Mass.Production by Northeastern School of Architecture

School of Architecture Northeastern University 151 Ryder Hall 360 Huntington Ave Boston, Ma 02115 http://www.northeastern.edu/camd/architecture/ 617.373.8589 Copyright ÂŠ 2014 School of Architecture Northeastern University The texts and images included in this booklet are intended for academic purposes only. No parts of this bookelet may be copied, reproduced, replublished, uploaded, posted, transmitted, or distributed in any way for commercial purposes.

MASS

N O I T C U D PRO Northeastern University School of Architecture ARCH 7130 Masterâ&#x20AC;&#x2122;s Research Studio

Edited by Ivan Rupnik with contributions from Sara Briggs, Thanhthuy P. Bui, John R. Burns, Kevin Chen, Sasha Clark, Julien Jalbert, Amanda Lockwood, Habib Maddahi, Maria Pantou, and Brian Sands

MASS PRODUCTION TABLE OF CONTENTS

THE MODULAR INDUSTRY

Industrial housing delivery as seen through prefabricated construction is composed of several types and techniques.

1.1

UNDERSTANDING THE INDUSTRY HAMED “HABIB” MADDAHI

THE ROLE OF THE ARCHITECT

These case studies exemplify the role architects have played in redefining the modular industry and their relation with.

2.1

Prefabricated construction has been an architectural interest for over a century, and this chapter provides insight into the similarities and differences between the modular and manufactured housing industries, and how they have evolved from a common ancestor.

1.2

EPOCH HOMES - A CASE STUDY JULIEN JALBERT

MODULAR INDUSTRY TECHNOLOGY SASHA CLARK

Contextualizing the modular ‘box’ as a product within the construction industry, this chapter compares it to other standard products, documents new products intended for use in conjunction with the box, and considers future technological trends in the modular industry.

AMANDA LOCKWOOD

Resolution 4 Architecture’s Modern Modular has been redefining the role of the architect since their Dwell feature in 2004; this chapter exhibits RES 4 as the exception of industry relationships, as they incorporate communication and collaboration with the modular industry.

2.2

Epoch homes is the only modular housing facility within 100 miles of Boston, and this chapter explores this typical manufacturer in terms of its production scale, material choice, and building & delivery ecology.

1.3

RESOLUTION 4 ARCHITECTURE

STEEL FRAME JOHN “RYN” BURNS

The steel frame modular is the investigation of this chapter, examining the structural system that allows greater freedom of form, achieves up to 90% finished factory construction, ensures precision installation, and interfaces with the intermodal transportation network.

2.3

ONION FLATS KEVIN CHEN

Onion Flats is an architecture firm specializing in the modular; this chapter looks at how they successfully employ the unique business model of vertical integration; establishing a relationship between the modular industry, multi-unit housing, and their unique mode of practice.

MACRO INITIATIVES

The macro issues of disaster response and displacement create a viable market for the modular industry to enter.

3.1

INTERNATIONAL - UNHCR THANHTHUY PHAM BUI

MICRO INITIATIVES

Boston has the potential to become a laboratory for affordable modular housing at a municipal and state scale.

4.1

With millions of people being forcibly displaced by disasters ever year, the modular industry could meet the everrising demands for proper housing solutions; this chapter investigates how architects can introduce a design solution to this political issue.

3.2

NATIONAL - FEMA BRIAN SANDS

FEMA is a national organization focusing on the delivery of large quantities of both manufactured and modular housing; this chapter looks at FEMA and the growing interest in more permanent housing solution for displaced peoples.

MASSACHUSETTS INITIATIVES MARIA PANTOU

Current MA housing plans, including the Compact Neighborhoods Plan and Boston Housing 2030, require dependable demand over an extended period of time which is a characteristic for industrialized housing delivery: this chapter investigates how the agendas of these plans can be potentially fulfilled by the modular industrial ecology.

4.2

TACTICS + IMPLEMENTATION SARA BRIGGS

In order to address these initiatives, the modular industry will have to embrace building types beyond the singlefamily home; this chapter explores new types that the modular industry is beginning to explore and those it has the ability to address.

THE MODULAR INDUSTRY

THE MODULAR INDUSTRY 3

1.1 UNDERSTANDING THE INDUSTRY Architects have been allured by prefabricated construction for over a century. Since the formulation of the HUD code in 1976, manufactured and modular housing have developed in tandem, both evolving in different ways. While most manufactured housing is restricted to single family housing, modular, which is more flexible in nature has the potential to provide multi-unit housing for densifying populations.

UNDERSTANDING THE INDUSTRY 4

MODULAR VS. MANUFACTURED INTRODUCTION The modular and manufactured housing industries share a common ancestor. With the introduction of a new building code by the U.S. Department of Housing and Urban Development (HUD) in 1976, what were orginally referred to as ‘mobile homes’ would be labeled as ‘manufactured housing.’ The strict new building code was administered to improve safety and standards for a housing type of growing popularity and affordability. The industrial process used to produce these manufactured homes proved to be more efficient in many ways than typical ‘stick-built construction.’ The modular building industry was most likely born from this method of housing manufacturing. There are several differences between the modular and manufactured industries, which are primarily dictated by the HUD building code. Manufactured homes, by code, are required to be built and remain on the metal chassis which is used to transport them to their final site. In contrast modular units are almost always removed from their shipping chassis. Modular units must adhere to local building codes and regulations, whereas

manufactured units are regulated by the Federal HUD code. This federal regulation allows for inspections during the production process, which enables expedited occupancy for home-owners. Both modular and manufactured units are often referred to as “boxes” within the industry. As a federally regulated program, the manufactured housing industry is welldocumented and each home is provided with a standard identification plate, however this is not the case for modular.

US TOTAL 9.0% MAN.

2.0% MOD.

POP. 316,128,839

Until recently, manufactured housing was restricted to single story construction, but developers have started to experiment with stacking multiple manufactured Manufactured & modular housing market share - 2013 modules. HUD code aside, the modular and manufactured housing industries are more similar than is generally perceived.

THE MODULAR INDUSTRY 5

upÊtoÊ11Êft 12Êft up

Êto

Ê90

Êft

Ê72

Êft

Êft ideÕ) Ê18 Êto e-w up oubl tÊÔd 0Êf

Êft

Ê15

Êto

A typical manufactured housing module is: - Policy driven - Regulated by Federal building code (HUD) - Fixed to its transportation chassis

A typical modular housing module is: - Market driven - Regulated by local building code - Removed from its chassis then aggregated

UNDERSTANDING THE INDUSTRY 6

MARKET SHARE (2013) - MANUFACTURED / MODULAR POP.Ê74,254,423

POP.Ê67,547,890

85.7%

POP.Ê55,943,073

4.5%Ê MAN.

0.5%Ê MOD.

5.7%Ê MAN.

4.0%Ê MOD.

11.8%Ê MAN.

7.2%Ê MAN.

7.2%Ê MOD.

1.0%Ê MOD.

POP.Ê118,383,453 The modular and manufactured housing industries have varying concentrations across the US. In 2013, manufactured housing in the south was significantly more prevalent than modular, the northeast was split evenly between modular and manufactured housing, and the midwest was similar to the northeast in this split. More manufactured than modular housing can be observed in the

western United State, which has been the trend for many years, and which could possibly be attributed to seismic conditions, therefore dissuading builders from adopting modular construction.

THE MODULAR INDUSTRY 7

PERCENT PRODUCTION CHANGE IN HOUSING MARKET 100

-100

The housing market in the United States operates cyclically, with ups and downs that are dictacted by a myriad of varying economic and social trends. The modular and manufactured housing industries are stronger in different regions of the United States, the former being more dominant in the northeast, and the latter more dominant in the southern region of the country.

100

NORTHEAST

-100 50

SOUTH

-50 100

MIDWEST

-100 200

WEST

-200

Ô03

Ô04

Ô05

Ô06

Ô07

Ô08

9 Ô0

Ô10

Ô11

Ô12

Ô13

After the economic downturn of 2008, the housing market plummeted, but has since returned to a steady increase. This demand has begun to shift over recent years, towards more manufactured and modular housing compared to the normative site-built construction. The economic crash may have forced developers and homebuyers to pursue safer and standardized home construction methods, as banks became more willing to provide mortgages for site-built construction as opposed to industrialized housing. Notably, studies have shown that the manufactured housing industry has been declining since 1996, and this can most likely be attributed to the availability of home loans described above.

MODULAR

MANUFACTURED

SITE-BUILT

UNDERSTANDING THE INDUSTRY 8

MODULAR & MANUFACTURED DATA SOURCE DESCRIPTION

Manufactured

Modular

Three data sources have been utilized to map the modular home industry: Google maps; NAHB (National Association of Home Builders and Modularhomeowners.com. Each of these resources had their advantages and limitations. The Google maps application has the advantage of accessing a large number of companies around the country in expense of accuracy. The other two resources had more detailed information, for instance, information about a companyâ&#x20AC;&#x2122;s market area. However the number of companies that they had in their dataset were very limited. By comparing these three datasets we were able to identify the modular home industry distribution around the country and realize which regions have the most number of companies. The Manufactured/Mobile home sector database was created from two sources, Manufactured housing institute (MHI) and U.S. Department of housing and Urban Development (HUD). Out of these three data sources only the MHI website provided more detailed information including Market area of companies.

modularhomes network.com

THE MODULAR INDUSTRY 9

CREATING THE DATASET !

! !

Google maps Api provides a service to query place information on a variety of categories. To acquire data from Google maps API, some mandatory information is required. Additionally several optional inputs can refine returned data. In this project NearSearch has been selected to carry out the job. Our goal was to find the name and location of the modular home companies and factories. Google maps

! !

50 ,0 00

! !

et er

! !

r = 50,000 m 2X2 = r2 X = 35355.3 m Y = 70710.6 m

needs Location, building type and keywords as the input to return the data. Location values in google api determines the center of a circle with a maximum radius of 50,000 meters. “Establishments” and “modular+home” were used as building type and keywords respectively. Due to the limitation of search distance radii, In Arcmap, the USA map has been segmented to 2,242 squares. The latitude and longitude of the center UNDERSTANDING THE INDUSTRY 10

MAP OF MODULAR & MANUFACTURED VENDORS

Modular Manufactured

Modular and manufactured home vendors based on google map search

point of each square was then calculated. These numbers were then inserted into a python script which created request codes to send to google maps api. The results of each request has been saved into a single cell of excel spreadsheet

for further processing. One of the challenge was parsing the useful data within returned data which were in JSON format. 12,886 data points were obtained. After filtering for duplicates 4,599 data points were remaining. In further refinement and

THE MODULAR INDUSTRY 11

filtering non-related types of buildings, 3,208 data points were remaining to represent modular industry vendors throughout the U.S.

UNDERSTANDING THE INDUSTRY 12

MODULAR HOMES COMPARING THE DATASETS

After retrieving data from NAHB and the modular home owners website to turn them into an excel dataset, and also geocoding the addresses via google geocoding api, we compared these three datasets. Almost all of the datapoints introduced by NAHB and modular home owners were within googleâ&#x20AC;&#x2122;s datapoints, NAHB had 34 points and modular home owners had 217 points in common with the Google

dataset. According to the map above and the graph on the next page we can recognize three regions in U.S. that have the most number of vendors in the modular home industry. In conclusion, the highest density of vendors are in Texas, California, Pennsylvania, New York, Virginia and the Carolinas.

THE MODULAR INDUSTRY 13

A las ka Hawaii P uerto R ic o Dis tric t of C olumbia Delaware A rkans as Mis s is s ippi R hode Is land S outh Dakota Wyoming North Dakota Utah Idaho Montana K ans as Nevada K entuc ky Nebras ka V ermont C onnec tic ut Mis s ouri New Mexic o A labama Maryland New Hamps hire Oregon Oklahoma Wes t V irginia New J ers ey G eorgia Iowa Minnes ota A rizona C olorado Mas s ac hus etts Maine T ennes s ee L ouis iana Was hington S outh C arolina Indiana Illinois F lorida Ohio Wis c ons in V irginia Mic higan New Y ork North C arolina P enns ylvania C alifornia T exas

% of T otal C ount NAHB

15%

10% 20%

15%

5% 10%

This graph shows the distribution of vendors by each state. The graph at top of the page is from google maps and below it is the graph based on the NAHB and modular home owners

% of T otal C ount T op

% of T otal C ount Google Map

DISTRIBUTION OF DATA BY STATES S T AT E NAME

Meas ure Names % of T otal C ount Google Map

% of T otal C ount NAHB

% of T otal C ount Top Modular

30%

25%

website. Data from NAHB and modular home owners are accurate. There is a similar trend between the two graphs, therefore demonstrating that the google mapâ&#x20AC;&#x2122;s data is reliable. UNDERSTANDING THE INDUSTRY

NORTHEAST MODULAR PRODUCTION FACILITIES Currently there is only one modular facility within 100 miles of Boston, Epoch Homes in Pembroke, NH. This is indicative of the the vehicular miles, costs, and time required to prefabricate and ship modules to the city and the surrounding metropolitan area.

