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  • 1. permanent modular construction 2011 Annual ReportThe Voice of Commercial Modular Construction™ 1
  • 2. COMPANY PROFILE: our global membership MODULAR BUILDING INSTITUTE Founded in 1983, the Modular Building Institute (MBI) is the only international non-profit trade association serving the modular construction industry. Members are manufacturers, dealers and contractors of commercial modular building projects, as well as associates supplying building components, services, and financing. Members are located in 12 countries around the globe and provide all types of building space, from relocatable buildings to complex multi-story permanent construction projects. MBI’s mission is to grow the industry and its capabilities by encouraging innovation, quality, and professionalism through communication, education, and recognition. Canada United Kingdom Poland Each year, MBI hosts World of Modular, the largest gathering of professionals in the modular construction industry. The next World of Modular will be held March 24-26, 2012 in Orlando, Florida. United States Portugal Afghanistan For more information about the industry visit, www.modular.org. Mexico Peru ABOUT THE Industry: Chile Australia South Africa Commercial Modular Construction New Zealand Commercial Modular Buildings are non-residential factory-built structures designed to meet federal, provincial, state and local building codes and in some cases designed to be relocated. The commercial modular building industry is comprised of two distinct divisions: Permanent Modular Construction – PMC is an innovative, sustainable construction delivery method TABLE OF CoNTENTS utilizing offsite, lean manufacturing techniques to prefabricate single or multi-story whole building solutions in deliverable module sections. PMC buildings are manufactured in a safe, controlled setting and can be constructed about pmc 4-5 of wood, steel, or concrete. PMC modules can be integrated into site built projects or stand alone as a turn-key solution and can be delivered with MEP, fixtures and interior finishes in less time, with less waste, and higher mcgraw-hill/ FMI reports 6-7 quality control compared to projects utilizing only traditional site construction. sustainability: minimizing waste 8-9 Relocatable Buildings – A partially or completely assembled building that complies with applicable codes, key markets served 10-15 and state regulations, and is constructed in a building manufacturing facility using a modular construction process. Relocatable modular buildings are designed to be reused or repurposed multiple times and transported to different data collection 16-19 building sites. Global outlook 20-21 This report focuses on the Permanent modular construction case studies 22-24 (PMC) Buildings division with a north american focus. see page 20 2010 summary 25 for our global outlook. BOARD OF DIRECTORS & mbi STAFF 262 3
  • 3. Whistler Athletes’ Village Days to complete: 392 About PERMANeNT MODULAR CONSTRUCTION Countless industries regularly use permanent modular The term “modular” describes a construction method or construction including schools, banks, restaurants, hospitals, process where individual modules stand alone or are assembled medical clinics, day care centers and correctional facilities – just to together to make up larger structures. Unlike relocatable name a few. The number of industries [as measured by the North buildings, PMC structures are intended to remain in one American Industry Classification System (NAICS)] that utilize our location for the duration of their useful life. services are numerous, but the most common categories include: An important but subtle difference for this report is that 236116 New Multifamily Housing Construction modular construction refers to three-dimensional building 236210 Industrial Building Construction “modules” that are prefabricated off site and transported to the Unique to modular construction, while modules are being assembled same time, and then brought together in the same factory to 236220 Commercial and Institutional Building Construction site to make up the entire building, rather than prefabricated in a factory, site work is occurring at the same time or in some form a building. This process often allows modular construction mechanical systems or wall assemblies. cases prior to construction. This allows for much earlier building times of half that of conventional, stick-built construction. The primary benefits of permanent modular construction occupancy and contributes to a much shorter overall construction include: Permanent modular buildings may be Type V (wood frame, period, reducing labor, financing and supervision costs. Saving even These practical time and money saving alternatives to site- combustible) or Type II (steel, concrete, non combustible) and 1. Streamlined construction process (in many cases more time and money, nearly all design and engineering disciplines built buildings effectively meet the specialized needs of diverse can have as many stories as building codes allow. occupancy occurs 50 percent faster than with are part of the manufacturing process. businesses. Customers served by modular construction include conventional construction) federal, state, provincial, and local governments, school boards, Primarily, four stages make up a modular construction project. 