The Commercial Modular Building Blog

One of the enduring misconceptions that the public has about the modular construction industry is that modular buildings are equal to “trailers” or mobile buildings. Of course, modular buildings can be put on trailers or made into mobile buildings, but that’s besides the point. The point is that the public often sees the term “modular building” as designating only these trailers and mobile buildings.

We see this misconception come up in a story in which President Obama is surprised that public school teachers teach in trailers, or as the article states, “modular buildings.” Now, we are not here to discuss the politics of the situation, but we do want to clarify this “modular building” term that is being used so loosely.

Many people view trailer buildings in a harsh light, seeing as how the buildings are only meant to be temporary and provisional. These buildings tend to be thin-walled and built with lower quality materials to provide cost effectiveness. It is this negative view that can occasionally overshadow the public perception of “modular buildings”.

While it is true that trailer buildings like these were once referred to as modular buildings, and some modular companies do in fact make these trailer type buildings, they no longer represent as a whole the types of buildings that modular construction produces.

Modular construction technology has advanced well beyond the trailer and the old prefabricated houses (of course modular buildings are prefabricated, but the technology and the process are different now). Modular construction is now a rapidly growing industry filled with all sorts of different construction methods and approaches.

Many of these modern modular construction approaches are attempts to streamline and make more efficient the construction of buildings that are meant to be more durable and high quality than the old prefabricated and trailer buildings. Sitting inside these new modular buildings, it is hard to tell that they aren’t traditionally constructed buildings. The walls are thick and well insulated. The construction is solid and durable. But at the same time, the buildings are flexible and easily rearrangeable. With modular buildings, you have the advantage of a sturdiness characteristic of traditionally constructed buildings and at the same time you have the advantage of a flexible, cost effective building that you can easily modify or take with you.

So a modular building is no longer simply a trailer building. It is a building that is built from a type of construction that involves factory fabricated components that can be put together in an almost infinite variety of arrangements. This is the new definition of a modular building that we hope the public will adopt.

Here is another article about the many benefits of using modular construction for your building needs. This article is about the many benefits of modular housing.

It is important to note that modular housing is actually quite different from commercial modular construction in terms of methodology and technique, but there are also many similarities, and share many of the same benefits. It is useful to compare the two fields because they both represent a new emerging pattern of thought in construction.

Modular housing usually consists of prefabricated “modules” that are manufactured in a factory. Unlike our modular building systems however, these modules are usually a complete room or facility or simply a larger piece of the building that is joined to other modules. Our building system, in contrast, consist of prefabricated universal panels and frames that eventually form buildings according to plan.

Housing modules, though different in practice, provide the same benefits that modular commercial construction provides. Housing modules are built indoors away from pesky external conditions such as weather and wear and tear, and so an entire portion of the construction process is streamlined in a factory setting, cutting down on waste, saving time, and minizing chances of damage.  

Commercial modular building systems work a bit differently, in that they are comprised of universal panels that are installed to create flexible buildings, but they offer the same benefits: a reduction in construction time, increased efficiency, waste reduction, and protection from the elements. 

We can see that the  transformation of construction is happening dramatically across industries.

Another colorful modular construction analogy is that modular components are like legos.

This is true as well, since legos are essentially universal blocks that have been designed to fit into one another. And so they can be combined in a number of ways to make whatever shape you desire.

Modular buildings are thus made out of modular components that fit into one another: modular wall panels and universal framing systems to be specific. Communicating with the client, we design plans for a layout and then manufacture the required components, and then ship it all off to the build site where they are snapped into place. Just like that.

Though the modular buildings mentioned in the article are some sort of concrete modular construction. Our modular buildings are composed of panels with polystyrene cores and vinyl facings which are joined together by aluminum framing systems and then we add whatever components are additionally needed to make the building come to life such as ceilings, flooring, roofing, HVAC, electrical, furniture, windows, you name it.

Very cool technology, but don’t just take our word for it. See for yourself! Have you ever experienced the joy of constructing your own little building out of legos? Now you can construct your own modular building out of modular components for your business needs.

Sometimes it can be difficult explaining to people exactly what modern modular buildings are, since there are different conceptions of it and differnt systems that use the name. We’ve tried to explain our system a few times on the blog in various ways and then we go on using the same terms to explain the technology to friends and other acquaintances.

Some people think of modular buildings in terms of modular housing, which embraces a similar idea, but modular houses are usually comprised of larger, pre-shaped pieces that lock into place and generally stay there, though these components are still more flexible than their traditionally constructed counterparts.

Our modular building systems are different though. Instead of several pre-defined pieces coming together to form a building, we use an assortment of universal wall panels and frames that come together to create all sorts of types of buildings.

Sometimes aspects of popular culture can be used to more easily explain something more technical, as a means of simplifying it. That said, one individual had a colorful analogy for modular buildings that we’d like to borrow for a minute: he compared them to transformers. Of course, the classrooms he was referring to were probably not of the same design we use, but we could still use the analogy.