There are approximately 34 modular housing production facilities in the northeastern United States. Twenty of these facilities reside in Pennsylvania, which accounts for almost 60% of the total. Notably, there are no facilities located in Massachusetts, and prefab modular units tend to be imported from surrounding states.

NORTHEAST

UL AR

100%

TURE

UFAC

MAN

UILT

-B SITE

Boston, MA 1

Ô12

Ô13

100Êmi.

Ô11

-100 30

34 600Êmi.

200Êmi.

500Êmi.

400Êmi.

THE MODULAR INDUSTRY 15

300Êmi.

Pop. 4,684,299

TEXAS MODULAR PRODUCTION FACILITIES In comparison to the northeast, Texas has approximately 15 modular housing production facilities, which all fall within or immediately adjacent to major metropolitan areas.Considering the dense and continuously expanding population of larger cities in the state of Texas, modular construction as well as manufactured housing, are an efficient and affordable means of supplying the housing demand.

Fort Worth

Dallas

Pop. 6,817,483

SOUTH 50% Pop. 4,117,054

Austin

0 San Antonio

Houston

50mi.

Pop. 6,371,667

-50

Ô11

Ô12

Ô13

MODULARÊNETWORKSÊKEY Manufacturer

Highway

MetroÊArea

UNDERSTANDING THE INDUSTRY 16

PENNSYLVANIA

NORTHEAST PRODUCTION FACILITIES - AERIAL COMPARISON

THE MODULAR INDUSTRY 17

NEW HAMPHSHIRE

MAINE

NEW JERSEY

VERMONT

NEW YORK

There are approximately 34 modular housing production facilities in the northeast. These aerial photographs show the facilities within their immediate surrounding context. All of these images are captured at the same scale, in order to provide insight into the varied size and footprint these facilities occupy. The vast majority of these facilities utilitize the Butler building to house their operations, which is practical considering the flexibility this typology can provide for floor space. Most of these facilities are located on larger roadways, for a more efficient and timely distribution. The majority of these companies are located in more rural areas.

Of these 34 factories, 20 are located in Pennsylvania alone, with five times more facilities than any other state. There are many factors that may contribute to this anomaly, arguably the most significant being a centralized location for maximum distribution potential across the United States. There are no factories located in Massachusetts, and the closest known facility to Boston is Epoch Homes, which is approximately 75 miles away, in Pembroke, NH.

UNDERSTANDING THE INDUSTRY 18

AGE OF BUILT FABRIC/ PREFAB FACILITIES NORTHEAST The age of built fabric maps of Northeast and Texas show that median age of buildings in Northeast are mostly before 1980 and for Texas mostly after 1980. Manufactured housing industry (HUD) started from 1976 and modular industry should have started around the same date. There are 34 prefab facilities In

Northeast and 15 in Texas. There is no clear correlation between the age of the fabric and number of facilities and number of prefab building in these regions.

NORTHEAST

D TURE UFAC LT -BUI SITE

MAN

Pop. 4,684,299

Ô12

Ô13

100Êmi.

Boston, MA

600Êmi.

200Êmi.

500Êmi.

400Êmi.

300Êmi.

85.7%

POP. 55,943,073

7.2% MAN.

7.2% MOD.

THE MODULAR INDUSTRY 19

TEXAS

Fort Worth

Dallas

Pop. 6,817,483

SOUTH Pop. 4,117,054

Austin San Antonio

Ô12

Houston

50mi.

Pop. 6,371,667 85.7%

Ô13

RÊNETWORKSÊKEY

urer

Highway

MetroÊArea

11.8% MAN.

1.0% MOD.

POP. 118,383,453

UNDERSTANDING THE INDUSTRY 20

HOUSING UNITS GROWTH % 2009-2014/ PREFAB FACILITIES NORTHEAST The housing units growth map in Northeast shows that there isn’t a direct relation between housing units growth and distribution of prefab facilities. For instance in radius distance of 200 mile from Boston which is the efficient distance to ship the product there are only 8 facilities. However in Texas all the facilities are reside

in the highest growth rate areas.

NORTHEAST

D TURE UFAC LT -BUI SITE

MAN

Pop. 4,684,299

Ô12

Ô13

100Êmi.

Boston, MA

600Êmi.

200Êmi.

500Êmi.

400Êmi.

300Êmi.

85.7%

POP. 55,943,073

7.2% MAN.

7.2% MOD.

THE MODULAR INDUSTRY 21

TEXAS

Fort Worth

Dallas

Pop. 6,817,483

SOUTH Pop. 4,117,054

Austin San Antonio

Ô12

Houston

50mi.

Pop. 6,371,667 85.7%

Ô13

RÊNETWORKSÊKEY

urer

Highway

MetroÊArea

11.8% MAN.

1.0% MOD.

POP. 118,383,453

UNDERSTANDING THE INDUSTRY 22

2014 HOUSEHOLD INCOME (MEDIAN)/ PREFAB FACILITIES NORTHEAST The Household income map shows that necessarily facilities are not located in the high income areas however all of them are within the 200 mile radius of high income areas. Interestingly in Texas which is the most dense area of prefab vendors, also in Dallas has the most dense area of prefab facilities. Seven facilities

reside inside the high density area of the city surrounded by low density donut-shaped area where people has the highest income.

NORTHEAST

D TURE UFAC LT -BUI SITE

MAN

Pop. 4,684,299

Ô12

Ô13

100Êmi.

Boston, MA

600Êmi.

200Êmi.

500Êmi.

400Êmi.

300Êmi.

85.7%

POP. 55,943,073

7.2% MAN.

7.2% MOD.

THE MODULAR INDUSTRY 23

TEXAS

Fort Worth

Dallas

Pop. 6,817,483

SOUTH Pop. 4,117,054

Austin San Antonio

Ô12

Houston

50mi.

Pop. 6,371,667 85.7%

Ô13

RÊNETWORKSÊKEY

urer

Highway

MetroÊArea

11.8% MAN.

1.0% MOD.

POP. 118,383,453

UNDERSTANDING THE INDUSTRY 24

HOUSING VALUE (MEDIAN)/ PREFAB FACILITIES NORTHEAST The housing value map in northeast shows sparse distribution of prefab facilities in the most expensive areas. 11 out of 34 facilities are reside in this area. In Texas except three facilities all the facilities are within 100 mile distance of major cities. majority of companies prefer to keep their facilities close to the major cities

while it’s more expensive than suburban areas.

NORTHEAST

D TURE UFAC LT -BUI SITE

MAN

Pop. 4,684,299

Ô12

Ô13

100Êmi.

Boston, MA

600Êmi.

200Êmi.

500Êmi.

400Êmi.

300Êmi.

85.7%

POP. 55,943,073

7.2% MAN.

7.2% MOD.

THE MODULAR INDUSTRY 25

TEXAS

Fort Worth

Dallas

Pop. 6,817,483

SOUTH Pop. 4,117,054

Austin San Antonio

Ô12

Houston

50mi.

Pop. 6,371,667 85.7%

Ô13

RÊNETWORKSÊKEY

urer

Highway

MetroÊArea

11.8% MAN.

1.0% MOD.

POP. 118,383,453

UNDERSTANDING THE INDUSTRY 26

the modular industry 27

1.2 EPOCH HOMES - A CASE STUDY In terms of production scale, materials, building and delivery methods, Epoch Homes is a typical modular manufacturer within the industry. Their production facility is the only modular housing factory within 100 miles of Boston, and there are no facilities of this kind in Massachusetts. Originally focused on single family home production, during the 2008 recession Epoch shifted its focus to high-end and multi-family housing, a steady demand that did not succumb to the downturn of the economy.

epoch homes - A case study 28

epoch homes introduction This case study intends to provide an understanding of how a typical modular housing company operates within the industry. As a producer of homes, Epoch Homes is both generic and specific in its practice, which makes for an excellent study model to learn from, and potentially expand upon. Located in rural Pembroke, NH, Epoch Homes was founded in 1983 by a small family of builders dedicated to custom quality homes. The factory that Epoch operates out of is in its 2nd generation, the original company that went on to become Epoch Homes originated in the 1970s. Epoch prides themselves on combining the finest materials and old world craftsmanship with the efficiencies and economies of modular construction â&#x20AC;&#x201C; a term that describes a construction approach, rather than any particular style of home.

around 200 to 16,000 square feet, respectively. Since their inception in 1983, Epoch has constructed more than 4,000 homes. With the economic downturn of 2008, Epoch was hard hit and forced to downsize its workforce. In 2006 prior to the crash, the company was acquired by a larger investor, which was a significant factor saving Epoch from financial ruin. With housing demands developing in Massachusetts, the modular industry can play a significant role in addressing this need in a more timely and cost effective manner compared to traditional construction methods.

Epochâ&#x20AC;&#x2122;s 65,000 square foot production facility employs 115 skilled professionals, who build from 100 to 160 unique homes and additions each year, ranging from 1 module to 33, the modular industry 29

OR SMALLER OVERARCHING TITLE

An Epoch employee, with the company for thirteen years, displays with pride a rendering of one of their more recent large scale projects. (Jalbert, September 2014) EPOCH HOMES - A CASE STUDY 30

REGIONAL IMPACT Epoch Homes serves and is centrally located in New England. Their production facility, located approximately two miles from New Hampshire’s capital, is only minutes from two major interstates which connect to neighboring states. Like most modular companies, the interstate is crucial to their success, as truck distribution is the primary means of delivery for the industry.

95 93 93

Concord,ÊNH

Epoch Homes

89 90

rri

1Êmile

ÊR

ive

statesÊserved STATES SERVED majorÊinterstate INTERSTATE THE MODULAR INDUSTRY 31

RANGE OF HOME SIZES The average home that Epoch constructs is between 2 and 4 modules, and will take approximately 2 days to complete work within the factory. On the far end of the spectrum, Epoch also builds much larger homes, such as the 20 module spec house. Epoch Model Home

Pembroke,ÊNHÊ

Builder Spec Home

Greenwich,ÊCTÊSpecÊHome 20ÊmodulesÊ-Ê11,000ÊSF

TypicalÊNewÊEnglandÊHome 4ÊmodulesÊ-Ê2,200ÊSF

approximateÊhomeÊcostÊ($80/SFÊavg.)

Greenwich,ÊCTÊ

ÊÊÊÊÊÊ ModelÊHome

This study demonstrates that the modular industry can build projects of varying scales, and Ê ÊÊÊÊÊÊ BuilderÊSpecÊHome is well equipped to provide housing of varying sizes and types. The current initiatives in Massachusetts requesting more housing throughout the state can be addressed using modular construction.

$1,000,000

$880,000

$500,000

$176,000

xesÕ #ÊofÊÔbo x ÊSF/bo

avg.Ê550

2 avg.Êhouse

module construction timeframe at factory (days) 2

Epoch Home Costs vs. Production Time EPOCH HOMES - A CASE STUDY 32

PRODUCTION FACILITY

Aerial views of both the Epoch facility (above) and its exterior production line (right). THE MODULAR INDUSTRY 33

EPOCH HOMES - CASE STUDY 34

PRODUCTION FACILITY BREAKDOWN INTERIOR PRODUCTION

1.6a 1.6a

1.3

1.5 1.3 1.6a

1.6b 1.1 1.6b

1.4

1.2

1.5

1.6a

1.6a 1.7

1.7

1.8 0

FACTORYÊPLAN INTERIOR 1.1Ê-ÊRailÊsystem 1.2Ê-ÊWallÊframingÊstation 1.3Ê-ÊFloorÊ/ÊceilingÊdeckÊframingÊstation 1.4Ê-ÊRoofÊframingÊstation 1.5Ê-ÊGeneralÊmaterialÊstorageÊ(aboveÊ&Êbelow) 1.6Ê-ÊOverheadÊingressÊ(a)ÊegressÊ(b)Êdoors 1.7Ê-ÊFramingÊmaterialÊstorage 1.8Ê-ÊOffice

50Êft

THE MODULAR INDUSTRY 35

EXTERIOR PRODUCTION 2.2

2.3

FACTORY

2.2

2.3

2.1

2.4 2.5

2.3

FACTORYÊPLAN EXTERIOR 2.1Ê-ÊRailÊsystem 2.2Ê-ÊExteriorÊsheathingÊstorage 2.3Ê-ÊFinishÊmaterialÊstorage 2.4Ê-ÊElectricalÊstorage 2.5Ê-ÊExteriorÊcladdingÊstorage

EPOCH HOMES - A CASE STUDY 36

MODULE ASSEMBLY PHASES INTERIOR ASSEMBLY

THE MODULAR INDUSTRY 37

Epoch Homes has broken their module assembly down into eight separate phases, four which occur within their enclosed facility, and four which are able to happen outside of the building envelope. Weatherproofing is applied as soon as the modules exit the building, so work can continue even in inclement weather.