2. Resource efficient – less labor and fewer materials First, design approval by the end user and any regulating Also unique to modular construction is the ability to simultaneously corporations, non-profit organizations, retail establishments, wasted. construct a building’s floors, walls, ceilings, rafters, and roofs. healthcare providers, as well as individuals, partnerships, and authorities; second, assembly of module components in a 3. Reduced environmental impact – less site During site-built construction, walls cannot be set until floors are sole proprietorships. Other uses include medical facilities, airport controlled environment; third, transportation of modules to a damage, less material exposure and less waste in in position, and ceilings and rafters cannot be added until walls facilities, military installations, restaurants, churches, and remote final destination; and fourth, erection of modular units to form landfills. are erected. On the other hand, with modern modular methods of telecommunications stations. a finished building. construction, walls, floors, ceilings, and rafters are all built at the Commercial modular buildings are non-residential structures, Modular contractors manufacture buildings (or contract to 60% to 90% completed “off-site” in a controlled environment, have buildings manufactured) at off-site locations. Responding Modular Construction Schedule . and transported and assembled at the final building site. This can to customer requests, they typically operate as general Design Permits & Site Development & Install & Site comprise the entire building or be components or subassemblies contractors on projects, coordinating the delivery, installation, Eng. Approvals Foundations Restoration Time Savings of larger structures. In many cases, modular contractors work site work and finish of the building. Construction primarily Building Construction at Plant with traditional general contractors to leverage the resources and occurs indoors away from harsh weather conditions preventing advantages of each type of construction. damage to building materials and allowing builders to work in comfortable conditions. Site Built Construction Schedule Design Permits & Site Development & Building Site Eng. Approvals Foundations Construction Restoration4 5
  • 4. SMART MARKET REPORT FMI Survey Shows Modular as McGraw-Hill Construction Growth Opportunity McGraw-Hill Construction recently released its latest SmartMarket Report, Prefabrication FMI Corporation, the largest provider of management consulting, investment banking and research and Modularization: Increasing Productivity in the Construction Industry which provides to the engineering and construction industry, reported in its fourth quarter 2010 Nonresidential insight into the role that prefabrication/modularization can have on improving productivity Construction Index (NRCI) that modular construction is considered a growth opportunity for the in construction—including impacts on project schedule, costs, safety, quality and waste industry. reduction. The NRCI report indicates that in light of the long recession, more contractors are thinking lean and Through techniques that have been around for decades, prefabrication/modularization looking for ways to build for less. FMI asked about one trend that could help make the construction are seeing a renaissance as technologies, such as BIM, have enabled better integration business leaner and more efficient, the growth of prefabrication and modular construction. Although of prefabricated/modular components; as changes in design such as the emergence of the trend for greater use of off-site construction has been growing slowly for years, the recession green have made certain advantages of prefabrication/modularization more important; and new technologies are set to increase the use of manufacturing processes and environments for and as innovative offsite techniques have emerged. Out of over 800 architecture, construction. engineering and contracting (AEC) professionals surveyed: Only 11% of the panelists surveyed expected growth for the next three years to be less than 1%, or • 66% report that project schedules are decreased - 35% by four weeks or more less than expected GDP growth. Thirty-seven percent expect growth to be between 1% and 5%, • 65% report that project budgets are decreased - 41% by 6% or more but 49% expect growth to exceed 5%. Panelists expect this area to grow faster than the market • 77% report that construction site waste is decreased - 44% by 5% or more in general due the growing use of BIM, owners wanting projects faster and for lower cost, safety, quality and the shortage of skilled labor once markets return to more normal growth. "Prefabrication and modular construction processes have “ been used for years, but today, with the emergence of new “This report confirms what we’ve believed for a long time, that modular construction is poised technologies and construction practices, we have the ability for take-off,” said Tom Hardiman, Executive Director of the Modular Building Institute. “Over the Lean Construction, BIM, and Green Building Trends: to utilize these strategies to create innovative and quality past five years there has been a growing interest in the commercial modular construction market buildings, while also improving construction productivity," What is most striking about prefabrication/ from building owners and investors alike. We expect to see continued growth for our commercial said Harvey Bernstein, Vice President of Industry Insights modularization is its ability to enable all building providers as the modular construction industry continues to adopt innovative and efficient and Alliances at McGraw-Hill Construction. "These reported these trends, in addition to being more construction techniques.” ” productivity benefits of prefabrication and modularization are prominent because of them. It [modular particularly exciting in todays economy given the benefits of The NRCI is a quarterly report by FMI which is a sampling of construction industry executives creating superior buildings while saving cost, time and waste." construction] brings all of them together to voluntarily serving as panelists for surveys about industry trends. The responses are based on their improve productivity in construction. experience and opinions, and the analysis is based on FMI’s interpretation of the aggregate results. For more information, or to download the free report, visit: http://construction.com/market_research.6 7
