The majority of modular construction takes place off-site in a climate-controlled environment. As modules are being constructed in the factory, site work and foundations are being completed at the job site. Because construction phases occur simultaneously, projects are completed much faster than traditional construction.
Once the design phase is complete, manufacturing begins at the factory. Modules are engineered to connect with adjacent modules, as well as those above and below for multi-story applications.
The first step is fabricating the building’s frame. The frame can be wood, steel or concrete, depending on the project. The floor is constructed, insulated and decked on the frame where floor coverings (floor tile, carpet, hardwood) are then added.
While the floor is being constructed, individuals in the mill department have already begun measuring, cutting and finishing the walls. Unique to modular construction is the ability to simultaneously construct components. Typically walls, ceilings and roofs are prebuilt, finished and stored well before they are needed. Pre-cutting structures increases efficiency and allows for quick assembly.
Walls are cut at the jig tables with window and door openings, staying true to the design layout. Walls are covered and dry wall is added to one side. When finished, the walls are lifted upright and set on the floor. The roof system is then framed and lifted into place.
The next step is to run all electrical, plumbing and mechanical systems and sheet the building with siding. Doors, windows and HVAC units are then installed.
In the final stages, the interior and exterior is completed. This includes adding any cabinetry, lighting fixtures and cleaning the unit. When all systems are working properly, the building receives its final inspection and is wrapped and sealed for transportation to the job site.
Every stage of factory production is carefully monitored. Independent building inspectors supervise the construction process from start to finish ensuring that all building codes are adhered to during each phase of assembly.
Click here to watch a video about the modular building process.