EXTERIOR ASSEMBLY

EPOCH HOMES - A CASE STUDY 38

SITE DYNAMICS AND ORGANIZATION

I D

A 1

B D

D 5

6 C 7

SITEÊKEY

FullyÊenclosedÊstructure

AÊ-ÊModelÊhome BÊ-ÊInteriorÊproductionÊfacility CÊ-ÊExteriorÊproductionÊfacility DÊ-ÊMaterialÊstorage EÊ-ÊChassisÊloadingÊzone FÊ-ÊBusinessÊoffice GÊ-ÊParking HÊ-ÊTemporaryÊmoduleÊstorage IÊ-ÊSatelliteÊweldingÊfactility

PartiallyÊenclosedÊstructureÊ(storage)

BUILDINGÊPHASES INTERIOR 1Ê-ÊDeckÊframing,ÊwallÊframing 2Ê-ÊRoofÊframing,ÊmoduleÊassembly 3Ê-ÊInteriorÊsheetrockÊ(walls)ÊroughÊelectricalÊ(walls)Ê&Êplumbing 4Ê-ÊInteriorÊsheetrockÊ(ceiling),Êinsulation,ÊelectricalÊ(ceiling) EXTERIOR 5Ê-ÊExteriorÊsheathing,ÊroughÊopeningÊcleanup,ÊinteriorÊcleanup 6Ê-ÊWaterproofing,ÊinteriorÊpainting,ÊfinishÊcarpentry 7Ê-ÊBaseboardÊheatingÊinstallation,ÊflooringÊinstallation 8Ê-ÊWindowÊinstallation,ÊexteriorÊfinishÊcladding

OpenÊmaterialÊstorageÊarea ConstructionÊmaterialsÊdeliveryÊroute CompletedÊÔmoduleÕÊroute FacilityÊentryÊ/Êexit

THE MODULAR INDUSTRY 39

MODULAR FACTORIES COMPARISON EpochÊHomes ModularÊFactoryÊ#1 Location:Ê Ê Ê Ê Ê Founded:ÊÊ Ê Ê Ê Ê YearlyÊ#ÊofÊHomesÊProducedÊ(Est.):ÊÊ ApproximateÊFacilityÊSize:Ê Ê Ê ServicedÊStates:Ê Ê Ê Ê DistanceÊfromÊMajorÊHighwayÊ Ê

Pembroke,ÊNH 1983 100Ê-Ê150 115Õ-0ÓÊxÊ300ÕÊ(34,500ÊSF) CT,ÊMA,ÊME,ÊNH,ÊRI,ÊVT

11.4ÊMIÊ(I-93)

How modular factories and the surrounding site are organized varies depending on a number of factors. The three examples depicted above produce approximately the same number of modules per year, and utiltize the same building typology, the Butler

ModularÊFactoryÊ#2

Location:Ê Ê Ê Ê Ê Founded:ÊÊ Ê Ê Ê Ê YearlyÊ#ÊofÊHomesÊProducedÊ(Est.):ÊÊ ApproximateÊFacilityÊSize:Ê Ê Ê ServicedÊStates:Ê Ê Ê Ê DistanceÊfromÊMajorÊHighwayÊ Ê

Wanyesboro,ÊPA 1966 100Ê-Ê200 124Õ-0ÓÊxÊ360ÕÊ(44,640ÊSF) MD,ÊPA,ÊVA,ÊWV

10.5ÊMIÊ(I-81)

building, yet the site organization varies depending on lot constraints, factory line size, indoor vs. outdoor production, and module storage locations. The plant plan (opposite) is a spatial breakdown of Epoch Homes and their storage, material delivery, and general

Location:Ê Ê Ê Ê Ê Founded:ÊÊ Ê Ê Ê Ê YearlyÊ#ÊofÊHomesÊProducedÊ(Est.):ÊÊ ApproximateÊFacilityÊSize:Ê Ê Ê ServicedÊStates:Ê Ê Ê Ê DistanceÊfromÊMajorÊHighwayÊ Ê

Sprakers,ÊNY 1963 150 200Õ-0ÓÊxÊ520ÕÊ(104,000ÊSF) CT,ÊMA,ÊNC,ÊNH,ÊNJ,ÊNY,ÊPA,ÊVT

16.2ÊMIÊ(I-88)

site configuration. Epoch is one of the only observed modular production facilities in the northeast that divides its production line evenly between interior and exterior.

EPOCH HOMES - A CASE STUDY 40

MODULAR FACTORY TYPOLOGY 115Êft

roofÊmembrane

structurallyÊinsulatedÊroofÊpanels 14,500ÊÊsqÊft

300Êft

corrugatedÊmetalÊexteriorÊsheathing

insulationÊpanels

36Êft

insulatedÊfiberglassÊdoors

3,910ÊÊsqÊft elevation

concreteÊslabÊonÊgradeÊwith continuousÊ4Õ-0ÓÊfrostÊwall 1,173,000ÊÊcuÊft volume

The Butler building is one of the most common typologies used for modular production factories.

THE MODULAR INDUSTRY 41

32Êft

plan

structuralÊsteelÊskeleton

SITE DELIVERY

The modular industry is advantageous in many ways, site delivery and minimized site work are one of its strongest suits. By performing the bulk of labor in a conditioned facilty prior to delivery, modules typically require minimal labor and time to complete the project. Upon arrival, the modules are craned

and anchored onto the foundation and one another, and finish tradesmen perform the final touches. Upon completion, modular homes are nearly indistinguishable from a comparable stick-built equivalent. EPOCH HOMES - A CASE STUDY 42

EPOCH INDOOR MANUFACTURING

Using an indoor facility for housing production has many advantages over the typical stick-built method. First, in a conditioned environment, houses can be built year round, which can significantly increase profitability. Second, multiple

trades are able to work on varied tasks simultaneously, where the order in which these different labors is not necessarily determined by the task before it.

THE MODULAR INDUSTRY 43

TYPICAL SITE CONSTRUCTION - TRIPLE DECKER

Typical site built construction, specifically the triple decker type, has developed techniques for construction within a tight lot. Several issues arise with this incremental construction

however, particularly the predetermined order of tasks which rely on one another. Modular housing can avoid these issues with its segmented project phasing.

EPOCH HOMES - A CASE STUDY 44

MODULAR LABOR

WORKÊPHASES

HOURSÊTOÊCOMPLETEÊMODULE

*basedÊonÊaverageÊ450ÊmodulesÊproducedÊperÊyear,Ê~2ÊperÊ8Êhours

OUTDOORÊWORK

INDOORÊWORK

.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50 7.00 7.50 8.00

This Gantt chart depicts the different phases of construction for (1) module at Epoch Homes. Since Epoch has two production lines that can run simultaneously, they are able to produce approximately two modules every work day. THE MODULAR INDUSTRY 45

STICK-BUILT LABOR

http://www.ownerbuilder.com/images/scheduling-generic-schedule.gif

This Gantt chart depicts a typical stick-built house construction timeline. Note the labor shared with Epoch highlighted in red, and the overall difference in timeframe which construction in a modular facility can provide. EPOCH HOMES - A CASE STUDY 46

TOOLS OF THE TRADE The track and chassis system is a crucial tool at the facility. After completing one of the four interior installation phases, the modules are escorted along the track to the next station. This mobility continues from interior to exterior, where the modules are completed outside.

The bridge crane makes placing constructed components on the modules possible. The crane utlilizes three-axis mobility, providing maneuverability for accurate placement of components such as roof and deck assemblies, and interior and exterior walls.

The elevated safety harness provides a harness and cable that will prevent workplace injury when crews are performing tasks on top of the modules. The harnesses are installed on a pulley system to prevent inhibited mobility of the workers. THE MODULAR INDUSTRY 47

The wall assembly station is where both interior and exterior walls are constructed. The elevated platform provides easier access for nailing the top plate studs. Incremental markings are painted on the station to save time in marking nominal stud locations.

The deck assembly station is an elevated platform 2’-0” off the ground, which allows workers to refrain from bending over for nailing. This station is located immediately adjacent to the track and chassis for a quick and efficient transfer.

The custom trailer chassis is a steel welded frame, which varies in size depending on the module it will carry. Once complete, the modules are raised via pneumatic jacks, and the trailer is placed underneath and the module is set.

EPOCH HOMES - A CASE STUDY 48

weathering an economic storm production diversity During the economic recession of 2008, one of the primary factors that contributed to Epoch avoiding closure was their manufacturing in the multifamily and educational markets. When single families are less likely to pursue constructing a new home during tough financial times, developers and other larger entities tend to capitalize on more affordable real estate and labor costs. Most schools have strict dormitory construction schedules, where new housing provides additional revenue. This tends to limit construction to summers between classes, in order to enroll students and ensure adequate housing. Modular construction as an industry is better suited to work within this rigorous timeframe compared to typical stick-built construction. With its conditioned factory environment, modular housing companies could build during the colder winter and spring months, and be prepared to deliver and install rapidly with minimal site work required.

was their acquisition by a larger capital investor in 2006, just two years before the crash. Although Epoch did unfortunately have to reduce its staff and labor force, they have since regained strength and are currently working on a variety of projects at varying scales. As a lesson learned from Epoch Homes, diversification in project types is an intelligent means of reducing negative impacts of an ever-fluctuating housing market.

Another signifcant factor that helped keep Epoch afloat during the recession the modular industry 49

Montserrat College Dormitory - Beverly, MA

Edgewood Condominiums - Wellesley, MA

Yellow Barn Music School “Green Classrooms” - Putney, VT

CoHousing Project - Cambridge, MA

EPOCH HOMES - A CASE STUDY 50

MODULAR POTENTIAL

HousingÊType

TypicalÊAggregation

microÊunit (2ÊpeopleÊperÊmodule)

stackedÊw/Êcorridor

rowhouse (4ÊpeopleÊperÊ3Êmodules)

sharedÊpartyÊwall

tripleÊdecker (9ÊpeopleÊperÊ6Êmodules)

siteÊseparation

IS IT RIGHT FOR BOSTON? Modular construction has several advantages compared to normative stick-built construction. In the right facility, modular units can be constructed year round, and can be built a great deal faster than their stick-built equivalent. In the Boston area, several typologies have been deployed over the years to achieve more successful densification, in hopes to reduce suburban sprawl and retain urban populations. Several of the more popular and effective types of housing in Boston and the surrounding metropolitan area include: The micro unit, a typology that has only been deployed recently in Boston, which is aggregated very densely. One of the primary issues with the micro unit in Boston is this type of housing tends to be located in more affluent districts, almost negating the costbenefit of a small unit. The rowhouse type has been in Boston for centuries, and continues to prove itself an effective means of densifying the city. A shared party wall is what makes this typology so effective, eliminating otherwise wasted space. The triple decker also has a long history in Boston and the surrounding metropolitan area, and is the primary reason why Somerville, MA is the 15th most densely populated city in the country. The triple decker with its site separation of dwellings, however, prevents it from densifying more effectively. THE MODULAR INDUSTRY 51

FACILITY POTENTIAL

Modular and manufactured housing companies have varying production potentials, but all base their construction around the module. This graphic represents possible housing production from four companies that differ in location, operation, and yearly output quantities.

3000

2250

1500

750

Homes - Scranton , PA plex Sim

b o r H o m e s - Ad d is o

- Pembro

H ar

k e,

Pa lm

och

H o m es

STATES SERVICED

n, T X

Fra n

k li n

H o m e s - R u s s e ll v il

l e,

Single module Rowhouse type Triple decker type Micro unit type

EPOCH HOMES - A CASE STUDY 52

MODULAR INDUSTRY TECHNOLOGY 53

1.3 MODULAR INDUSTRY TECHNOLOGY Windows and doors have been mass-produced products for a century - more recently, prefabricated roof trusses have also become an essential off-the-shelf product, due in part to Toll Brothers. Similarly, since 1976, entire single-family units, HUD (US Department of Housing and Urban Development) Code Homes, have also been offered as products, constituting 9% of all single-family home sales in the United States. Over the last decade, architects have become increasingly interested in another product, the modular ‘box’ or ‘module’, offering more flexibility with the potential for multi-unit construction. This chapter contextualizes the modular product within the construction industry, comparing it to other standard products, documenting new products intended for use in conjunction with the box, and considering future technological trends in the modular industry. THE MODULAR INDUSTRY 54

MODULAR INDUSTRY: TECHNOLOGIES + TECHNIQUES Site-built wood construction remains the predominant method of construction in the US, however many homes are now constructed using some prefabricated wood structure building components. In addition, prefabricated windows and doors, among other building components, are used in nearly all new construction. As the industry for prefabricated building components continues to grow, so do the technologies and techniques used in the modular construction industry. The current technologies of the modular industry are to a certain extent, rudimentary. Such technologies include prefabricated hinged-roof modules which are shipped flat and unfolded on site. Other current technologies include the use of prefabricated shear wall panels and prefabricated foundations for speedy construction. As technology advances, could the utilization of robots and advanced techniques enable the modular factory be developed to ‘plug’ prefabricated components into modules proliferating the modular industry’s scale of production?