  • 5. sustainability minimizing waste It is now widely accepted that the modular construction process is more resource efficient, not only in terms of labor and money, but also with regard to material usage and waste. The previously cited McGraw-Hill Smart Market Report (on page 6), indicated that 77% of architects, engineers and contractors surveyed reported a reduction in site waste. Incredibly, 44% reported that site waste was reduced by 5% or greater. The EPA reports that the average amount of construction and demolition waste generated for a non residential project is 4.34 lbs/sq ft. For a 10,000 square foot facility, this amounts to 43,400 pounds of waste, or over 21 tons! If owners Stephenson Park Preschool are able to reduce this amount by just 5% using modular construction techniques, that translates into 2,170 pounds of Days to Complete: 122 waste, or over a ton of waste per project diverted from the landfill. Projects utilizing modular construction also have the ability to reduce waste in another manner. Due to the fact that these buildings are designed and constructed to be assembled on site, they are also therefore “designed for disassembly” or “design for deconstruction (DfD).” In short, it is much more practical to disassemble a modular project and salvage or reuse significant components of the building compared to a similar site built facility. The increasing use of BIM technology as well as the general public’s growing disdain to pay for wasteful practices Repurposed modular buildings turn into Chetwynd Seniors’ Housing. Over 320 modular housing units are two key reasons why modular from the Olympic and Paralympic Village at Whistler were relocated and converted into 156 permanent, affordable apartments for low-income seniors. construction techniques will continue to gain in popularity. The picture to the bottom right is an example of DfD. The original building was a 10-unit custom office. After 6 years of BEFORE use, the building was disassembled and sent to storage. In 2009, a development in Florida required a sales center. It was RENOVATED REUSE (After) Days to complete: 110 determined that 6 of the original 10 units could be relocated and used with renovation. The renovated building features 7,700 total sq. ft. 10 ft. tray ceilings, custom millwork, granite countertops, and a portico entry with a four-plane clay tile roof system. 8 9
  • 6. key MARkets SERVED Market Size Permanent modular buildings make up approximately 42% of the total modular 5% Retail/ Hospitality 6% “Other” construction industry’s $5 billion in annual revenues in North America (leasing EDUCATION 42% Education Residential Education Center and sales of relocatable buildings account for the remainder). For 2010, these 20% Multi-Family/Student Days to complete: 270 Housing/Dorms companies reported revenue from the following top markets Permanent modular buildings are considered real property, built to the same building codes and requirements as site-built structures, and are depreciated in a similar manner. As such, the markets for permanent modular 26% Office & Admin construction are similar to the markets for site-built contractors, with few exceptions. k-12 Education From single classrooms to complete campuses, modular construction offers public, private, and charter schools what other construction methods cannot: accelerated project timelines, more economical pricing, and less disruption. Permanent modular schools are indistinguishable from other schools and can be constructed to any architectural and customer specifications. MBI members design and build schools of all types and sizes using traditional building materials such as wood, steel, and concrete. Virtually any size permanent school can be built, installed, and ready for occupancy in as little as 90 days. Perhaps most importantly, using off-site technology, open construction sites are eliminated while school is in session. Students are safer and teachers can compete with less EDUCATION Oregon Child Development Coalition disruption. Days to complete: 287 HIGHER EDUCATION STUDENT HOUSING From single dormitories to complete campuses, permanent modular construction offers public, private, and charter schools what other construction methods cannot: accelerated project timelines, more economical pricing, and less disruption. Permanent, modular student housing is indistinguishable from other school buildings and can be constructed to any architectural and customer specifications. MBI members design and build student dorms of all types and sizes using traditional building materials like wood, steel, and concrete. Virtually any size permanent student housing facility can be built, installed, and ready for occupancy, some in as little as 90 days. OFFICE & aDMINISTRATIVE SPACE Permanent modular buildings serve as corporate headquarters, satellite bureaus, institutional and administrative buildings, and offices for all business types. Modern single- and multi-story buildings can be configured in a number of ways to include independent offices, conference rooms, elegant lobbies, kitchens, restrooms, and large open spaces for cubicles or other partition systems. MBI members have architectural and engineering designs for workspace planning, storm water management, landscaping, parking, and zoned heating and air conditioning. If it is time to capitalize on company growth, modular construction offers a fast, economical approach. BARRACKS for Enlisted Soldiers Fort Hood UEPH10 Days to complete: 337 11
