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Modular Construction Cubix Othello Multifamily Case Study
- 1. Multi-Family Case Study: CUBIX OTHELLO Sponsored by Housing Development Consortium
- 2. Your Presenters Matthew Laase Principal Jackson | Main Architecture Craig Mitchell Director Innovative Solutions Metric Modular Daniel Stoner NexGen Housing Partners
- 5. 13 How Can We Build Affordable And Market Rate?
- 6. Innovative Strategies Such As Modular Give Us an Advantage
- 7. Why Aren’t More Developers Pursuing Modular?
- 8. Most Modular Builders Stop After One Project … Is it an indictment of the technology? The developer? Why?
- 9. The Answer is a Multi-Project Thesis Answered in 3 Phases:
- 10. Multi-Project Thesis 3 Phases Proof of Concept MODULAR 1.0 Create a Set of Modular “Legos” MODULAR 2.0 Apply “Legos” to a Variety of Different Building Sites MODULAR 3.0
- 11. Cubix North Park Modular 1.0 108 Units 93 Efficiency Units / 15 Live / Work 4 Stories Type V-A 3 Stories of Modular Modules Set To Occupancy: 15 Months
- 12. Cubix Othello Modular 2.0 6 Stories, 85 Units NC3-P85 (1.3) IZ 5 Floors of Type I-A 56 Studio Units / 29 1-BDRS Modules Set in 6 Days! From MOD-Set to Occupancy: 10 Months
- 13. Tour of Othello Video Placeholder
- 15. Modular Benefits Stable Pricing $ • Factory work is done under contract • No wage requirements for factory-built structures Build in Controlled Environment • Multiple buildings can have duplicate parts ensuring brand consistency • Trade damage and sequence issues are avoided in factory Excellent Quality Control • Factory allows for high quality and consistency within a controlled environment • Multiple buildings in a portfolio can be assembled with similar parts ensuring brand quality Assembly Line Efficiency • Modules arrive with finishes in apartments • Modules set onsite in weeks rather than months of framing Pre-Approved Building Components • State-approved building plans make up most of local building permit • Pre-approved modular units can be re-used in multiple projects, expediting permit process
- 16. Modular Integrated Design Traditional DAY 1 6 MONTHS 12 MONTHS 18 MONTHS Design Timeline
- 17. Design DAY 1 6 MONTHS 12 MONTHS 14-15 MONTHS Standard Construction
- 18. Design DAY 1 6 MONTHS 12 MONTHS 14-15 MONTHS Modular Construction
- 19. Disruptive strategies are needed to meet the 2030 building challenge of 100% net zero buildings Factory built construction emits 43% less carbon than site built Typically 10% of construction materials can end up waste, modular factories can achieve less than 2% Passive house level envelope for a 4-8% increase Single source of procurement for specified materials Skilled labor trades can be cross-trained in many construction fields with experience in manufacturing and even robotics! Sustainability Is Built in the Factory
- 20. Design: It’s in the Details
- 21. Modular Building Basics Kit of Parts Pre-Approved Boxes Pre-Approved Connection Details
- 22. Jurisdiction Modular Builder Design Team Coordinated reviews Eliminate in-unit matelines No MEP shafts Simple structural system Bad weather set More factory work More off-site construction Coordinated inspections Modular Design: Opportunities & Improvements
- 23. Corridors act as drag struts, precast stair towers as shear columns No vertical wood shear walls No vertical tie rods Simple exterior sheathing connection Smaller boxes eliminate need for panelized inside & outside corners 19 Design Concept: Structural Drag Struts – Collectors – Saw Boxes
- 24. How do the site trades coordinate and interact during the set? Set sequence plan Draft stop planning Inspections and AHJ coordination Detailed set coordination planning Staging site location How many crane picks? Stacking order, boom lock? Modular Design It’s in the Details
- 25. Adding the element of time to your details Defining the scope of work for each component Any inspections required, by who and when? Modular Design It’s in the Details
- 26. Adding the element of time to your details Defining the scope of work for each component Any inspections required, by who and when? Modular Design It’s in the Details
- 27. Corridors do all the hard work MEP coordination has to be done to BIM 400 level Balance factory work vs. site work Pay attention to fire membrane continuity Make your details inspectable Modular Design It’s in the Details
- 28. Modular Team Fit: Who’s In, Who’s Out?