MODULAR INDUSTRY TECHNOLOGY 55

PREFABRICATED COMPONENTS

100% of windows are prefabricated in the construction industry.

64% of all residential roofs are made up of prefabricated wood trusses.

Source: Conditions of Competition in the U.S. Market for Wood Structural Components. United States International Trade Comission. 2002.

THE MODULAR INDUSTRY 56

up to 11 ft 12 ft up

60 ft

’) ft 18 -wide to up ouble d ‘ t 0f

Manufactured houses constitute 9% of all United State’s house sales.

Modular houses constitute 2% of all United State’s house sales.

MODULAR INDUSTRY TECHNOLOGY 57

PREFABRICATED WOOD CONSTRUCTION

c b a

roof plate

roof truss

ridge board

North America (USA and Canada) is the leading world consumer of wood products. The wood product market in the United States is driven by residential construction, residential remodeling and repair, and commerical construction. The market for prefabricated wood structural components represents approximately 8% of the market for wood products. This number is steadily increasing with the growing size of housing in the United States requiring an increasing demand for wood; notably, houses have doubled in size since 1950.

now constructed using some prefabricated wood structural building components. Wood trusses are the most widely used prefabricated wood structural components. Wood trusses, connected by metal plates, were first introduced in the 1950s. The advantages of using trusses include on-site labor savings, speedy construction time, the ability to engineer specific design values, and design flexibility; all of which help the prefabricated wood structural component industry to expand. In 2002, the production of wood trusses alone was estimated to be an $8 billion market in the United States.

Site-built wood construction remains the predominant method of construction in the US, however many homes are

Source: Conditions of Competition in the U.S. Market for Wood Structural Components. United States International Trade Comission. 2002.

THE MODULAR INDUSTRY 58

FOLDING ELEMENTS 1

3 2 2 3

Roof sections are fabricated separately and shipped flat. Once the module

1 The first roof panel is lifted on its hinge

2 A support is placed to keep the panel upright

is set, the hinged sections are lifted by crane and set.

3 The secondary roof panel is unfolded from the raised roof

1 The low-positoned hinged eave with an overhang is lifted

4 The joining roof panel is raised & unfolded to meet the first

2 A top section flips out

roof panel at the roof’s ridge

3 A support system is raised into position

The Folding Roof System is a standard technique for shipping a roof module in two flat pieces and then constructing the module by unfolding a hinged connection on-site.

down and lay flat on top of the module during shipping to maintain road height requirements. Each section of the roof is fabricated in two or more components, which are hinged to the module and each other. A set crew uses a crane to lift and unfold the roof to the correct height once the module is set on its foundations. When sectional hinging is impossible, the manufacturer will build roof components as separate modules or panels to be attached on site.

The maximum height of a vehicle and its cargo is 13’-6” in most states, with the height of the carrier typically 2’-6” from the ground; the resulting maximum height of a module is 11’-0”. Epoch’s folding rafter roof systems have 6” overhangs and 2x4 top-flips; allowing the roof to be folded

Source: Epoch Homes

MODULAR INDUSTRY TECHNOLOGY 59

PANELIZED ELEMENTS 3

Structural Insulated Panels (SIPs) combine conventional building components such as joists, stud walls and insulation into a high performance panelized element. The panelized element is made up of an insulating core sandwiched between two layers of structural board. The structural board is typically Oriented Strand Board (OSB) or plywood. SIP’s are manufactured and can be customized to fit almost any building design.

walls, floors and even roof and foundation systems. Blu Homes use SIP’s as the roofing components for their folding modules. Once the module is set on its foundations and unfolded, the SIPs are lowered onto the module by crane. The SIP is later covered with the necessary components for weatherproofing.

SIP’s are energy efficient, extremely strong, cost effective, and quick and easy to install. SIPs can be used for

OSB (Oriented Strand Board) or plywood

Insulation (expanded polystyrene foam)

Connection points to other panels Source: Structural Insulated Panel Association

THE MODULAR INDUSTRY

PREFABRICATED FOUNDATION SYSTEMS LOAD

10 1/4”

60o

30o

6” crushed stone footing depth

Benefits of the foundation wall system include speed of installation - foundations can be installed in less than a day. This means a modular home can be set on the foundation walls immediately after installation.

Foundations can also be prefabricated components. An example is the “Superior Walls Foundation System,” which uses a low water/cement ratio concrete that requires no additional damp-proofing. Full length insulation is built into the system in the factory to increase energy efficiency. The concrete is also reinforced with steel rebar and polypropylene fibers for added strength. In addition, the foundation wall panels are manufactured with integrated access for wiring and stud facings for easy dry wall installation with screws. Standard wall heights for the foundation panels range from 4’-0” to 10’-0”.

The foundation footing consists of crushed stone with a steel reinforced footer-beam. The wall panels are bolted together at the top and bottom of each panel, along with the use of a polyurethane sealant to seal the panel joints of the foundation system. Source: Superior Walls of America Ltd.

MODULAR INDUSTRY TECHNOLOGY 61

SHEAR WALL SYSTEMS shear wall panel F (Shear)

F (Shear)

vent holes

H (Lever Arm Length)

sill plate T Prying Arm Length

T steel wall panel placed over anchor bolts

Prying Arm Length

foundation

For the same shear force (F), and height (H), the narrow shear wall panel causes a larger anchorage force (T).

Traditional building code relies on using 4’-0” wide bracing panels, using a variety of bracing methods and materials. However increased size, and using more windows and doors leaves little space for traditional bracing methods. Instead, narrow, high-strength shear wall panels are an option. Shear wall systems, such as the ‘Simpson Shear Wall Panel’ (up to 20’-0” in height and as narrow as 12”), allows for more architectural flexibility in increasing both size and quantity of windows and doors.

A 16” wide panel can withstand forces up to 1200 lb., and a panel 24” wide can withstand a force of 5000 lb. Panels can be simply inserted into a wood or steel frame wall assembly. A 12” wide shear panel has the same strength as a traditional 4’-0” wide bracing panel. Therefore quarter of the space is required for bracing using shear wall panels.

Source: Simpson Strong-Tie Shear Wall Systems

THE MODULAR INDUSTRY 62

’-0

’-6

”m

”o

.c.

Narrow Shear Wall Panel

4’-

0”

Conventional 4’-0” Brace Panel

4’-

0”

Heavy Duty Anchors

’-0

Prefabricated shear wall panels can be wood or steel and are believed to withstand some of the highest allowable loads in the construction industry. Furthermore, the prefabricated panels are quick and easy to install. Fewer anchor-bolts and fasteners coupled with easy access to the top and bottom of the wall result in more efficient installation.

”

The Simpson Shear Wall system aims to simplify use for all trades, using techniques such as easy-to-use anchor-bolt templates for concrete contractors, and pre-attached wood studs with predrilled holes for wiring by electricians.

MODULAR INDUSTRY TECHNOLOGY 63

TECHNOLOGY IN THE MODULAR INDUSTRY

Credits: Gramazio Kohler Research ETH Zurich Departement Architecture

Winery Gantenbein, Gramazio + Kohler The wine producers at the Gantenbein Vineyard wanted a new service building to house a large fermenting hall, a storage cellar and a roof terrace for wine tastings. Gramazio + Kohler designed the buildingâ&#x20AC;&#x2122;s brick facade. The design proposed a concrete skeleton filled with bricks, since masonry acts as a temperature buffer and also filters sunlight for the fermentation housed inside. Sunlight penetrates the hall through gaps between offset bricks.

data was transferred to the rotation of each brick. Wall elements were manufactured as a pilot project in the research facilities at ETH Zurich. The bricks were constructed into wall modules and transported by truck to the construction site. The wall modules were then installed via crane to create a total facade. The construction process took 3 months, with the manufacturing process for the 1,300 sq. foot facade accelerated by the development of an automated process for laying each brick. Since each brick had a different rotation, every single brick had a different and unique overlap with the brick below it. A method was established in which 4 parallel bonding-agent paths were applied to each brick at predefined intervals before each brickâ&#x20AC;&#x2122;s final placement. Load tests revealed that the bonding element was so structurally effective that reinforcements typically applied to conventional prefabricated walls were unnecessary.

A robotic production method enabled the laying of 20,000 bricks according to precise programmed parameters - at desired angles and intervals. The result means each wall possesses the desired light and air permeability. Gramazio + Kohler compare the pattern on each elevation to pixels on a computer screen; the angled bricks reflect light differently, resulting in the culmination of a wall with a distinct image. The concept for the facade reflects a gigantic basket filled with grapes. After modeling this on the computer, the digital image

Source: GramazioKohler Architects, Zurich. www.gramaziokohler.com

THE MODULAR INDUSTRY 64

ROBOTS: AUTO INDUSTRY VS. MODULAR INDUSTRY

4’-9”

4’-11”

’-6

”

’-0

”

The same robots that build cars also built Gramazio + Kohler’s brick wall modules. Notably, Gramazio +

Kohler’s wall modules are almost the same size as a Volkswagen Beetle.

Source: GramazioKohler Architects, Zurich. www.gramaziokohler.com

Source: 2014 Volkswagen Beetle Specifications

MODULAR INDUSTRY TECHNOLOGY 65

TECHNOLOGY AND TECHNIQUE

An operator applies adhesive to each brick

The robot places each brick in position to form a brick wall

Gramazio + Kohler’s system for brick construction utilizes a robot and an operator. The operator systematically applies adhesive to each brick before handing it to the robot to place in position. The robot will construct

multiple brick wall ‘modules’, approximately 5’-0” by 16’-0” each. Once the wall modules are built, they are transported by truck to the site. Each wall module is then lifted by crane and placed to construct an even larger wall system. Source: GramazioKohler Architects, Zurich. www.gramaziokohler.com

THE MODULAR INDUSTRY 66

The brick wall modules are transported to the site...

...and lifted into position by crane to create an even larger brick wall

The construction of such modular wall systems means the brick wall can be constructed in a factory by robot and then easily fitted onto a standard-sized truck for transportation. The crane in this instance is a larger

scale robot, creating a larger brick wall from the modules created by a smaller robot in the factory.

MODULAR INDUSTRY TECHNOLOGY 67

AUTO INDUSTRY Epoch Homes Location: Pembroke, NH Founded: 1983 Yearly # of Homes Produced (Est.): 100-150 Approximate Facility Size: 115’ x 300’ (34,500 SF) Distance from Major Highway: 11.4 MI (I-93) Current Total Employment: 175 employees Source: Epoch Homes

Ford Motor Company Location: Chicago, IL Founded: 1924 Yearly # of Automobiles Produced (Est.): 830,000 Approximate Facility Size: 2,345’ x 1,200’ (2,814,000 SF) Distance from Major Highway: 2.2 MI (I-94 E) Current Total Employment: 4,099 employees Source: Ford Motor Company

Credits: Google Earth

THE MODULAR INDUSTRY 68

TECHNOLOGY IN THE AUTO INDUSTRY

PRESSING MACHINES Flat sheet metal is placed into a pressing machine where a tool and die surface forms the metal into a net shape. Uses include: punching, blanking, embossing, bending, flanging, hemming and curling. Pressing can be used on metal and other materials such as polystyrene. Pressing machines are used in both construction and car manufacturing industries.

ROBOTS Robots move like a human arm with a rotating wrist at the end. Robotic arms can perform repeat tasks better than a manual laborer, but require recalibration or reprogramming. The arm can operate continuously, and can perform tasks such as welding in addition to handling the part. In certain tasks such as welding, a human operator will sometimes need to prepare the materials to be welded, depending on the application.

