised platforms to extend the most constrained sites Modular buildings can easily be expanded vertically and horizontally and the floor area can be reduced if your capacity needs change Architects have been using modular construction for more than two decades, and the best architects are willing to embrace the efficiency benefits of modular construction and work with the UK s leading manufacturers to develop inspirational, award-winning architecture Hints and Tips: Design tools are available to help architects produce project drawings for modular construction, more quickly and with greater accuracy Make sure your module manufacturer can accommodate changes at any stage but bear in mind that it will be more cost effective to avoid late revisions to your building design. Leading architects work with modular construction to help realise its design potential 12 Return to index

13 Myth 4 Modular buildings have bouncy floors If you choose a modular building supplier that offers a range of floor options, you can easily avoid the issue of floor vibration factors. A good manufacturer should offer you a high performance pre-installed concrete floor option which is ideal for: High traffic areas such as secondary schools Buildings that need to accommodate heavy loads, such as supermarkets and highly fitted out laboratories or production units Facilities with sensitive equipment, such as operating theatres Yorkon has integrated a pre-installed concrete floor system into its steel-framed modular manufacturing process. This allows concrete to be poured into individual modules in a quality controlled factory environment, reducing the need for extended chutes and pumps, for cleaner, safer and quieter work on site. What Performance Criteria Should you Specify? Performance specifications for high performance floors to look out for include: A point loading of 7kN A uniformly distributed load (UDL) of up to 9kN/m 2 A concrete floor which is pre-installed in the factory to minimise work on site, reduce disruption and improve quality It is also important to note that specifiers and construction clients are often not aware of the range of floor performance options that are now available with an advanced modular system. This should be able to deliver the different floor response factors required for a variety of applications and prevent over-specification. Hospital theatres and night wards, for example, will require the highest specification, whereas office accommodation has less stringent floor performance requirements. A pre-installed concrete floor for a hospital environment 13 Return to index

14 The Facts: A good modular building system should offer you a range of floor response factors to meet specific project requirements The most effective solution is a pre-installed concrete floor system to maximise work off site and maintain quality A high performance floor solution will easily accommodate heavy loads, sensitive equipment and areas of high footfall Concrete floors are ideal for supermarkets and other high traffic areas Hints and Tips Make sure your modular partner can offer the most appropriate floor response factor for your application to prevent over-specification Check the performance specifications of the floor options available and ensure they meet your precise requirements 14 Return to index

15 Myth 5 Modular is a cheap solution How many times have you heard that modular construction is a cheap solution? The reality is that whilst it can be more cost effective, it is unlikely to be cheaper. If you specify a system with the same high quality components designed for longevity as a traditionally-built project, why would it be cheaper? You are simply moving construction into a controlled factory environment, the materials remain the same from the brick cladding to the steel frame and plasterboard. However, there can be clear cost benefits when you take into account the advantages of the approach over site-based construction methods. What are the Cost Benefits? If you reduce the programme time by up to 50 per cent, you can occupy the building at a much earlier stage. For commercial companies, this means taking a modular approach will generate a faster return on investment. In the education sector, it can help local authorities address the severe shortage of school places and for healthcare providers, waiting lists can be reduced and Government targets met more quickly for a very positive impact on patient care and the benefit of additional revenue. It is therefore important to look at how a modular solution could add value to your scheme. Are there cost or service benefits to your organisation of earlier completion? It may be that a reduction in time on site will be hugely beneficial to your existing operations, simply because modular construction is safer, quieter, cleaner and requires much less supervision on site as the latter can also have cost and resource implications for a client, such as an airport operator or nuclear power company. There is also much greater certainty of completion on time and on budget with a modular approach because construction in a factory environment is more predictable and less reliant on subcontracted trades. This means budget overruns and delays are much less likely. The Facts: Modular construction is not generally cheaper than site-based building methods because it uses the same materials, but it can be more cost effective and it can add considerable value to your project The approach can give you a faster return on investment and earlier occupation which can have positive cost implications and generate additional revenue for your organisation Modular is more predictable so budget overruns and delays are much less likely, helping you to avoid unforeseen costs Precision engineering will lower energy consumption and running costs, making the approach even more cost effective 15 Return to index

