What to Expect With the Modular Construction Process
Modular construction consists of five essential phases. Knowing what these steps entail and how to plan for them helps you keep your project moving and on time.
Like any construction project, the modular construction process requires a series of steps for an idea to become reality. Unlike traditional construction, modular construction timelines can be significantly expedited by knowing the process and keeping the following suggestions in mind. But before we get too into the details, let’s define terms.
What is the difference between modular and traditional construction?
There are similarities between modular and traditional construction, such as the dream team of contractor, engineer and architect you need to hire. But there is a clear difference between the two: the construction locations.
In traditional construction, a project is built at the intended site from the ground up. It follows a linear timeline with vertical construction following site preparation.
In contrast, modular construction happens off site while the onsite location is being prepared, meaning this kind of construction has a parallel timeline with onsite prep and off-site fabrication simultaneously happening. Therefore modular construction can beat conventional construction timelines by up to 50%.
But how do you create the setting for a best-case scenario of 50% time savings? There are two things to keep in mind: the phases of modular construction and the details of your project.
Know the Phases of Modular Construction
Phase 1: Initiation and programming
While a phone call with a modular expert to discuss an idea is a good start, there are four questions you should be asking before approaching a modular construction firm, like Universal Modular Inc. (UMI).
Who are the stakeholders, and are they all on the same page about the idea for your project?
What is your budget and the location of the intended project?
What is the purpose of the building?
Are there any special requirements?
To clarify special requirements, sometimes customers may decide to handle all on-site work rather than having the modular construction company managing the on-site work. Or on-site workers might need to check certain boxes such as union contracts, citizenship requirements, or off-hours labor. These things need to be discussed early on. (See more below in “Know the Details of Your Project.”)
Having clear answers to each of those questions will set you up for success when the modular contractor begins the programming phase, which simply entails a back-and-forth conversation to create a unified, clear vision for what the final product should look like. This will entail UMI creating a schematic design, outlining project requirements, and developing a rough expectation of timing. Once the modular construction company has a consensus from the customer on the plan, they move to bidding. The timeline for this phase depends on your readiness as the customer to clarify the plans and goals.
Phase 2: Bidding and award
The bidding phase entails a site visit to assess the project site and gather information that could impact pricing. The company will get bids from their subcontractors and create a formal proposal with an estimated schedule. Once that is completed, the customer can award the project to the contractor, and the construction company wraps up the last phase of project initiation. The bidding phase at UMI will usually take about 4-6 weeks for a larger project, and the timing on the award is up to the customer on how fast they are able to move.
Phase 3: Design and approval
After all of the contracts are executed and the POs are issued, the company will draft architectural designs and engineering plans. The customer and the company will need to obtain permits and approvals from designated officials depending on their jurisdiction and location. Once all is designed and approved, a final schedule is drafted and materials are ordered. Design and engineering could take anywhere from 8-16 weeks, depending on the complexity of your project, but the completed timeline will depend on the approval process of your specific jurisdiction and city protocols.
Phase 4: Construction and delivery
As materials arrive, the assembly line of fabrication begins. The warehouse workers have their own steps of construction, and the structure will move down the line as each section is built. They will start with the frame and floor, then the walls and finished drywall, then electrical and so on. While the fabrication phase is happening, the on-site location will also be prepared by clearing the space, laying a foundation, installing utilities, etc.
Once the fabrication is completed in the factory, the structure will be shipped or trucked to the site. This phase can be completed in as few as six weeks.
Phase 5: Installation and finishes
The structure will be assembled and secured on the customer's site according to the plans. Electrical, mechanical and plumbing are finished and checked for code compliance. The project will wrap up with final finishes that include siding, access steps and ramps, flooring, fixtures, furnishing, cabling, and any specialized equipment.
The building gets commissioned to confirm all is in order, and a final walkthrough will complete this phase. Paperwork (aka approvals and documentation) are the last step.
The project is done! The keys are turned over, and you are free to move into the space.
Know the Details of Your Project
Coming into initiation with those four questions that were mentioned earlier can dramatically impact the speed of the process.
As a reminder, the questions were:
Who are the stakeholders, and are they on the same page?
What is your budget and the location of the intended project?
What is the purpose of the building?
Are there any special requirements?
But how do you get to the bottom of those questions? The best way to get the details squared away is to meet with all key stakeholders.
Typically at the beginning, it can feel like a game of telephone with your team trying to define the need. Typically, one person is trying to answer all the questions from the modular supplier, but in reality, the different departments that will be affected by the project might all have different answers. Internal collaboration is key to maintaining efficiency and speed.
Set up a meeting with all the stakeholders. This could include (but is not limited to):
A person from finance
An end user
A facilities department member
An executive sponsor
An IT department member
Everyone has different priorities and objectives, and many times, the objectives conflict. To keep a project moving, it is important to have your team on the same page and communicate objectives up front.
If there will be special requirements for the construction, such as on-site workers required to be union labor, citizenship requirements, limited to work hours at night, etc., be sure to communicate that early. Once you have clear answers to tough questions, you can help us with clear vision and timeline goals.
At Universal Modular, we have on-staff experts in modular construction who can help you succeed with your project goals. We know the process and can guide you through every step of the process. Contact us today to start phase 1 of the modular process.