Modular Construction Explained
Modular construction has been around in one form or another for many decades. However, its adoption is becoming increasingly widespread due to advances in technology and the benefits it offers. In this post, we explain what modular construction is, what the modular construction process involves, the benefits it offers and a brief history of the use of modular construction in the UK.
What is modular construction?
Modular construction is also known as prefabricated construction or offsite construction. It is a method of building in which components of a structure, or entire structures, are manufactured in a factory or offsite facility. They are then transported to the construction site, where they are assembled.
With traditional onsite construction, most elements are built from scratch onsite. In contrast, modular construction involves the creation of standardised building modules offsite, which are later transported and interconnected to form a complete building or structure.
The modular construction process
The process of modular construction typically involves the following steps:
Design and engineering
Architects and engineers work together to design the building and create modular units that can be assembled in a factory setting. This process can involve collaboration with multiple stakeholders, including architects, engineers, contractors, developers and more. Modular units and components can be customised to a desired specification.
Factory manufacturing
In a controlled factory environment, skilled workers construct the modular units, including walls, floors, ceilings, and even fully finished rooms with electrical and plumbing systems such as kitchen and bathroom pods. Components are then quality controlled in the factory environment, ensuring a high degree of accuracy.
While this stage is taking place, essential onsite works can be undertaken concurrently. This helps to reduce the overall build time for a project as it allows multiple stages to take place at once.
Transportation
Once the modular units are completed, they are transported to the construction site using trucks or other transportation methods.
Onsite assembly
On the construction site, the modular units are lifted using cranes and placed into position. They are then fitted together to form the complete building. These units are often connected using various techniques such as welding, bolting or adhesive bonding.
Integration and finishing
After the modules are assembled, the building's components are integrated, and the final finishing touches are applied to achieve the desired appearance and functionality.
What are the advantages of modular construction?
Modular construction is used for a wide range of building types, including residential houses, apartment buildings, hotels, schools, healthcare facilities, offices, commercial buildings and more. It offers several major advantages compared to traditional, onsite construction methods. These are:
Speed
Modular construction can significantly reduce construction times. This is because many elements are fabricated simultaneously while essential preparatory work occurs onsite, such as groundworks, landscaping, plumbing and electrical works.
Cost-efficiency
The controlled factory environment allows for streamlined production processes and better cost management. Offsite construction reduces the costly expenses associated with running a construction site.
Costs can be more accurately forecast in advance using advanced processes and technologies. Due to the high levels of accuracy modular units offer, costly errors and reworks can be reduced or avoided.
Consistency and quality
Since modules are manufactured under controlled conditions, quality control is more manageable. The entire process of modular construction results in consistent and high-quality products. Errors are reduced because units are designed and manufactured to precise specifications and quality controlled before leaving the factory.
Sustainability
Modular construction can produce less waste and reduce onsite disturbances, making it a more sustainable building method. The materials and processes used in modular construction are typically more environmentally friendly compared with traditional building methods. As such, modular construction is becoming increasingly popular in the UK as a means of creating more sustainable and energy-efficient housing as well as public and commercial buildings.
Flexibility and repurposing
Modular buildings can be easily expanded, reconfigured or even disassembled and relocated to another site if needed. This makes them an extremely versatile and flexible solution. As such, modular buildings are commonly used to create temporary structures which can then be repurposed elsewhere.
Weather independence
Factory production is not affected by weather conditions. This reduces project delays due to adverse weather and ensures that building projects can reliably take place year-round, with minimal weather disruptions, regardless of site location.
A brief history of modular construction in the UK
Over the past few decades, modular construction in the UK has evolved from simple prefabricated components to highly advanced and versatile offsite construction techniques. It continues to play a significant role in addressing the country's construction needs due to the many benefits it offers compared to traditional construction methods.
Early modular concepts began to emerge in the UK after World War II. Early experiments in precast concrete panels and other prefabricated building components were aimed at addressing the housing shortages caused by bombing during the war. Modular construction was viewed as a way to increase construction efficiency to quickly meet housing needs across the country.
In the 1960s, system-built homes gained popularity as a solution to housing demands arising from a growing population. These homes were constructed using factory-produced components such as wall panels and floor systems, which were then assembled onsite. Various experimental projects were undertaken to explore the benefits of system-built construction.
In the 1970s, there were advancements in Industrialised Building Systems (IBS). IBS encompassed various offsite construction methods, including volumetric modules and panelised systems. This decade marked the growth of modular construction as a viable alternative to conventional building methods.
In the 1980s, modular construction continued to gain traction in the UK. Several large-scale housing projects and public buildings were constructed using modular methods, demonstrating the efficiency and speed of this construction approach.
In the 1990s, modular construction expanded beyond residential projects into commercial and institutional applications. More complex and sophisticated buildings, such as schools and healthcare facilities, began to be constructed using modular techniques.
The 2000s saw advances in technology, including computer-aided design (CAD) and building information modelling (BIM). These technological advancements further improved the efficiency and precision of modular construction. An increasing number of offsite facilities adopted modern manufacturing techniques to streamline production.
The 2010s saw a surge in the popularity of modular construction in the UK. It became increasingly accepted as a mainstream building method for a wide range of projects, including hotels, offices, retail spaces and residential buildings.
During the current decade, the UK has continued to face housing challenges and sustainability concerns. Modular construction is increasingly being viewed as an environmentally friendly building solution. Innovations in renewable materials, energy efficiency and waste reduction are further advancing the use of modular methods in the construction industry.
Modular construction is gaining popularity in the UK and globally as a modern and efficient approach to building, which offers numerous benefits that cater to various construction needs and demands. Advances in technology and design are expanding the scope and popularity of modular construction.