  • 7. RETAIL & HOSPITALITY Market Share Simply put, quicker occupancy equals quicker return on investment. Modular construction is accelerated construction. By many accounts, it can be expected for more owners, Why is this so important to banks, restaurants, convenience developers and contractors to consider modular stores, child care centers, and other retail establishments? construction practices. In fact, the recent McGraw-Hill Because earlier occupancy means a customer generates SmartMarket Report on modularization indicates that revenue faster. In fact, it’s not uncommon for many modular contractors forecast a 22-23% increase in usage of Learning Tree Daycare buildings to be up and running in as little as 24 hours— Days to complete: 172 prefabrication and modularization over the next two an important consideration for retailers of all types. Typical years. Additionally, a recent FMI survey indicated a growth retail applications include hotels and motels, restaurants opportunity for modular construction. and diners, banks, golf pro shops, convenience stores, gas University of Toronto Ticket Booth stations, car washes, college bookstores, and concession The U.S. Census Bureau reports monthly the value of Days to complete: 160 stands, to name a few. MBI contractors provide a full array construction put in place for residential and commercial, of services including site, mechanical, and electrical work. and for public and private projects. Year end data for 2010 Customers can accommodate their emerging business with indicated that the total U.S. construction put in place was modular buildings customized to their financial needs, space about $788 billion annualized- $236 billion in residential requirements, and deadlines. and $552 billion in non residential. The non residential category can be further delineated HEALTHCARE Administration Building Days to complete: 151 into “buildings” and non building categories such as Perhaps a customer’s interest is in serving patients as quickly power, highway and street, and water supply. Building as possible in the most safe and aesthetically-pleasing categories that align with industry key markets are: environment available. If so, modular construction offers lodging, office, commercial, healthcare, and educational. quiet, safe, and clean applications for medical, surgical, These categories totaled $201 billion for year-end 2010. clinical, and dental use. The insight MBI contractors have The $2 billion PMC building market, therefore is roughly from designing and building thousands of medical facilities one percent of this total. has resulted in satisfied healthcare professionals the Kirkham Childcare Center world over. If an organization or community needs a new Days to complete: 259 Interior Below rehabilitation clinic, emergency room, operating room, hospital extension, laboratory, diagnostic center, or other medical facility, remember that modular construction can be used for custom-built facilities with the tightest budgets while maintaining strict medical and aesthetic specifications. UVa Medical Center Days to complete: 151 PUBLICLY FUNDED FACILITIES Governmental users consist of federal, state and local public sector agencies and organizations, public education entities, and military housing and administrative projects. The industry has enjoyed success in focused niches such as prisons and jails, courthouses, military installations, national and border security buildings.12 Communications Building 13 Days to complete: 335
  • 8. Case Study: target market: Bryn Athyn CollegeStudent Company: NRB, Inc. Average Size of Modules: 12’ x 52’ x 14’ Total Square Feet: 24,342 sq. ft. housinG Days to complete: 251 Architectural Excellence First Place & bEST OF show This 160-bed, 80,000 sq. ft. building, The Modules, is near Temple These three-story Residence Suites of Bryn Athyn College emulate an “old University in Philadelphia, Pennsylvania. Designed by Interface Studio world” charm prevalent on the campus, with the cut stone, brick and stucco Architects, the apartment project includes design-driven living space facade with lead coated copper trims and gutters. Each residence building and cutting-edge amenities. What’s impressive is not just that it is a contains 6 apartment style suites, with 2 double and 1 single occupancy prefab, green, contemporary apartment building, but that it may be the bedrooms, bath and beautifully appointed open concept living spaces. largest modularly-constructed LEED for Homes project in the nation. Painted gypsum in accent colors, Italian ceramic tiled floors in common areas, Major features include light-filled common spaces, generously-sized quartz countertops and solid wood cabinets and stainless steel appliances all operable windows, environmentally sound finishes, and a green roof come together to offer the students a luxurious living environment. A center terrace with dramatic views of the Philadelphia skyline. The project was stairwell opens up two stories to display a large cathedral type chandelier. designed, bid, manufactured and occupied within 12 months. Technical Innovation The steel framed building with pre-poured concrete floors offers the permanence and performance of conventional construction. The innovative use of “faux” chimneys on each building houses the lower floor ADA compliant laundry room and carries the mechanicals from the basement to the third floor suites. The entire chimney structure was prefabricated off site, and craned into position on site. Dormers were prefabricated at the plant and installed on site with the roof. Cost Effectiveness & Energy Efficiency “Modularizing” the false chimneys off site, and pre-building the dormers helped reduce the on-site time and cost as well as disruption to the campus. Each room or area of the residences have Energy Star rated P-Tach unit heat pumps installed for energy efficiency. Insulation is a combination of spray foam in the roof truss and floor areas, and fibreglass with liquid spray applied vapour barriers for the walls, exceeding most residential standards. These buildings were completely built together at the plant, including stairwells, ensuring fit and precision alignment of the modular components so site time was minimized.14 15