Source: â&#x20AC;&#x153;Hydaulic and Mechanical Presses.â&#x20AC;? www.thelibraryofmanufacturing.com

Source: International Federation of Robotics. www.ifr.org

MODULAR INDUSTRY TECHNOLOGY 69

2’-4”

4’-6”

6’-8”

TECHNOLOGY IN THE AUTO INDUSTRY

SMALL ROBOTS Carrying Capacity: 13 lb. # of Axes: 5 Max. Reach: 2’-4” Weight: 106 lb. Tasks: assembly/disassembly; fastening; handling; inserting; mounting; loading/unloading; coating operations; cutting tools. Mounting Positions: floor, ceiling

LOW PAYLOAD ROBOTS Carrying Capacity: 26 lb. # of Axes: 6 Max. Reach: 4’-6” Weight: 280 lb. Tasks: handling; welding; loading/unloading; soldering; coating operations; Mounting Positions: floor, ceiling

THE MODULAR INDUSTRY 70

MEDIUM PAYLOAD ROBOTS Carrying Capacity: 66-132 lb. # of Axes: 6 Max. Reach: 6’-8” Weight: 1,466 lb. Tasks: assembly; handling; packaging; loading/unloading; painting; inserting; fastening; testing; application of adhesives & sealants. Mounting Positions: floor, ceiling

10’-11” 5’-11”

HIGH PAYLOAD ROBOTS Carrying Capacity: 265 lb. # of Axes: 6 Max. Reach: 5’-11” Weight: 1,508 lb. Tasks: assembly/disassembly; handling; packaging; loading/ unloading; inserting; fastening; welding; soldering. Mounting Positions: floor, ceiling

HEAVY DUTY ROBOTS Carrying Capacity: 529-793 lb. # of Axes: 6 Max. Reach: 10’-11” Weight: 5,337 lb. Tasks: assembly/disassembly; handling; packaging; loading/ unloading; inserting; fastening; spot welding; laser welding; soldering. Mounting Positions: floor, ceiling* * reach shortened to 9’-11” Source: Kuka Robot Group. www.kuka-robotics.com

MODULAR INDUSTRY TECHNOLOGY 71

ROBOTS: AUTO INDUSTRY VS. MODULAR INDUSTRY

Epoch Home’s workers are able to perform upper-case work on modules safely with a high degree of mobility. This is due to the use of harnesses attached to a gantry crane system. The harnesses are attached to the overhead gantry crane, which can follow the track of the modules so that upper case work can be performed at various locations in the factory.

Similar to the Epoch Home’s factory, Gramazio + Kohler’s Robotic Fabrication Laboratory (RFL) is set up for robotic fabrication in architecture and construction. A multi-robotic system runs on an overhead gantry system, allowing four 6-axis robots to work simultaneously and cooperatively on a volume up to 140 by 62 by 26 feet. Research at the RFL aims to enable the simulation of robotic fabrication and human-machine cooperation on-site, in addition to advanced automated factory-based fabrication.

THE MODULAR INDUSTRY 72

PRECISION AND TOLERANCE

Tolerances are therefore added to shop drawings, to provide a window in which the dimensions of fabricated components can vary. In a factory setting, tolerance levels do not usually exceed 3/8 - 1/4”.

Modules with a steel structure utilize welding processes to strengthen the joint connections between structural members. Tolerances account for an allowable variation in precision within construction processes. Due to material variations it is impossible to use absolute dimensions in construction. In traditional construction, on-site adjustments are made by skilled laborers to improve precision.

Robotic welders are able to achieve better precision than human welders due to the use of sensors. The typical tolerance of an automated welder does not exceed 1/24”. Consequently, automated welders are increasingly utilized in fabrication processes to speed up productivity, increase precision and reduce variable labor costs.

Comparatively, components built in the factory are fabricated as isolated components; therefore decisions for adjusting discrepancies cannot be made without knowing how they will affect adjacent components.

Source: Crowe, D.“Designing for Successful Robotic Arc Welding Automation.” The Fabricator.com 2001. American Welding Society, www.aws.org

MODULAR INDUSTRY TECHNOLOGY 73

TECHNOLOGY AND TECHNIQUE

Epoch Home’s Nailing Bed

Credits: Jalbert, 2014

Jointec’s Nailing Bed

Credits: Jointec

At the Epoch Home’s Factory, the wall assembly station is where both interior and exterior walls are constructed. The elevated platform provides easier access for nailing the top plate studs. Incremental markings are painted onto the station to save time marking nominal stud locations. Such traditional nailing processes include an operator loading lumber onto a nailing table and using an automated hammer to nail lumber together. In the pallet industry, this process has replaced operators with robots.

Jointec’s ‘Simple Robot Nailer’ builds complete pallets using fixed but easily changeable jigs. An operator is required to load jigs, which the robot rotates so it can nail and stack the pallets. The same Jointec Simple Robot Nailer can be applied to nailing processes in construction, as a method to both speed up the construction process and also increase precision. Source: Epoch Homes, Jointec, www.jointec.se

THE MODULAR INDUSTRY 74

BUILDING COMPONENTS

Building components such as windows, doors, cabinetry and roofing systems among others are already manufactured at a large scale and delivered to a site ready for installation. Such mass-produced components could be produced and installed into a module in a modular factory to increase the speed of construction by minimizing site work.

geometry, grain angle, density and decay. The scan captures data every 36 thousandth inch along a board’s length. Once the lumber is scanned and cut accordingly, the frame for windows can be constructed and then a prefabricated glass panel is slotted in. Typical lead time (receipt of order to distribution) for vinyl and aluminum windows is two weeks, and for wood windows between four and eight weeks. Typical lead time for doors is between two and five weeks. For a scale of production, the American Window and Glass factory produces 160,000 windows annually (438 windows a day). On average, one module will contain 14 windows, meaning the factory could produce windows for up to 31 modules a day.

In window and door factories, rough lumber comes into the factory by train. Machines scan boards for maximum yield. Using computer algorithms, the scanner figures out which sections of the wood are usable. The scanner also formulates a cutting plan for how automated saws should cut the wood, using first a rip saw and then a crosscut saw. ‘True-Q Board Tracking’ technology uses six sensors to simultaneously scan for traits such as: color, tracheid,

Source: Lucidyne Technologies, Inc., www.lucidyne.com/gradescan The American Window and Glass Factory, www.americanwindowandglass.com

MODULAR INDUSTRY TECHNOLOGY 75

The auto-industry has long-recognized the potential behind robotic fabrication and its ability to not only conduct repetitive and precise tasks, but also to proliferate the scale of production. The car factory is able to mass-produce due to the prefabrication of standard systems. Since building components such as wood-truss roofs, windows and doors, amongst others, are already prefabricated and highly

standardized, the modular factory has the potential to construct and ‘plug-in’ such components where necessary with a -potential to catapult the modular industry’s scale of production.

THE MODULAR INDUSTRY 76

THE ROLE OF THE ARCHITECT

CHAIN OF PRODUCTION INTRODUCTION

MANUFACTURED HOUSING INDUSTRY

In the manufactured housing industry there is minimal architect involvement, and in the modular industry they typically have little to no control over the manufacturing process. These case studies exemplify the role in which the architect plays within their respective companies and the relationship they form between the factory, the builder, and the client.

the factory

the distributor

the client

MODULAR HOUSING INDUSTRY

the factory

the builder

the architect

THE ROLE OF THE ARCHITECT 79

the client

RESOLUTION: 4 ARCHITECTURE

the factory

the architect

CONNECT HOMES

the factory

the builder

the client

the architect

ONION FLATS

the factory

the client the architect

the builder

THE ROLE OF THE ARCHITECT 80

the role of the architect 81

2.1 RESOLUTION: 4 ARCHITECTURE Over the past century, architects have shown an interest in the potential of industrialization and mechanization while concurrently keeping a distance, wary of inherent flaws in the system. On the other hand, the modular industry has shown significant growth over the last three decades, with little understanding or involvement from architects. Resolution: 4 Architecture is one of the few exceptions, working with the modular industry, learning its internal logics in order to innovate within their framework. This productive symbiotic relationship between architect and industry, conducted over 28 projects in the past decade, has generated a valuable insight into the potential role of the architect as user and disruptive innovator of the modular industry is explored in through this section. 82

INTRODUCTION MANHATTAN LOFTS

DWELL MAGAZINE

Ron’s Loft. New York, New York. 1995.

http://www.dwell.com/magazine/groundbreaking-ideas-home-design

Resolution: 4 Architecture was founded in 1990 by Joseph Tanney and Robert Luntz. The firm initially started off thinking “inside the box” as a practice in Manhattan renovating loft spaces. The long and linear footprint of the loft was the first step for Tanney and Luntz to start a series of studies called “modules of use.” These conceptual “bricks” in turn went on to create a thinking towards developing a system. This invented system of design is what became the “Modern Modular”.

In 2003, Dwell Magazine contacted Resolution: 4 Architecture to invite them to compete to design a home along with 16 architects from around the world. The home was to be a modern home that could be mass-produced. After winning the competition, Resolution: 4 Architecture not only gained recognition, but also opportunities.

THE ROLE OF THE ARCHITECT 83

THE MODERN MODULAR

THE DWELL HOME

http://re4a.com/the-modern-modular/

Dwell Home, Dwell Competition Winner, Pittsboro, NC. 2004.

The Modern Modular evolved from Resolution: 4 Architecture’s first completed works, Manhattan loft interiors, the modern modular takes advantage of assembly-derived construction techniques and works with the customer’s wants, needs and specific site to create limitless options of customization.

Resolution: 4 Architecture started to conceive of a prototypical suburban home - three bedrooms, two baths, and importantly a building that would fit on a prototypical suburban lot. When the program exceeded the 16 foot wide limit set by the Department of Transportation, prefabricated “saddle bags” could be added to extend the interior space. Materiality was also considered, recognizing cedar plank siding to be a fool proof material to be put on by the local contractor on site. This in turn became the Dwell Home. RESOLUTION: 4 ARCHITECTURE 84

loft versus modern modular Upon completion of the first built “Modern Module” home, the Dwell Home, in 2004, Resolution: 4 Architecture has completed over 28 projects throughout the United States. The design of each home is not only unique to its clients wants and needs as well as site, but also show an evolution as to Resolution: 4 Architecture’s design process. These evolutions include products used within the factory, for instance the Simpson Shearwall and Strong Tie as well as the on-site products such as the use of prefabricated concrete foundaton walls. These evolutions also include techniques collaborated and communicated with the factories themselves that Resolution: 4 Architecture has implemented into their projects as they have produced optimal quality results without slowing down the factory’s assembly line. For instance, the “flash and batt” in terms of layering batt insulation followed by spray insulation to ensure quality insulation for the module.

the role of the architect 85

MANHATTAN LOFT & SIMPLEX MODULAR HOMES

One of Resolution: 4 Architecture’s first loft projects completed in 1995, Ron’s Loft, is 1,700 sf.

Commonly used Simplex in Scranton, Pennsylvania can easily accommodate the 16ft by 60ft (950 sf) maximum sized modular due to restraints set by the Department of Transportation.

RESOLUTION: 4 ARCHITECTURE 86

PROJECT ITERATIVES Resolution: 4 Architecture started the Modern Modular design process prior to their recognition within the Prefabricated Industry in 2004. Since then, Resolution: 4 Architecture has completed over 28 projects that have been iteratives of one another, each advising the other to be a better project.

DWELL HOME: FIRST MODERN MODULE MODERN MODULE ITERATIVES SADDLEBAGS LIVING ROOM STANDARD

THE ROLE OF THE ARCHITECT 87

RESOLUTION: 4 ARCHITECTURE 88

RESOLUTION 4 OFF-SITE FACTORY PRODUCTION

Dwell Home in factory, Carolina Building Solutions (CBS) in 2004. This was the first Modern Module home Resolution: 4 Architecture completed with a factory so communication was key.

Dwell Home in factory, CBS in 2004 where the modular is nearing completion and the prefabricated butterfly roof is tested in the factory but to be dismantled for shipping due to ovesized deliverable load restrictions.

THE ROLE OF THE ARCHITECT 89

Connecticut Pool House in factory 2010 with a panelized fire place already in place prior to delivery on-site where the final finshes will be applied.

Fisher Island Home in Simplex Homes factory in 2012. The eight boxes were essentially fabricated in place allowing for an 80% completion prior to leaving the factory.

Suburban Villa in Simplex Homes factory in 2013. The four module home is nearing completion to leave the factory having already received both spray insulation and batt insulation for an optimal thermal performance.

North Fork Bay House in Simplex Homes factory in 2014. The two module home is at the end of the factory production line and is awaiting to be shipped to the site.

RESOLUTION: 4 ARCHITECTURE 90

RESOLUTION 4 ON-SITE FOUNDATION TECHNIQUES

The Mountain Retreat module is being carefully set in place on the cast in place concrete “stilts” that act as a foundation for the living room as well as an overhang for parked vehicles in 2005.

Harmony Hill is one of Resolution: 4 Architecture’s first noted projects to use a panelized foundation system in 2006.

THE ROLE OF THE ARCHITECT 91

The Leighton Maine Retreat uses a traditional form work and slurry foundation on site in 2007.

Fisher Island Homeâ&#x20AC;&#x2DC;s foundation was also modular and installed by Superior Walls of Pennsylvania on site in 2012.

Long Beach Cottage steel frame foundation is incorporated with poured concrete on top of the existing deteriorated 700 sf summer cottage foundation in 2012.

North Fork Bay Houseâ&#x20AC;&#x2122;s concrete grade beams have been poured on-site, ready for the erection of the steel frame to come in 2014.

RESOLUTION: 4 ARCHITECTURE 92

RESOLUTION 4 ON-SITE SETTING THE MODULES

The Dwell Home delivered on five flatbed trucks to the site in Pittsboro, North Carolina. The modules and butterfly roof are set by a crane onto the constructed foundation in 2004.