Transformers are robots with interchangeable parts that when toggled, change positions to accomodate an entirely different function. This makes the robot flexible and adaptable: it can go from a human form to a vehicular form, which affords it all sorts of advantages.

Our modular building systems go even further. They aren’t just one form that can change into another: they are components that can assemble into limitless forms, offering the best in adaptability and flexibility.

So if you ever find yourself in the position of explaining a universal modular panel system to a layman, trying comparing modular buildings to transformers. You might just get the understanding and response you are looking for!

We’ve talked about downtime before on this blog, but we haven’t exactly gone into specifics, and how fast costs can add up because of downtime.

Some companies are aware of the costs of business downtime while others know it is undesirable, but they don’t know what it is costing them exactly. In fact, 67% of companies do not know the financial cost of downtime to their business. Downtime costs add up fast. Below are some data points that illustrate typical revenue losses that are a consequence of business downtime for a handful of surveyed companies:

• 54% of these companies experienced estimated losses of $10,000 – $100,000 an hour.
• 25% of these companies experienced estimated losses of $100,000 – $500,000 an hour.
• 13% of these companies experienced estimated losses of $500,000 – $1 million an hour.
• 4% of these companies experienced estimated losses of greater than $1 million an hour!

So what is downtime? Downtime is basically a period of time in which your business processes are put on hold due to construction, infrastructure changes, reorganization, remodeling or anything else that can disrupt the daily functions of your business. Construction downtime can be especially taxing: airborne particles, dust, paint, various messes and noise pollution can be highly disruptive to your daily business processes and your employees’ productivity.

During periods of downtime, you are losing out on output and the ability to address the needs of your customers. Employee productivity can go down and your customer service can suffer. Losses from downtime can include revenue from product, customer loyalty, loss in efficiency and more. If you want to run a successful business, you will certainly want to avoid downtime as much as possible, or at least minimize its overall impact.

With our modular construction method, installation of a modular building is minimally invasive. We manufacture the components of the building in our factory and then ship the components to the build site, where we install the building quickly and cleanly. Our construction method is much more efficient than traditional construction methods, which can involve messy, time consuming processes such as drywall work, patching, and painting. With our modular construction method, we can reduce your business downtime to minimal amounts, or even eliminate it altogether, allowing you to continue your business processes without interruption or loss in revenue.

Several more articles have come up pertaining to the increasing modularization of our construction industry. This is a theme we have been talking about for a while now. Simply put, the concept of  modular design is permeating our understanding of manufacturing and construction and the process of building and producing items of utility. The flexibility, adaptability, and efficiency of a modular design is quickly making it the dominant mode of productive thought in this increasingly complex and fast paced society.

The first article has to do with how modular design benefits those looking to build central utility facilities, or facilities that produce utilities such as chilled air, heat, compressed air, and steam for a larger complex like an academic institution or medical complex. The article does a good job of laying out the benefits of modular design, such as increased efficiency and adaptability, while arguing that modular design can help infrastructure development in myriad ways, and consequently our society. The article is of longer length, but well worth a read for those interested in modular design from an engineering perspective.  

The second article deals with the U.S. Navy’s increased demand for the flexibility and adaptability of a modular ship design, explaining how modular ship designs are more efficient and cost effective.

One underlying theme we can take away from reading all of these articles is that the very nature of material change is evolving. Previously, we would have new iterations of a product, making the previous one obsolete and destined for the trash bin. Now, we see that technological change will come through the components themselves, and we can gradually update a building or ship design by replacing older parts over a longer period of time without having to waste all of the energy of throwing something out and building something completely new. By compartmentalizing change itself, we are making our own processes more efficient, and cutting down on unnecessary waste.

Quite a development!

Williams Scotsman, a mobile and modular space company serving the North American region, needed walls for a temporary modular complex to be built in the Washington state Capitol. The building was to serve 64 state legislators and their assistants and staff, and needed to be built within a very short timeframe. Williams Scotsman’s goals regarding the project reflected their characteristic inclinations to high standards: the modular complex was to be completed within a challenging timeline while providing the customer with quality office space that’s cost effective, all of it delivered with exceptional service. In the end, Williams Scotsman decided to go with Allied Modular’s demountable modular wall system. In doing so, Williams Scotsman was able to deliver to their customer a temporary modular complex in the timeframe specified while meeting all of the project goals with ease.   

Initially, Williams Scotsman considered conventional stick-built 2×4 walls for the project, as their initial costs were somewhat lower. However, the company quickly found out that not only were the stick-built walls less time effective, but less cost effective when it came to long term savings. Upon considering modular walls, Williams Scotsman found that modular wall systems can save up to 50% or more over stick-built walls. Also, a modular wall serves as an asset: modular walls can be reused over time due to their flexible nature, whereas stick-built walls often end up in landfills after their initial use. In this light, modular walls are not only cost effective but a smart choice in building sustainable, green buildings. Given these considerations and the fact that modular wall construction would reduce the project’s overall completion time, Williams Scotsman decided to go with Allied Modular’s wall system. The walls would be used to form the enclosed office and conference room spaces to be used by the legislators.