  • 9. FINANCIAL SURVEY RESULTS DATA COLLECTION average building project size PERMANENT MODULAR CONSTRUCTION In many cases, a project can be entirely completed by a modular contractor. These turnkey projects typically range in size from 5,000 to 10,000 square feet. In fact, respondents indicated that 65% of their projects were under 5,000 square feet; 20% of projects were between 5-10,000 square feet; and 7% of projects were between 10-25,000 square feet. Eight percent of projects reported were over Data for this report was compiled from previously conducted 25,000 square feet. surveys with contractors and manufacturing companies (both members and non–members of MBI). In addition, MBI obtained In other cases, modular construction is integrated into the overall project with a traditional general contractor overseeing the site data from a variety of sources including public statistics and work, foundation, utilities, and various phases of the building itself. These “hybrid” projects allow modular construction techniques information, information obtained from state and provincial to be employed on much larger projects than the typical turnkey modular project. It is not uncommon for modular construction to modular regulatory agencies, and direct communication with be utilized on hybrid projects exceeding 100,000 square feet. company leaders. Most modular contractors are not limited by project size, but rather by other factors such as bonding capacity, staff resources, or simply a lack of understanding about the modular process by the owner or architect. While some companies are capable of much larger projects, many survey respondents indicated that a single turnkey project in the $10-15 million range is well within their scope. production and productivity Modular manufacturers are located throughout North America, with larger “clusters” of manufacturers in Pennsylvania, Georgia, Texas, Indiana, California, and Alberta CN. Most manufacturers in North America are single location operations and can competitively transport units within a 500 mile radius of their plant. Peak employee size varied significantly obviously impacted by market and geography as well as the physical size of the plant. While not necessarily an indication of actual activity, the average manufacturer is approved to build in 20 states. In general, larger facilities employ between 140-150 workers during their peak production, while smaller plants employ between 60- 70. Many economists and state agencies use a “multiplier” to determine an industry’s total impact. Common construction industry multipliers range from 1.76 to 2.12, meaning that for every construction job, another 0.76-1.12 jobs is indirectly created. The typical modular manufacturer produced about 158,000 square feet in 2010, producing an average of 232 “floors” or “modules.” This production is about 7% less than reported in 2009. Each module is roughly 600-700 square feet, commonly 12 feet wide by 50+ feet in length. Transportation regulations are commonly the limiting factor in module size. Depending on the level of customization required by the owner and architect, most modules leave the factory 60-90% complete, with wiring, plumbing, structural, and mechanical systems inspected and approved before arriving at the site.16 17
  • 10. First Place Permanent Education over 10,000 sq. ft. Revenue & pricing North America’s Largest Modular Project Medical Education Training Center Annual corporate revenue attributed to PMC was just under $10 million per company. Over 1 Million sq. ft. built off-site Many of these companies also generated additional revenue from other sources such as general contracting services or through leasing activities associated with relocatable buildings. Companies reported an increase in pricing from material suppliers in 2010 compared to 2009. Thirty-eight percent reported increases of 1-3%, while 19% reported increases of 4-7%. Fifty percent of the PMC companies are forecasting revenues for 2011 to be about the same or slightly better than 2010 (1-5%). market indicators There are several market indicators that serve as predictors for the health and viability of the commercial modular industry. By most accounts, 2010 started off slow and ended with an overall decrease in non residential building activity. McGraw-Hill Construction (MHC) reported that non residential building dropped 9% for 2010. However, several indicators point towards an increase in construction activity in the near future. Non-Residential Construction Starts – MHC reported that new non residential construction starts for December 2010 jumped 25%, lead by a Federal Government significant increase in larger healthcare projects. While not as strong as in previous years, the federal government remains “Fortune 1” when it comes to procurement. Many construction opportunities were put on hold while Congress grappled with continuing resolutions to patch the 2010 budget. Nonetheless, BRAC and other The Architectural Billings Index (ABI) is a leading economic indicator of construction activity and shows an approximate 9 to 12 month lag time military programs still present strong opportunities for modular construction. between architectural billings and construction spending, with a score above “50” indicating an increase in billings. The ABI for December 2010 was 54.2. This marked the first time