The House on Marthaâ&#x20AC;&#x2122;s Vineyard had its modules transported to the site by barge up the East River to the island, and then transferred to the local site to be set. A steel frame was built into the prefabricated glass box for ease of transporation and set; most notably marking the first instance a modular manufacturer has integrated steel into conventional wood framing in 2005.

THE ROLE OF THE ARCHITECT 93

High Peak Meadow House set in 2009 by crane on-site was set atop an insulated concrete form finished basement in the Catskill Mountains.

The Long Beach Cottage set in 2012 was done so by crane configured on the neighbor’s property as the site itself was between two houses on a 20’ by 90’ lot directly on the beach.

The eight boxes for the Fisher Island Home were set by a crane after arriving to the island by ferry in 2012.

Olive Bridge House set in 2013 by crane on-site onto a poured concrete foundation as well as a hardwood frame.

RESOLUTION: 4 ARCHITECTURE 94

RESOLUTION 4 ON-SITE APPLICATION OF FINAL FINISHES

Berkshire House in 2007 is completed with exterior finishes of cedar siding, cement board panels, galvalume metal roof, and ipe wood decking. The interior finishes are near completion including bamboo flooring, slate bathroom floors and cherry cabinets.

Connecticut Pool House in 2011 has the exterior cedar siding applied by the local contractor and is nearing completion awaiting the application of the interior finishes to be complete.

THE ROLE OF THE ARCHITECT 95

Dune Road Beach House in 2012 has exterior cedar siding applied and is awaiting the completion of the railing at the roof deck by the local contractor.

Olive Bridge House in 2013 is awaiting the completion of exterior finishes including the ipe wood decking and cement board panels as well as the interior finishes.

Suburban Villa in 2013 nears completion with the application of both the exterior finishes and interior finishes by the local contractor.

North Fork Bay House in 2014 construction on-site is nearly complete including the application of the exterior finishes and interior finishes by the local contractor.

RESOLUTION: 4 ARCHITECTURE 96

RESOLUTION 4 COMPLETED EXAMPLE CONNECTICUT POOL HOUSE, SHARON, CONNECTICUT 2011

July 1, 2010 Interior finishes applied in factory are complete as well as the installation of the panelized fireplace. The module is nearing completion for shipment to site to complete the rest of the applied exterior and interior finishes.

July 1, 2010 Interior finishes including kitchen cabinetry and Ceasarstone are completed in factory, prior to shipment to site.

THE ROLE OF THE ARCHITECT 97

July 1, 2010 Modules at factory are at the end of the line, wrapped with weather proofing and awaiting to be delivered to site.

August 27, 2010 The one modular home is being set on-site. The homeâ&#x20AC;&#x2122;s foundation was prepped for the home to utilize radiant heat and solar hot water.

January 4, 2011 Exterior details on-site nearing completion including cedar siding, cement board, ipe wood decking and Pennsylvania blue stone.

2011 The Connecticut Pool House is compete!

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RESOLUTION 4 COMPLETED EXAMPLE DUNE ROAD BEACH HOUSE, EAST QUOGUE, NEW YORK 2012

2011 The Dune Road Beach House is in production in the Simplex Homes factory, off site in 2011 where the four module home was nearly fabricated in place.

November 11, 2011 12” diameter, 40’ long poles are driven into the beach house site as the foundation for the home.

THE ROLE OF THE ARCHITECT 99

2011/2012 The four module home is set by crane on the beachfront property site.

2011/2012 The southern elevation features floor to ceiling hurricane rated windows which were installed into the modules in factory for ease of on-site production.

February 23, 2012 The exterior cedar siding has been applied and the installation of the railings at the roof deck are nearing completion by the local contractor on site.

2012 The Dune Road Beach House is complete!

RESOLUTION: 4 ARCHITECTURE 100

RESOLUTION 4 COMPLETED EXAMPLE SUBURBAN VILLA, BETHESDA, MARYLAND 2013

November 30, 2012 Foundation on-site is nearing completion and awaits the arrival of the module boxes.

January 2013 Off-site, factory production at Simplex Homes is nearing completion with the four modules already receiving the spray insulation and batt insultation for optimal thermal performance.

THE ROLE OF THE ARCHITECT 101

January 23, 2013 Off-site, factory production is at the end of the production line. Modules are wrapped to withstand the elements during delivery to the site.

February 15, 2013 Module boxes arrive on-site and are set by crane, orchestrated by the local contractor.

February 15, 2013 Modules are set and await exterior finishes to be applied once they arrive on-site by local contractor.

April 5, 2013 On-site construction progress is nearing completion, applying exterior finishes and interior finishes by the local contractor.

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RESOLUTION 4 COMPLETED EXAMPLE NORTH FORK BAY HOUSE, PECONIC BAY, NEW YORK 2014

May 17, 2014 12â&#x20AC;? diameter piles were driven on-site to create the starting point for the foundation for the project.

April 18, 2014 Formwork for the concrete foundation is complete and ready for the concrete to be poured on-site.

THE ROLE OF THE ARCHITECT 103

April 23, 2014 The concrete grade beams have been poured on-site awaiting the erection of the steel frame to come.

June 12, 2014 Simplex Homes Factory visit to check on the progress of the two-module 1,375 sq ft home. The modules are nearly complete and are nearing the end of the factory production line.

June 18, 2014 Interior finishes that were installed in the factory are complete including kitchen cabinets, bathroom wall tile and plumbing fixtures, windows and sliding doors, and Ceasarstone countertops. Boxes to go to site next day.

July 7, 2014 Modules trucked and set on-site by crane. November 17, 2014 Construction is nearly complete on-site including the application of the exterior finishes and interior finishes by the local contractor.

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THE ROLE OF THE ARCHITECT RESOLUTION 4â&#x20AC;&#x2122;S FOUR STAGES Resolution: 4 Architecture redfines the role of the Architect with their four stage process. Each stage requires approximately four months for an estimated start to finish timeline of 16 months. The first stage is the concept/design stage. The client comes directly to Resolution: 4 Architecture. Together, the architect and the client conceptualize a design that meets the customerâ&#x20AC;&#x2122;s needs in terms of site specificity and cost. The second stage consists of seeking an appropriate factory to coordinate the project as well as recieve engineering consulting. The state modular approvals are achieved as well as the local general contractor whom prior, bid for the completed in house construction documents.

the factory

the architect

The third stage is the fabrication of the modules in the local factory as well as the preparation on-site in order to receive the modules once complete.

the client

The modules are delivered to the site where the fourth stage can be completed, which entails the local general contractor siting the exterior and interior finishing details. THE ROLE OF THE ARCHITECT 105

the local builder

EPOCH HOMES COMPARED TO RESOLUTION 4 ARCHITECTURE

http://www.epochhomes.com/

Epoch Homes colonial modular consists of four modular boxes. The onsite assembly arranges the boxes themselves as well as the prefabricated roof attached to hinges allowing the roof to “pop-up” from the modules.

http://re4a.com

Resolution 4 Architecture’s Fisher Island house is composed of eight modules with an additional prefabricated roof. RESOLUTION: 4 ARCHITECTURE 106

MAPPING BUILT PROJECTS

500 MILES Resolution: 4 Architecture has been fortunate to build homes throughout the United States. Over the years, the number

of factories the firm work with has been refined due primarily to facilities they communicate the best with.

THE ROLE OF THE ARCHITECT 107

500 MILES

PREFERRED FACTORIES

500 MILES Since 2004, Resolution: 4 Architecture has refined the list of factories they prefer to work with, seeking factories that

build with the quality and expectations of their own design standards, shown here highlighted in red. RESOLUTION: 4 ARCHITECTURE 108

PREFERRED FACTORIES BREAKDOWN METHOD HOMES

IRON TOWN HOMES

500 MILES

Location: Ferndale, Washington & Pottstown, Pennsylvania

Location: Spanish Fork, Utah

Service Areas Include: The United States & Canada

Service Areas Include: California, Colorado Highlands, Idaho, Montana, Nevada, Utah & Wyoming.

Method Homes partners with Architects with custom or pre-existing design for off-site construction.

Iron Town Homes 60,000 sq ft facility has been in business for over 25 years.

They focus their projects by building within residential, multi-family, retail, office and hospitality.

Resolution: 4 Architecture collaborates with Iron Town Homes is because “[they] build the highest quality... of modular homes by building completely custom mid and high-end modular homes.”

Resolution: 4 Architecture collaborates with Method Homes is because “[Method Home’s] mission is grounded in the principles of quality and sustainability.” http://methodhomes.net/about-method/

http://irontownhomes.com/about/

THE ROLE OF THE ARCHITECT 109

STRATFORD HOMES

SIMPLEX MODULAR HOMES

Location: Strattford Wisconsin & Rathdrum, Idaho

Locations: Scranton, Pennsylvania

Service Areas Include: The United States & Cananda

Service Areas Include: Maine, New Hampshire, Vermont, Massachusetts, New York, Rhode Island, Connecticut, New Jersey, Pennsylvania, Delaware, West Virginia, Maryland, Virginia & Georgia.

Founded in 1973, Stratford Homes focuses on residential homes and commercial building systems.

Family owned since 1971, Simplex Modular Homes works directly with Kountry Kraft for simple fabrication of cabinetry in-factory.

Resolution: 4 Architecture collaborates with Stratford Homes is because “[their] key is... advanced modular construction method, which produces a strongly built home.”

Resolution: 4 Architecture collaborates with Simplex Modular Homes is because “Simplex Homes builds the finest quality modular homes and custom homes.”

http://www.stratfordhomes.com/page/the-stratford-difference

http://simplexhomes.com/default.asp RESOLUTION: 4 ARCHITECTURE

500 MILES

110

COMPLETED PROJECTS MATRIX

2004

2005

Dwell Home

2005

2006

2007

House on House on Marthaâ&#x20AC;&#x2122;s Chesapeake Bay Vineyard

Mountain Retreat

Summer Retreat

Harmony Hill

Cape House

Artist Retreat

Berkshire House

2,396 sf

2,989sf

1,800 sf

2,968 sf

2,987 sf

4,425 sf

4,296sf

2,227 sf

cedar siding, cement board panels, standing seam metal roof, recycled wood composite decking

cedar siding, cement board panels, standing seam metal roof, ipe wood decking

cedar siding, cement board panels, standing seam metal roof, cedar decking

cedar siding, ce- hemlock siding, ment board panels, cement board ipe wood decking panels, pella windows, ipe wood decking

cedar siding, corrugated metal t&g cedar siding, cedar shake sid- cement board siding, cedar sidingcembonit board ing, cement board panels, composite cement board panels, galvalume panels, ipe wood wood decking panels, ipe wood metal roof, ipe decking decking wood decking

bamboo flooring, plastic laminate on baltic birch countertops, slate bathroom floors, maple cabinets, aluminum clad wood windows with low e, insulated glass, hot rolled black steel cladding

bamboo flooring, custom walnut stone countertops, cabinets, bamboo slate bathroom floors, slate floors, aluminum bathroom floors, clad wood windowshot rolled black with low e, insulat- steel cladding, ed glass caesarstone countertops

bamboo flooring, bamboo flooring, caesar stone caesar stone countertops, slate countertops, slate bathroom floors, bathroom floors, maple cabinets, maple cabinets, aluminum clad aluminum clad wood windows withwood windows with low e, insulatlow e, insulated ed glass glass

4,273 sf

concrete bamboo flooring, bamboo flooring, stone countertops, slate flooring, stone bathroom floors, countertops, slate maple cabinets, bathroom floors, custom bulthaup aluminum clad cabinets, alumiwood windows with low e, insu- num clad wood windows with low lated glass, hot rolled black steel e, insulated glass, hot rolled black cladding steel cladding

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111

bamboo flooring, caesar stone countertops, slate bathroom floors, cherry cabinets, aluminum clad wood windows with low e, insulated glass, hot rolled black steel cladding

2007

2008

Brown Box Swingline

Leighton Maine Retreat

Bronx Box

1,800 sf

2,707 sf

1,816 sf

4,542 sf

galvalume hardieplank metal roof, cement siding, standing board, cedar seam metal roof, ipe wood decking, siding, ipe wood custom mahogany decking windows & trim

bamboo flooring, maple cabinets, bamboo flooring, stone countertops, bamboo floors, stone countertops, slate bathroom slate bathroom slate bathroom floors, maple floors, black steel, floors, maple cabinets, aluminum caesarstone coun- cabinets clad wood windowstertops, aluminum with low e, insulat- clad wood windows ed glass with low e, insulated glass

bamboo flooring, stone countertops, slate bathroom floors, maple cabinets

2008

2009

Brown Bar Peconic House on Bay House Sunset Ridge

Catskills Suburban

High Peak Vermont Meadow Cabin House

Lake Iosco Connecticut Wisconsin Dune Road Long Beach Fisherâ&#x20AC;&#x2122;s House Pool Cottage Cabin Beach Island House House House