16 Hints and Tips: A note of caution there is considerable instability in the current economic climate which applies to modular and site-based contractors alike so it is strongly advisable that specifiers and construction clients look closely at the financial stability and resources of any building partner Consider how a modular solution could add value to your project and try to quantify the benefits to your organisation, particularly of earlier completion The UK s largest superstore to be built off site an eco-store for Tesco in Southam 16 Return to index

17 Myth 6 Modular means sub-standard accommodation There should be absolutely no compromise on the quality of the accommodation because a building is manufactured off site in a factory. However, as the demand for modular construction continues to increase, so has the number of specialist contractors. It is therefore critical to recognise that not all specialists are the same and the level of technical expertise and quality of the finished buildings can vary hugely between suppliers. In the selection of a modular partner, construction clients and specifiers should take care to compare solutions that are like for like. Assess the Quality of the Building System at First Hand Clients, architects and contractors should always visit completed buildings to see the quality of construction and finish delivered by the manufacturer at first hand. Do not limit your assessment to projects in your sector talk to other contractors and end users who have used the system and use their experience. This will help you differentiate the leading modular specialists from any poor performers. And ask for statistics to show how much of the manufacturer s business is from repeat customers. Ideally this figure should be more than 50 per cent. This is a really good indicator of a company s track record for delivery on time, and its commitment to the quality of construction, finish and customer service. The Facts: The quality of the accommodation should not be compromised because a project is manufactured in a factory remember you are just changing the process not the materials Hints and Tips Visit completed buildings to assess the supplier s commitment to quality and service Look at the manufacturer s statistics for repeat business ideally they should be well in excess of 50 per cent to demonstrate this is a reputable company to work with This award-winning modular building in London broke new ground in the construction industry and received international acclaim 17 Return to index

18 Myth 7 Modular buildings are cold in winter and overheat in summer As with site-based construction, the quality of insulation for any building is key to ensuring it has a comfortable internal environment. All buildings should be designed to be warm and easy to heat in winter and to not overheat in summer. The modular wall construction should offer good quality insulation in order to achieve the targeted U value. A production system that uses the latest open pour polyurethane insulation technology will give you more consistent quality as well as zero ozone depletion potential, and reduced manufacturing time. Can the Building Achieve the Required U Value? A modular building can achieve the same targeted U values as a traditionally-constructed facility. It will also heat up more quickly and using less energy. Can a Modular Building be More Thermally Efficient? Fact A high quality modular building can actually exceed Building Regulations requirements for air permeability! Full-scale, independent tests for air leakage in accordance with Building Regulations Part L2A demonstrated that Yorkon buildings, for example, consistently perform up to 70 per cent better than site-based construction. This is further evidence of how steel-framed modular technology can achieve a higher degree of precision to minimise the draughts that reduce thermal efficiency leading to lower energy consumption and running costs, and reduced carbon emissions. This makes the approach highly sustainable. The Facts: All buildings should be designed to be warm and easy to heat in winter and to not overheat in summer A modular building can actually be quicker to heat up and using less energy A good modular building system should easily exceed Building Regulations Part L2A requirements for air permeability, allowing you to benefit from reduced energy consumption and lower running costs Hints and Tips: Specify a modular wall construction that uses open pour polyurethane insulation technology for better quality insulation Verify claims and check test results to ensure your modular solution offers the highest standards of thermal efficiency and that it easily achieves or exceeds Building Regulations requirements 18 Return to index

19 This report has been prepared by award-winning off-site construction specialists, Yorkon. For further information and technical advice about how off-site construction can add value to the construction of primary and community care facilities, call , or visit YORKON is a registered trade mark. YORKON Yorkon is a member of the Portakabin Group. Return to index