What You Should Know About Prefabricated Modular Buildings

Modular buildings are code-compliant commercial structures built with individual prefabricated sections called “modules.” They’re constructed in an off-site manufacturing plant and delivered to the final construction site for assembly. The individual modules are built to size so they can be transported over the road to the site, where they will be fitted together to form the complete building structure. 

Normally the individual building sections are between 8 and 16 feet wide with lengths varying from 20 to 60 feet long. The final size of a modular building can be several stories high, like when using a solution such as our SmartSpace system.

While there are variations among manufacturers, below is a high-level account of the modular construction process.

Individual modules are built in a controlled factory setting using assembly-line methods, beginning with the frame construction and ending with the interior and exterior finishes. Modular construction starts with a steel or wood frame, which can be designed as an “outrigger” or a “perimeter” frame. 

Each module is most often designed to be within a range of 12′ width and 60′ length, mainly due to transportation restrictions. While the frame is being welded, the floor joists are assembled and the decking is attached. The complete floor assembly is fastened to the frame as the module moves down the assembly line. 

Next, the walls are built on the floor assembly. Made with traditional wood studs, the walls are constructed horizontally and then lifted to their vertical position, often with a light-duty overhead crane. 

After the walls are secured to the flooring, the interior wall finish is applied, while windows, insulation, electrical wiring, plumbing, and any custom components are installed. The module moves further down the assembly line where the roof structure is ready to be installed. 

An overhead crane is used to hoist the roof onto the walls. With the roof installed, duct work, additional electrical wiring, and other components can be completed. Exterior finishes are attached while doors and interior trim are completed. 

As each module reaches the end of the assembly line it is weather-proofed with plastic wrap and moved to an outside staging area for delivery to the site. If a building is fully watertight, plastic shrink wrap may not be necessary. 

Modular buildings are manufactured in a specific order so that they can be delivered to the project site and installed in an organized manner maximizing schedule efficiency.

Modular buildings are built using high-quality materials (just like traditional construction) because prefabricated modular buildings undergo the same inspections and must meet the same building codes. The building’s base frame, as well as the framework for the ceiling and walls, is typically made of steel or wood, depending on the application and site requirements. 

The foundation materials used for permanent modular buildings are dependent on the site conditions and soil compaction. That being said, typical materials we use in permanent foundations would be the same or very similar to what you would find supporting a site-built structure. This includes a combination of poured concrete with rebar for strength and crushed stone for drainage.

Though often seen as temporary solutions, modular buildings offer surprising longevity. Though often seen as temporary solutions, modular buildings offer surprising longevity. With proper maintenance, they can provide a functional and cost-effective space with an average lifespan of 25-30 years. Permanent modular structures, on the other hand, can last anywhere from 35 years, 50 years, and onward; the same as any traditional, permanent building.

New modular building layouts and designs are practically limitless. From single-unit office trailers to multi-story professional modular complexes, modular buildings can be constructed to meet your every need. 

Not sure what you need? Tell us your building needs and space requirements and we’ll create a modular design suited to your business. From there you can further customize your building with interior and exterior finishes, lighting selections, technology options, and security systems.

Modular construction is durable and long-lasting. Both permanent and temporary prefabricated buildings are required to meet the same building codes as traditional construction. 

Furthermore, they are constructed to comply with additional standards since they need to maintain their structural and aesthetic integrity during transportation to the building site. Whether they are permanently affixed in one location or relocated from site to site, our modular structures are built to last for decades.

We believe construction doesn't have to be wasteful, so we do our best to follow sustainable and eco-friendly processes. Our modular solutions minimize excess material waste by promoting adaptability and reuse. Here are a few ways Britco makes sustainability a priority: 

Less Waste

Pre-fabrication makes it possible to optimize material purchases and usage while minimizing on-site waste and offering a higher-quality product to you. Bulk materials are delivered to the manufacturing facility where they are stored in a protected area safe from theft and damage.

Less Exposure

Modular structures are built in a factory-controlled setting where materials are protected from inclement weather conditions. So you can keep on schedule, saving you time and money.

Less Site Disturbance

In the modular building process, off-site construction happens at the same time as on-site work, such as leveling the ground and laying the foundation. This reduces the impact on the surrounding environment, as well as the number of vehicles and equipment needed at the site. 

Energy Efficiency

A large selection of high-efficiency mechanical systems can be installed from heating and cooling systems to energy-efficient lights to help your building be eco-friendly. We can also use energy-efficient windows to doors to help keep your costs down.  

Reuse

When your needs change, prefabricated modular buildings can be disassembled, relocated, or refurbished. This reduces the demand for raw materials and minimizes the energy needed to create a building.

Doing regular maintenance on your modular building is important for longevity and safety. To ensure a healthy environment, change your HVAC filters at least monthly or more often if needed.  Additionally, never block vents and clean ducts as required. Your building should come with instructions on how to keep all your systems clean and functional.

Fix any leaks promptly and regularly inspect your roof for damage. Maintaining floor coverings and smoke detectors is also crucial. Finally, run your air conditioning occasionally to regulate temperature and humidity, and routinely check caulking to ensure a tight seal around windows, doors, and siding. 

Modular construction offers a faster and more streamlined approach to building compared to traditional methods. By constructing prefabricated modules in a controlled factory setting, builders can significantly reduce construction times and minimize weather delays. This efficiency translates to cost savings, as projects are completed quicker and require less on-site labour. 

Additionally, factory production allows for stricter quality control, ensuring a higher standard for the finished building.

Beyond the speed and cost benefits, modular buildings boast environmental advantages. Less waste is generated during the factory production process compared to traditional construction methods. Furthermore, the modular design allows for future repurposing of units, reducing the need for demolishing and entirely rebuilding structures.