in the last three years that the ABI was above 50 for two consecutive months. research and development In Canada, Reed Construction reported that commercial construction recorded nearly 30 million square feet of new project starts, 17% higher The Modular Building Institute continues to advance construction industry competitiveness through a network of research and educational than in 2009. This growth was driven by government office buildings, recreational, and retail sectors. Industrial construction, such as projects in partners. MBI has two affiliated foundations – the Modular Building Institute Educational Foundation, a U.S. based 501(c)3 entity, and the Alberta’s Oil Sands region, are expected to lead the modular construction activities in 2011. Modular Building Institute Canadian Foundation. School Population Increase in K-12 Through these entities, MBI hosts student design competitions, awards scholarships, and underwrites white papers and other industry research. Public elementary enrollment is projected to continue a pattern of annual increases through 2016. Public secondary enrollment is projected to decrease 2% between 2007 and 2011, and then begin increasing again through 2016. Public secondary school enrollment in 2016 is expected to MBI also supports and partners with university-based programs in architecture, engineering and construction management on white papers, be about 2% higher than in 2007. presentations, and research and development opportunities.18 19
  • 11. global OUTLOOK MBI estimates the PMC market in North American is about $2 billion, making this region the largest in terms of revenue. It is expected that an additional $4 billion in revenue is generated in the modular construction industry outside of North America, perhaps higher. Data from regions that utilize modular on a regular basis is difficult to obtain. The UK is the world leader in high-rise modular construction, and Futureform Large markets for modular construction use include the UK, Japan, is undertaking one of the tallest modular buildings at 19 stories in Wembley. The project, and Australia, while China and India are poised to reshape the entire for client Victoria Hall is a student residence with over 438 student rooms. The striking construction industry. While smaller in terms of total revenue, regions new building is split into three wings around a central spiral-shaped tower. This project such as Scandinavia, where an estimated 90% of homes are prefab and also is a ‘first’ in terms of the size of the modules which are exceptionally large, being modular, are leaders in advancing modular construction techniques. around 16m’s long and 3.8m’s wide. China & India – While it is virtually impossible to get accurate construction data from these regions, no one will dispute the insatiable appetite these giants seem to have for construction services and materials. By some accounts, non residential construction spending in India is expected to exceed US $300 billion by 2013, while China’s market is expected to be double that figure. China builds the equivalent of one “Chicago-sized” city each year. A one percent market share for modular construction would equate to nearly US $10 billion in these regions, five times the size of the current US market. United Kingdom - In the U.K., the market for modular construction is approximately $2.44 billion, of which 33% is associated with leasing activity while 67% ($1.63 billion) is for sales of modular buildings. Key markets in the U.K. are similar to the U.S. – education, healthcare and offices. The modular construction industry is driven by different markets in different parts of the world. For example, the energy/extraction industry utilizes modular facilities heavily in parts of South America and Australia, as well as in Northern Alberta, Canada. Oil, natural gas, and coal extraction often occurs in underdeveloped parts of these regions, creating a demand for building infrastructure to accommodate workforce housing and administrative office space. This adoption of modular construction in the energy sector has often led to wider spread acceptance in other markets such as education, as is the case inEurope’s Tallest Modular BuildingVictoria Hall both Alberta and Australia. 20805 Modules, Built in 27 weeks. *Photos courtesy of O’Connell East Architects 21
  • 12. Projected Energy Metrics (kWh/year) 7852 Projected Energy Consumption EnviroHomes Creates Landmark modular Case study: landcaster 7882 net Z Renewable Energy net Zero energy Production Zero Carbon 0 Net Energy Use *Based on ASHRAE Benchmark kWh/year modular live/ work townhomes School Building Located in a colorful mixed industrial/artist/residential urban c ase study neighborhood in Oakland, California, ZETA launched the first Haydon Bridge High School has recently taken delivery of the first zero carbon modular school building in the UK which was manufactured by North of net zero energy, urban infill, multifamily project. England based EnviroHomes Limited. Haydon Bridge High School was awarded £1 million to create a new building that would minimise the school’s overall carbon footprint. The building is comprised of a 65 square metre classroom area, plus a 90 square metre science lab. The classroom area also The 1,540 square foot, zero lot line, townhome provides a includes a chicken coup and incubator to help the students learn directly about the rearing and care of animals. ground floor work studio, 2-bedrooms, light-filled great rooms, decks, and sustainable landscaping, in addition to a The result is a landmark building which not only showcases renewable energy but provides a state-of-the-art environment in which students can learn one car parking garage. about it. Just outside there is an area with polytunnels, a greenhouse and raised beds where