- 30. The Why & The How to Build A Prototype
- 31. Prototype Schedule Where do you schedule a prototype in?01 Understand Why to Build a Prototype Is it for constructibility, or for design elements?02 How to Build a Prototype Understanding owner-supplied materials vs. factory-supplied and disruption to the process 03 Costs of a Prototype Is it a stand-alone module or does it get incorporated in?04
- 40. Logistics Your logistics partners Are they prequalified?01 International Considerations Paperwork, Customs, Duties: What to know 02 Lay-down Yards & Neighborhood Disruptions Considerations 03 Module Setting Set plan and coordination04 Loose Ship Items Some things to think about …05 Requirements: Roofing / Elevator / Doghouses built / Buttoning up on site 06
- 46. How Do We Expedite Permitting?
- 47. Permitting: The Dual Stream & Coordination Early Coordination Meetings STATE PERMITS Submitted in Phases, Required State Approval Prior to Review LOCAL PERMITS WA Labor & Industry (L&I) FACTORY INSPECTIONS During Crane Setting: Welding Firestopping Structural SPECIAL INSPECTIONS During Setting
- 49. 35% of Time in Permitting Is spent Producing Drawings Administrative design review and priority review of modular projects with MHA performance over required minimums Pre-approved modular unit plans for SEDU and OH compliance Additional in-person meetings • Post cycle 1 corrections coordination • Multi-department coordination • Reduce correction cycles • 1 less correction cycle can save 2-3 months Long lead times and backlogs for reviews with multiple correction cycles • Over 100 hours spent between architect and OH coordinating housing declaration and covenant Complicated OH process for IZ and MHA performance Long lead time and backlog for DRB Calendar Multi-departmental coordination issues DAY 1 6 MONTHS 12 MONTHS 18 MONTHS Neighborhood Meeting Early Design Guidance Design Review Board Modular Permitting:
- 51. Challenges Outside the Box: Modular Financing
- 52. Challenges Outside the “Box”: Modular Financing Loan Committees prefer easy deals!01 General lack of experience makes Loan Committees nervous!02 Financing a Modular Project has “unique” requirements • It’s a Personal Property until it’s affixed (UCC filings needed) • Draw requests could be more frequent than monthly • Deposit required to start ordering materials • Balance sheet strength of the modular building 03
- 53. Challenges Outside the “Box”: Modular Financing Irony Alert! The stronger the economy, the harder to get a modular loan! 04 How do you get a Loan Committee to buy into “unique” requirements? • Work hard to get early buy-in / anticipate concerns • Modular as a tool in the affordable housing toolbox • Have an experienced team 05
- 54. What Have We Learned?
- 55. Design: Lessons Learned Early Collaboration • With the modular manufacturer design/engineering team a necessity 01 Material/Product decisions • Requires advance thought and commitment 02 Site-Built Coordination • It cannot be figured out during construction if it is to match the offsite components 03 Prototype Box Review • A critical part of the process04 Simplify, Simplify, Simplify • The advantage of modular is efficiency, the design is a key component to that 05
- 56. Manufacturing: Lessons Learned Timing between module prototype construction and main production run 01 Suite mix drives modular construction efficiency02 Don’t overlook transport coordination and logistics03 Load and Close – who should supply what04 Weekly team collaboration meeting a must05
- 57. Construction / Ownership: Lessons Learned Pre-construction coordination with City Officials, inspectors, etc. 01 Have roofing components built off-site as well as (dog houses, parapets, etc.) 02 Pre-fabricating the hallways03
- 58. Questions? Thank You! This concludes our Multi-Family Case Study