Williams Scotsman’s project was completed on time, thanks in part to the time effective aspects of modular walls. After the project was completed, we asked the company to give us feedback on the crucial aspects of their experience with Allied Modular. First, we asked them how their experience was in working with us. They replied, “The experience was very good. We worked closely with Allied to track actual installation time vs. scheduled time and when progress fell behind Allied’s anticipated schedule they met their commitment by adding additional installers to their crew.” Williams Scotsman was definitely impressed by our Service Beyond Belief philosophy in working with customers. We also asked Williams Scotsman about the most important qualities of the project, i.e. time, cost, look, and if those qualities were delivered upon. What they said was this, “The most important factor was time, followed by quality, appearance, and sound attenuation. Allied’s product and service met the challenge on all four.”

Williams Scotsman also reported that the results of the project exceeded theirs and their customer’s expectations. We are happy that the project went so well.

It is very interesting following the latest developments in skyscraper construction, as the current shift from traditional construction to modular construction is slowly occurring in that sector as well, along with modular’s challenges and benefits. This article illustrates the changing trends quite nicely.

The benefits are similar to the benefits of other types of modular construction. Advocates are claiming as much as 50% in cost savings. For a project as involved as skyscraper construction, this could amount to huge savings for sure. There is also the fact that modular construction uses less labor and is more time/energy effective. Modules are manufactured in a factory, then transported to the site, where they are lifted on top of one another and secured by cranes. Cost savings also allow the builder to construct affordable housing for middle to low income families.

One of the unique challenges pertaining to skyscraper construction is the question of sturdiness. As a building grows in height, more sophisticated supports and anti-seismic technologies are required to ensure that the building is sturdy. Human ingenuity will definitely meet these challenges while cutting costs, improving quality, and saving time and energy.

We applaud modular technology in all its forms, and its growing acceptance in the world of construction. Here’s to our skyscraper-building friends!

The green movement has been quickly gaining ground in the past couple of years, especially after the vulnerable  recovery period following the recession. We found that we needed to start looking at more efficient and sustainable ways to use energy and resources for economic, social, and ecological reasons. Many began to take the green movement more seriously, and many companies adopted green standards in energy and sustainable practices, which led to more business activity and growth in services such as clean energy, thanks to the mobilizing effects of the green movement itself.  

Well, the green movement is going to become even more pronounced in the next few years, maybe even to the extent of it ceasing to be a movement and becoming the norm. This is due to the actual institutionalization of the movement, thanks to the General Services Administration.

If you read their “Strategic Sustainability Performance Plan,” you’ll find that the GSA is actively adopting a green/sustainability policy, and will advocate the spread of such practices throughout our government. This means that any business that would like to build government buildings or acquire other similar contracts will most likely be required to adhere to a certain green/sustainable standard in energy and resource use.

Soon it will become absolutely crucial for all construction methods to employ green, sustainable practices. Modular construction is often touted as being green through and through, which is correct. Modular buildings not only save resources by recycling materials and using available resources more efficiently, but they also save landfills from demolition waste, due to their reusability. Modular buildings also boast better insulation and containment ratings, which saves on energy.

This is definitely an encouraging trend. We will see higher efficiency in our building processes and better management of our limited resources and energy sources. We here at Allied Modular are happy to rise to the challenge.

We’ve talked about the efficiency of modular construction in general terms. How it saves on labor and energy and resource costs. But what we often don’t think about are the many more subtle ways you save time, money, and effort by manufacturing modules instead of engaging in hard construction.

Think about construction crews for instance. Depending on how well the project is planned, how materials are managed and what stores of materials the construction crew will have ready at the site, minor mistakes can be smoothed over or they can cause huge delays and efficiencies.

For example, many construction crews run their workers back and forth from hardware stores, plumbing supply depots, and lumber yards as they need more materials, especially if changes need to be made or there are miscalculations on required materials.

This can be highly time consuming, especially if adjustments need to be made in a rural area where potential supply outlets can be miles and miles away. These sorts of inefficiencies can account for more working hours, gas being used up as workers make supply runs, materials being wasted, plans being altered, resulting in demolished sections, really anything.

With modular construction, all of the planning and manufacturing happens at one site, in a controlled factory setting. Everything is planned out advance, and then the manufactured modules are brought to the build site, usually in one trip, where they are cleanly installed and then the project is done. Through planning and controlled manufacturing, many of the errors that can arise during the course of hard construction simply dissolve in this case, ceasing to be possibilities. Of course, mistakes can be made anywhere really; but with modular construction, a mistake can be found and corrected much more quickly and efficiently, especially considering the nature of the module itself.

Modular buildings can be taken apart or expanded at will, without the need for demolishing, due to the flexibility of the building’s components.

It is one thing to make processes more efficient through planning and streamlining and coordinating, but modular construction achieves a new plateau of efficient construction by completely altering the methods of construction themselves.

Expect more of these hidden efficiencies to start popping up and giving us pleasant surprises.