students can grow their own produce. The building received a LEED Platinum rating (99.5 points out It’s zero carbon, highly sustainable and finished to a very high specification. The attention to detail is fabulous throughout and the fact that it was of 85), a 206 Green Point Rating, and EPA’s highest indoor manufactured off-site meant the school didn’t have months of disruptive construction going on during term time. Jill Collinson is the Capital Projects air quality rating, Indoor airPLUS. Additionally, this project Officer at Northumberland County Council, responsible for Carbon Management Procurement, stated “We definitely see this method of construction as has qualified for the DOE’s Builders Challenge program that the way forward for school buildings in the future. “ sets a high bar for building energy efficiency. It was also the winner of the 2009 Green Builder Home of the Year Award, Simon Astill, Managing Director of EnviroHomes explains, “Right from the start the Haydon Bridge brief called for a zero carbon building. Our ‘fabric first’ the PCBC Gold Nugget Award for Net Zero Energy, and AIA approach means starting with the choice of insulation materials to be used. Then we selected the most efficient heating, lighting and control systems to San Francisco’s Energy & Sustainability Merit Award. suit the needs of the building, the students and staff who would be using it. Finally we added renewable technologies to the building, which in this case was solar thermal & PV and a wind turbine. In fact the addition of these gives the building an A+ energy rating which shows Some building features: the building to be carbon negative, that’s to say the building will generate more power than it uses.” Zero Energy System | High Indoor Air Quality | Resource Conservation • Passive solar design This is a purpose built, permanent building with full planning permission. The other key point to make is that our efficient modular construction method • zTherm: automated energy controller provides a high quality zero carbon building, manufactured, installed and finished in 21 weeks. From the moment the manufactured sections arrived • Thermal storage conditioned basement on-site, there was a fully watertight building within 10 hours. • Ultra-efficient envelope: R-39 Roof, R-25 Walls, R5 exterior rigid foam, R-22 Floor, Serious Materials Robert Doran, Principal Building Control Surveyor for Allerdale Borough Council commented, “My role was to check the building for compliance with Windows: R-5 & R-7 Energy Star Rated building regulations which involved regular inspections for quality control and consistency. Because this method of manufacturing is done inside a • Air-to-air heat exchanger controlled factory unit, consistency is much easier to achieve. In addition there’s no degradation of materials due to bad weather. All in all this is a very • Whole-house integrated fresh air system • Heat recovery ventilator efficient construction method which has resulted in a high quality building that’s fully compliant with all building regulations. • Wastewater heat recovery system • High efficiency lighting – LED and CFL • EnergyStar™ appliances • 100% photovoltaic power • Rigid insulation wrapped building system • High performance cellulose and spray foam insulation • Sustainable finishes including locally produced artisan ceramic tiles, 100% recycled glass & cement composite countertops, locally fabricated casework and salvageable and recycled materials *Photos courtesy of EnviroHomes Ltd. - Hayden Bridge High School, Northumberland County Council *Photos courtesy of ZETA Communities, Nandita Geerdink, Louis Langlois and Taeko Takagiar22 23
  • 13. case study: energy efficiency honorable mention Green Building Design and Technical Innovation 2010 SUMMARY Performance I.Q. Classroom, built by M Space Holdings LLC and their affiliate Walden Research from construction industry experts such as McGraw-Hill Structures, Inc., is a 960 sq. ft. classroom with the utmost energy efficiency and technial Construction and FMI indicate that prefabrication and modular innovation. The classroom comes equipped with a thermal displacement ventilation (TDV) construction techniques are poised to grow at a much stronger system which regulates both the heating and cooling of the building. Cool air flows out of rate than traditional construction opportunities. The ability to a diffuser at floor level; as it starts to rise it picks up heat from the occupants and exits the incorporate lean manufacturing techniques, Building Information room through the exhaust vent located in the ceiling. This system produces improved indoor air quality, eliminates the transfer of pollutants from one occupant to another, is almost ten Modeling and sustainable construction processes are part of the decibels quieter than other units, uses 40% less energy than a standard mixed ventilation reason for wide spread optimism. approach and creates a constant and comfortable air temperature. In addition to the TDV system, the building contains one self-regulating thermostat and is energy management The reduced construction schedule advantage is appealing to any system (EMS) ready. This technology allows the temperature of the classroom, to be regulated owner or developer interested in maximizing return on investment. by a central location, allowing the district to manage and regulate appropriate temperatures In some cases, such as school campuses or healthcare facilities, the and on/off times to save energy. reduced site disturbance coupled with the quick turnaround are The structure of the classroom was designed for optimal daylighting. The building has a critical to the project’s success. vaulted open ceiling with clerestory windows, exterior light shelves, and operable casement windows. The interior light