2,000 sf

2,208 sf

2,900 sf

1,646 sf

2,100 sf

corrugated metal siding, cedar siding, cement board panels, ipe wood decking

cedar siding, azek cedar siding, ce- cedar siding, harment board panels, die board panels, infill panels, cement board panels, ipe wood decking, ipe wood decking ipe wood decking, pennsylvania blue stone aluminum clad

2,364 sf

2008

3,034 sf

9 200

cedar siding, ce- cedar siding, ment board panels, cement board ipe decking, cedar panels, ipe wood railings decking

cedar siding, cement board panels, arcadia aluminum clad windows, ipe wood decking

horizontal cedar siding, cement board panels, epdm roofing, ipe wood decking

maple cabinets, bamboo floors, caesarstone countertops, slate bathroom floors

maple cabinets, bamboo floors, slate bathroom floors, hot rolled black steel cladding, caesarstone countertops

concrete and bamboo flooring, bamboo flooring, ceasarstone caesarstone and countertops, slate bathroom floors, corian countermaple cabinets, tops, merillat cabinets, hot rolled aluminum clad black steel cladding wood windows with low e, insulated glass, black steel, custom baltic birch bench

maple cabinets, bamboo flooring, walnut millwork, caesarstone countertops, slate bathroom floors, aluminum clad wood windows with low e, insulated glass

2010

maple cabinets, bamboo floors, caesar stone countertops, kohler plumbing fixtures, slate bathroom floors, hot rolled black steel cladding

2011

832 sf

2011

1,970 sf

walnut cabinets, maple cabinets, bamboo floors, bamboo floors, black steel, caesar- cedar ceiling, stone countertops, caesarstone batlic birch tables countertops, hot rolled black steel and shelving cladding, stacked stone fireplace, aluminum clad wood windows with low e insulated glass

2012

2,200 sf

2012

1,700 sf

2012

2013 Suburban Villa

4,469 sf

t&g stk cedar t&g stk cedar siding, azek infill siding, azek infill panels, wood com- panels, ipe wood decking, cement posite decking board panels

maple cabinets, maple cabinets, bamboo floors, bamboo floors, caesarstone caesarstone countertops, slate countertops, slate bathroom floors, bathroom floors, aluminum clad aluminum clad wood windows withwood windows with low e, insulated low e, insulated glass, unico high glass velocity hvac system

RESOLUTION: 4 ARCHITECTURE 112

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2.2 STEEL FRAME

CONNECT / DELIVER / PROTECT An investigation of the modular industry in California identified the existence of high quality steel frame modular fabricators. The high precision and strength of this robust structural system allows for greater freedom of form and allows up to 90% of construction to be completed in the factory. Connect Homes designs their modules to conform to standard container dimensions and requirements, enabling delivery via intermodal shipping networks. STEEL FRAME 114

MODULAR MAP

Sacramento

San Francisco Fresno 50mi.

Bakersfield

Riverside Los Angeles

CALIFORNIA MODULAR NETWORKS Manufacturer (24)

Distributor (11)

Highway

City

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San Diego

CALIFORNIA MODULAR

This chapter will examine the modular industry in California through in depth case studies of two companies and their solutions to design, manufacture, and deliver high-quality steel modular buildings. The final section will look at how modular companies have used architectural patents as a means to protect and legitimize their innovations. The modular industry is well established in California. This map shows the distribution of the 24 modular factories and 11 modular distributors with concentric circles with 50 mile radii centered in dense production zones. These zones are generally located on the periphery of major population centers, predominantly in the inland regions of the state, such as the Inland Empire in the south and the Central Valley. Production zones are located in more affordable light industrial areas that are contiguous with the interstate highway system. Welder connects steel structural components at Factory in California STEEL FRAME 116

CALIFORNIA MODULAR: AERIALS FACTORIES

ROLE OF THE ARCHITECT 117

DISTRIBUTORS

This collection of aerial photographs shows the modular factories and distributors in California. Rail and road infrastructure is visible in many of the photos. This matrix of images was refined from a list of sites compiled from GoogleEarth with a script identifying locations associated with a keyword search for Modular Homes. The number and scale of production facilities indicates that the modular industry is both well developed and widely distributed throughout the state.

STEEL FRAME 118

FRAMING STEEL : WEST COAST PRECISION

Connect Homes grew out of existing modular company Marmol Radziner to develop an innovative solution for modular building. Access to M+Râ&#x20AC;&#x2122;s existing high-quality fabrication facility led Connect to develop a structural solution that allowed modules to be transported by standardized international delivery systems. The company leveraged architectural patents as a means to protect their original solutions at various scales. Exploiting existing and established systems, Connect Homesâ&#x20AC;&#x2122; creates an insulated network that can fabricate in a central location with the potential to deliver modular residential solutions across the United States and the globe.

ROLE OF THE ARCHITECT 119

MODULAR SPINOFF MARMol RAdzInER --> ConnECT HoMES

M+R module being set

SHAREd PRodUCTIon - MARMol RAdzInER FACTORY The lA based architecture firm, a pioneer of steel frame prefabricated architecture, opened a 65,000 square foot factory in Vernon, CA in 2006. The factory had the capacity to accommodate the concurrent fabrication of 20 prefab modules, and included a cabinet shop, metal shop, and door and window shop. Centralized operations allowed for greater control over every detail of prefab home production, from welding of steel frames to the installation of doorknobs. Connect Homes founders Jared levy and Gordon Stott both worked with Marmol Radziner Prefab for over 5 years before deciding to break off in 2012 and start a company of their own. The core of their plan was to use high quality fabrication (like Raziner) to produce only modules that conform to intermodal shipping container sizes in order to decrease the cost and difficulty of delivering modules. Their solution uses a robust steel frame with standard hoist points, affording enough stability for modules to be substantially completed in the factory. While typical prefab systems complete only 55% of the house in the factory, Connect completes ~90%, maximizing efficiencies from building in a controlled setting and from bulk pricing. Extra capacity of the M+R factory provided a perfect place for Connect to begin.

Connect module being set 120

STEEL FRAME

STEEL FRAMES

14’

54’

MARMOL RADZINER MAXIMUM MODULE SIZE

8’

10’ - 6”

54’ 9’

This image compares Connect Home’s standard module size to Marmol Radziner’s maximum module. Connect is optimized to intermodal container size while M+R uses the maximum size shippable via California highways.

ConnECT HoMES ModUlE ALSO M+R’S MINIMUM MODULE SIZE

ROLE OF THE ARCHITECT 121

CONNECT HOMES FACTORY RAIL

FACTORY

CIRCULA TION

WORK AREA

500’

Connect’s factory in Corona, CA

Connect Homes shares space in a 212,000 sf. factory composed of indoor and outdoor work areas and is located next to critical road and rail infrastructures for distribution of modules throughout California and the surrounding states.

STEEL FRAME 122

CONNECT HOMES SYSTEM OVERVIEW

Welded Steel Frame produced in shared facility

Frame transported via truck to shared production warehouse

Trades infill building modules and finish to a high degree

Protective panels are affixed to the exterior, creating an intermodal shipping containter

Transport to site via intermodal shipping

Protective panels and waterproof wrapper are removed

Modules are unloaded and stacked by forklift

Seams are sealed and final details and finishes added

ROLE OF THE ARCHITECT 123

MOVING INDOORS

A singe frame is suspended from a light crane so it can be moved to its next position in the fabrication process. The lightweight steel structure can be safely moved with a range of common machinery.

This steel frame is being loaded into the factory for the next step in the fabrication process. The ability to move modules with light machinery reduces both cost and risk to workers.

The interior of the factory space is quite generic. Since the M+R factory ceased operation, Connect has been able to share production with other modular factories in the inland of los Angeles County.

STEEL FRAME 124

MODULAR STEEL FACTORY OUTDOOR

The first workstation was just outside the factory’s rear entrance, where deliveries of recycled steel were deposited. Steel was cut to length and constructed into each module’s basic structural skeleton. Completed homes were transported directly to the sites, with sizes strictly dictated by trucking regulations.

dedicated steel piles, yellow in the photo above, serve as a staging and stationary platform for steel frames under construction. The structure’s light weight allows for transport by forklift, crane and other standard equipment. Staging metalwork outside of the factory limits the danger of fire.

ROLE OF THE ARCHITECT 125

Pictured above are steel frames in the production line with a cherry picker being used for worker access to upper levels. The elevated frames allow welders and machinery easy access as the frames move toward the factory.

INDOORS

once the frame is moved to the interior it is inspected for integrity and defects. Controlled conditions in the factory warehouse are necessary for thorough inspection of the structure.

After the closure of the Marmol Radziner factory, Connect was forced to use other fabrication facilities. Some completed steel frames are loaded onto a truck bed for transport to be completed at a different production facility.

The light frames can be lifted to increase ease of access for workers and inspectors. This allows crews to move quickly and spend the majority of their time working from the ground. This creates a safer working environment and expedites the construction process.

STEEL FRAME 126

MODULAR STEEL FACTORY INFILL

Completed frames are then sealed to prevent corrosion. The free standing frames allow for greater precision in weather proofing.

Movable wooden blocks replace the fixed steel piles as scaffolding for the frame. These blocks allow for greater flexibility on the factory floor. This setup allows Connect to operate with little fixed infrastructure.

ROLE OF THE ARCHITECT 127

Though the building is being produced in a factory setting, much of the construction is traditional. Pictured here is stick frame infill, routed to receive plumbing and electrical conduit, similar to standard construction types.

FACTORY OR LAY ORY LAYOUT A OUT AY INFILL

STEEL FRAME 128

FACTORY COMPONENTS: OUTDOOR Factory workers are a key part of the construction process. Skilled laborers, such as welders, forklift and crane operators and carpenters are needed in large numbers -- this type of high precision building favors highly skilled labor.

outdoor steel chassis are mounted in fixed locations to hold the steel frames level and elevated during their construction. outdoor work is possible year round due to the temperate climate in Southern California.

lightweight modules can be moved using cranes and light moving equipment such as forklifts. The ability to use light equipment adds flexibility to the process.

ROLE OF THE ARCHITECT 129

FACTORY COMPONENTS: INDOOR The factory itself is a very typical Butler building, with little specific infrastructure beyond its size, open plan and location near critical transportation infrastructure.

Modules are staged on wooden piles by forklifts, creating a highly flexible factory floor that can be reconfigured to fit the nature of work being performed at any given time.

The steel frame itself is key to the Connect Homes model, providing a rigid and robust frame that can enclose open spaces or contain finished construction.

STEEL FRAME 130

CONSTRUCTION SEQUENCE

A basic steel I-beam and box beam frame is erected and clamped in place. Welded joints connect the vertical and horizontal members.

Secondary steel members are added to reinforce the basic frame as necessary, and to connect with other building elements.

ROLE OF THE ARCHITECT 131

Wooden joists frame the floor, creating a sturdy base from which to build upwards.

CONSTRUCTION SEQUENCE

Relatively standard stick framing defines walls and opening for fenestration components.

Insulation fills the space between the framing. A moisture barrier is also applied to prevent intrusion of humidity into the wall cavity.

Interior cladding is applied over the framing and insulation.

STEEL FRAME 132

Windows and doors are fixed into place and then sealed with non-toxic sealants and adhesives.

Exterior cladding is applied over the insulation and vapor barrier. Cladding can be any number of materials, including standard metal and FSCcertified wood siding.

ROLE OF THE ARCHITECT 133

Flooring and decking are applied to finish the construction of the model. After this step, appliances and built-in furniture can be installed in the factory.

CONNECT ON SITE PREPARATION & SETTING

Prior to delivery, finishes, furniture and appliances can be installed and/or loaded into the container-ized modules. Pictured here is a carpenter installing finished cabinetry in the factory. Flooring has already been installed and covered with a protective layer to prevent damage during construction.

Rather than using a sling, connections to the crane can be made from the modulesâ&#x20AC;&#x2122; built-in hoist points. This allows the building to be dropped directly onto any foundations type without tethers interfering. Site work and preparation are completed before the modules arrive.

By starting both the site work and the factory production concurrently, Connect is able to cut the overall construction schedule nearly in half. Site work includes foundations, utility connections and any additional features included in the landscape design.

STEEL FRAME 134

CONNECT TO SITE STACk & FInISH

Modules can be stacked to create multi-story structures. Connect has engineered extra carrying capacity to allow for stacking without significant structural modifications.

once modules are set, the building is near completion. After a few days of patching the seams, on site work is completed and the building is ready for occupancy.

ROLE OF THE ARCHITECT 135

The finished home is an elegant modern construction. The Connect Homes systems allows for accelerated delivery and installation of housing solutions with promised cost benefits.