fixtures have auto dimming ballasts that increase or decrease the For these reasons, many Fortune 500 companies, government brightness of the artificial light in correspondence to the amount of natural light available agencies, architects, and entrepreneurs are fueling the growth of in the room throughout the day. The daylighting system also creates a more comfortable the modular construction industry. environment for the occupants as flicker, glare and noise of fluorescent lights often causes eye strain, irritation, headache, fatigue and/or stress. As research and awareness of these advantages becomes part of the The sound quality inside the classroom is superior. The TDV system’s low ventilation rate causes the fan motor to produce less noise than conventional conventional wisdom, the market share for off-site construction is cooling systems. Also, the majority of the ceiling is made up of acoustic ceiling tiles. The tiles help to keep the classroom quiet by reducing the expected to double over the next five years. reverberation of noise generated both inside and out of the building. The classroom has a full steel moment frame structure, a concrete floor, 6” steel studs, and 5/8” drywall underlayment making it a strong and durable structure. Materials were selected from recycled or recyclable products as much as possible. Recycled/recyclable products include, steel components (i.e. steel frame, studs, door, window frames) acoustic ceiling tiles, carpet, tile and fiber cement siding panels. This classroom exceeds Title 24, California’s Energy Efficiency Standards for Residential and Nonresidential Buildings, by 26% in interior lighting and exceeds the total energy efficiencies in Title 24 by 40%. The building also has a web based Crestron control keypad. This keypad controls the lights, thermostat, audiovisual equipment and any other technology that may be present in the classroom. 24 25
  • 14. Board of Directors 2011 MBI Sponsors Champion Commercial Solutions championhomes.com MBI sponsors are commercial modular construction leaders who President Board Members: align themselves with MBI in a collaborative effort to promote the DeLuxe Building Systems, Inc. Mike Ridley Rick Bartolotti Harry Klukas industry, educate participants within the industry, and ensure a deluxebuildingsystems.com President President Senior VP positive and ethical business environment throughout the industry. Construction Simplified TM 800-843-7372 ext 281 Britco Structures Universal Modular Building Solutions, Inc. johnerb@deluxebuildingsystems.com Black Diamond Group www.deluxebuildingsystems.com 8 Storeys Kendra Cox Nora McGrath M Space Holdings President Elect Production Manager - Stayton Director mspaceholdings.com John Lieffrig Region Vice President Blazer Industries, Inc. M Space Holdings LLC Above: Example of an 8 Story Building ModSpace William Duffield Christopher Peterson Universal Modular Building Solutions, Inc. “Year-round assembly with up to 50% faster time to occupancy.” Building Modular Mid & High Rise VP and General Manger Vice President, Finance & Operations umodular.com Commercial Residential Structures Throughout the Mid-Atlantic, Northeast, & Caribbean Vice President McDonald Modular Solutions, Inc. Satellite Shelters, Inc. www.deluxebuildingsystems.com Building Modular Mid & High Rise 800.843.7372 ex. 281 | johnerb@deluxebuildingsystems.com Commercial Residential Structures Michael Bollero Throughout The Walter Griffin Laurie Robert Mid-Atlantic & Northeast & Caribbean President/CEO NRB, Inc. Modular Program Manager VP Sales & Marketing Southern Modular Industries, LP nrb-inc.com Mule-Hide Products Co., Inc. NRB, Inc. Treasurer Garth Haakenson Kathleen Tell Gary Bockrath CEO/President VP Sales Ramtech Building Systems MBI Headquarters CFO Pacific Mobile Structures, Inc. Tell Manufacturing, Inc. ramtechmodular.com Acton Mobile Industries 944 Glenwood Station Lane, Suite 204 Bill Haliburton Jody Werner Charlottesville, Virginia 22901 USA Vice President, Manufacturing Vice President & General Manager, Southeast Walden Structures, Inc. Secretary Toll-free phone: 888-811-3288 ATCO Structures & Logistics, Ltd. Vanguard Modular Building Systems, LLC waldenstructures.com Wesley Carter Phone: 434-296-3288 Walden Structures Awarded NAVFAC Permanent Sales Manager Doug Henriquez Kathy Wilmot Fax: 434-296-3361 Modular Barracks Warrior Group Director Vice President info@modular.org Clayton Building Solutions Wilmot Modular Structures, Inc. www.modular.org Warrior Group, Inc. warrior-group.net Past President Joseph Lopardo Vice President, Modular Buildings MBI Staff Size: 37,000 sq. ft. Currently Under Construction For more information, please contact us at: 801 Opal Avenue, Mentone, CA 92359 Williams Scotsman Phone (909)389-9100. Fax (909)389-9134. Website: www.waldenstructures.com Evans-Kimmell Hall Executive Director Accountant & Office Manager Days to complete: 113 Executive Director Tom Hardiman, CAE Annie Diggs Tom Hardiman x 158, tom@modular.org x 157, annie@modular.org Executive Director Modular Building Institute Operations Director Marketing Specialist Steven Williams Joni Lane, LEED Green Associate x 153, steven@modular.org x 156, joni@modular.org Cover Image: The Modules Photo by Sam Oberter Photography Communications Manager Business Development Director Back cover Image: Kirkham Childcare Center Erin Whitt David Sikora x 152, erin@modular.org x 155, david@modular.org26 27 © 2011 Modular Building Institute, all rights reserved. All products are trademarks or registered trademarks of their respective owners.
  • 15. Modular Building Institute 944 Glenwood Station Lane, Suite 204 Charlottesville, Virginia 22901 USA Toll-free phone: 888-811-3288 Phone: 434-296-3288 Fax: 434-296-3361The Voice of Commercial Modular Construction™ info@modular.org28