THE CONNECTED HOME ConnECT HoME FEATURES

R45 STANDARD ROOF INSULATION

REFLECTIVE COOL-ROOF SYSTEM

LOW VOC SEALANTS & PAINTS

DURABLE FACTORY INSTALLED METAL PANEL SYSTEM

RECYCLED PAPER INSULATION

WOOD TRELLIS FOR SHADING

LOW FLOW FIXTURES

R30 INSULATED FLOOR

ADJUSTABLE SUNSCREEN

90% RECYCLED STEEL FRAME

THERMALLY BROKEN DUAL GLAZED LOW E, .25 U FACTOR WINDOWS AND DOORS FSC CERTIFIED SUSTAINABLY HARVESTED SIDING & DECKING

STEEL FRAME 136

BUILDING SECTION

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SECTION DETAIL

WOOD JOIST STEEL ANGLE CONNECTION HOIST POINT WITH CAP STEEL C-CHANNEL BEAM WOOD HEADER TRANSPORT PANEL RAIN SCREEN EXT. ENVELOPE INSULATION

B C

Connect works to fit all assemblies within the tight space constrains of the intermodal container. However, the strength and lightweight nature of their steel structure allow them to have larger openings and accumulate modules to achieve grand open spaces. Structure packs tightly within the steel frame, which protrudes at the corners to interface with standard hoists, such as gantry cranes. STEEL FRAME

138

STANDARD MODELS

ModEl 2.1

640 sf , 1 bedroom, 1 bath, 2 Modules This is the smallest standard home in Connectâ&#x20AC;&#x2122;s product line. A galley kitchen opens up onto a covered deck.

ModEl 5.2 1,600 sf total, 2 bedroom, 2 bath, 5 Modules Series of configurable floor plans with a centralized kitchen in an open plan with a flexible number of bedrooms.

ModEl 8.3

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2,560 sf total, 3 bedroom, 2.5 bath, 8 Modules large galley kitchen that opens to a covered deck. double height space in the living area and different bedroom layouts upstairs.

Double height in the 8 series living space with structure visible

Living room in the 5 series with sliding door system and deck

STEEL FRAME 140

MODEL CONFIGURATIONS

8 Modules

ModEl 8.3

contained within a single wet wall in the center of the space. Sliding wall systems can open the interior and connect to the deck and landscape beyond.

Modules are stacked to create a second story and aggregate vertical and horizontal open spaces. The robust steel frame allows Connect Homes to frame open space. Services are ROLE OF THE ARCHITECT

141

ModEl 5.2

STANDARD MODULE

5 Modules

1 Module

54’ 8’

This is the size of a single connect Home module in plan. The module is 8’ width by 9’ height with a maximum length of 54’

ModEl 2.1

In this model, modules connect horizontally and frame open space to create larger rooms. The kitchen is central with services separated into their own areas.

2 Modules

This is the minimum aggregation, joining two modules to create a sixteen foot wide space with a single bedroom and combined living/dining room joined by a galley kitchen. STEEL FRAME

142

ROLE OF THE ARCHITECT 143

DELIVER: PLUG IN PLACE Connect Homesâ&#x20AC;&#x2122; innovative solution for modular building aims to harness the existing intermodal shipping network in order to extend the reach of a single factory effectively across the globe. This chapter will examine this network and Connectâ&#x20AC;&#x2122;s ability and desire to work at a large scale across vast distances.

STEEL FRAME 144

SEND HOME PROTECTIONS

Connect Homes completes a significant percentage of the work in the factory, including installing services, finishes, furniture and appliances. Their patented system of protective panels interfaces with the steel frame, complete with hoist points, to create a standard module that is also an intermodal container.

ROLE OF THE ARCHITECT 145

CONTAINER/MODULE

8’

54’ 8’

9’

54’ 9’

Connect Homes only uses an eight foot wide module, conforming to exact specifications to operate as an intermodal shipping container. STEEL FRAME 146

SENDING HOMES MODULE SIZES

Connect Homes module on semi-truck

Marmol Radziner module on semi-truck

In Connect’s model, all modules conform to eight feet, with a maximum 56’ length width to meet requirements for shipping via intermodal container networks. A series of cladding panels are affixed to protect the module during transport. Hoist points, integral to the frame, protrude to facilitate the transfer of modules. Unlike the M+R modules, Connect’s module does not require a lowered bed for transportation

M+R’s modules are typically two different widths and can be varying lengths. Twelve feet is the widest module that can fit on a truck without getting a special permit in California. The other width is eight feet, which M+R typically uses if a house is going somewhere distant or difficult to navigate—a tight access road or a hill site. After completion at the factory, each home is shrink-wrapped and loaded onto a truck for direct site delivery. A crane drops the modules into their foundations, and the homes are ready for final detailing within a few days.

ROLE OF THE ARCHITECT 147

INTERLOCK

Standard container interlocking mechanisms are employed as strong connections between modules. This simple system helps achieve precision in installation. STEEL FRAME 148

LOCKING & ALIGNMENT

Crane moves house onto foundation

Workers help to align second unit

ROLE OF THE ARCHITECT 149

First & second units locked in place, third is aligned

BUIlT PRoJECTS COMPARISON Connect

M+R

Factory

4 3 4

6 8 1

CONNECTing TO SITE Conforming to standard container module dimensions creates the potential for Connect to fabricate at one facility and ship globally. However, to date, Connect has only delivered projects in California, covering a smaller range than M+Râ&#x20AC;&#x2122;s built projects.

7 5 7 2 5

STEEL FRAME 150

BUILT PROJECTS : MARMOL RADZINER 1

Moab, Utah

13 modules - 2 bedroom, 2 bath, 2100 sf

Mendicino, California

37 modules, 4 bedroom, 5 bath, 8100 sf

Venice, California

10 modules, 2 bedroom, 2 bath, 2203 sf

Las Vegas, Nevada

Desert Hot Springs, California

15 modules - 2 bedroom, 2 bath, 2500 sf

14 modules, 3 bedroom, 2.5 bath, 2800 interior sf

Dry Creek, Colorado 5 modules, 2 bedroom, 1 bath, 1,325 interior sf

Hollywood, California 13 modules, 2,576 interior sf ROLE OF THE ARCHITECT

Santa Cruz, California 16 modules, 3 bedroom, 3.5 bath, 3200 interior sf

151

Marmol Radziner executed a number of residential steel frame modular projects of various sizes in the western United States beginning in 2006. Their fabrication facility played a key role in the development of Connect

BUILT PROJECTS : CONNECT 1

Sonoma, California

Menlo Park, California

5 Modules, 1,600 sf, 2 bedroom, 2 bath

modules, 640 sf, 1 bedroom, 1 bath5

Orinda, California 10 modules, 6160 sf, 4 bedroom, 2.5 bath

Mendicino, California Modules, 1,600 sf total, 2 bedroom, 2 bath

Bonsal, l California 4 modules, 2,560 sf total, 3 bedroom, 2.5 bath

Los Altos California 2 modules, 640 sf, 1 bedroom, 1 bath

Los Angeles, California 2 modules, 640 sf, 1 bedroom, 1 bath

Connect Homes has built a smaller number of houses in a smaller range that M+R, but has the potential to develope a global distribution network. However, the potential to leverage the intermodal shipping network globally has yet to be realized. STEEL FRAME 152

This map illustrates the network of commercial shipping modes in the western United States

TRANSPORT NETWORKS ROLE OF THE ARCHITECT

Road

Rail

Sea 153

This his map of shipping routes illustrates the relative density of commercial shipping in the worldâ&#x20AC;&#x2122;s oceans

TRANSPORT SHIPPING STEEL FRAME

Commercial Shipping Traffic Halpern, B.S., et al. 2008. A Global Map of Human Impact on Marine Ecosystems

154

THE PRoMISE oF SCAlE

Connect 8.3: 64â&#x20AC;&#x2122;

Panamax vessels, can accommodate over 14,000 containers. Planned Super-Post Panamax ships will accommodate more that 18,000 containers.

The global intermodal container shipping network is vast and operates at staggering scales. The current largest class, Post ROLE OF THE ARCHITECT 155

has managed to operate consistently at significant scale or on the international stage.

At the scale of international cargo shipping, larger scale building, even the delivery of an entire town on a single ship is completely feasible. However, to date, no modular builder

STEEL FRAME 156

ROLE OF THE ARCHITECT 157

PROTECT: PATENT PROCESS

Connect Homes grew out of an existing modular company to develop an innovative solution for modular building. The company leveraged architectural patents as a means to protect their original solutions at various scales. This section looks at architectural patents as a means to legitimize and protect architectural inventions.

Connect Homes Patent Diagram STEEL FRAME 158

ARCHITECTURAL PATENTS PATENT COMPONENTS Abstract Inventors Applicant Prior Publication Data Related U.S. Patent Documents Foreign Patent Documents Other References Claims 69Description

Background of the Invention Summary of the Invention Brief Description of the Drawings Detailed Description of the Invention Figures

CONNECT HOMES’ Patent

Patents are on means for architects to legitimize their innovations and protect their work. The Architecture & Copyright Law suggests that all projects as completed works should be protected and patented – but the procedure requires two steps because architecture is interpreted in two ways. First there are the drawings and specifications which fall under “technical drawings” and then there is the completed structure which is registered as “architectural work.”

ROLE OF THE ARCHITECT 159

CONNECT HOMES PATENT STACk & FInISH

Steel Frame conforming to Multi-Modal Shipping Container Requirements

Shipable Module and Protection Panels

Connect homes protects its innovation modular delivery by patenting the structure at several levels, from system to detail including; frame with hoist points, protective panels, joint details and aggregation of structure. Aggregation of Modules to Form Multi-Story Buildings STEEL FRAME 160

dyMAXIonâ&#x20AC;&#x2122;S IndIVIdUAl PATEnTS

Building construction US 2343764 A

Idea for a prefabricated house US D133411 S ROLE OF THE ARCHITECT

Prefabricated bathroom US 2220482 A

161

ConnECTâ&#x20AC;&#x2122;S PATEnT TREE

ConnectHomes - US20110162293

US 4854094 A

US 5706614 A

US 4891919 A

US8371091 Building system and method with prefabricated structures

US5447000 Prefabricated building kit

US4854094 Transportable building system incorporating cargo shipping

US20020129566 Portable modular factory structure and method

Expandable shelter system

US8640396 Wind resistant modular ISO building

US7418802

US20030009954 Self-contained transportable dwelling

US20070107321

Expandable shelter system STEEL FRAME 162

UNSUCCESFUL PATENTS PATENTING THE SKYSCRAPER

ROLE OF THE ARCHITECT

FORM PATENTS

This 1989 patent by Rado Vero illustrates could not prevent international iterations of the idea 163

HSB Turning Torso Building in Sweden by Santiago Calatrava

THE ROLE OF THE ARCHITECT 164

THE ROLE OF THE ARCHITECT 165

2.3 ONION FLATS - A CASE STUDY Pennsylvania is the single largest concentration of modular manufacturers with a push towards multi-unit modular. Onion Flats is an architecture firm specializing in modular through a series of projects since 2012. Their unique business model of an architectural firm utilizing vertical integration successfully establishes the relationship between the modular industry, multi-unit housing and Onion Flatsâ&#x20AC;&#x2122; unique mode of practice.

ONION FLATS 166

WHY ONION FLATS? MODULAR INDUSTRY IN A PACKAGE The purpose of this case study is to analyze the unique business model of the company Onion Flats, its relationship to the city and its initiatives, and its growth from a typical architecture firm into a develop/design/ build collective. Onion Flats provides a relative case study towards our study of modular housing because of the company’s focus on the use of modular systems, their wide expanse of project types ranging from single family rowhouses to apartment complexes, and the similarity of Philadelphia’s recent initiatives and push for affordable housing stock to Boston’s. Looking at the uniqueness of the Onion Flats business model, it can be compared to the modular housing industry as a whole. Each field of expertise, engaged by the modular housing, is represented in Onion Flats and instead of working as individual industries, they are incorporated together into a single entity.

MODULAR HOUSING INDUSTRY

The Factory

MANUFACTURED HOUSING INDUSTRY

The Builder

The Client

The Factory

THE ARCHITECT

CONNECT HOMES

THE LOCAL BUILDER

The Factory

The Builder

THE CLIENT

The Architect

ONION FLATS, THE ROLE OF THE ARCHITECT

The Factory

The Client

The Architect

THE ROLE OF THE ARCHITECT 167

The Client

The Architect

RESOLUTION 4 ARCHITECTURE, THE ROLE OF THE ARCHITECT

THE FACTORY

The Distributor

The Builder

The Client

GET TO KNOW ONION FLATS PREFABRICATED HOUSING DEVELOPER WITH A FOCUS ON NET-ZERO PASSIVE PROJECTS Onion Flats founded in 1997 by brothers Tim and Pat McDonald. The small firm was located in their first experimental project, Market Flats; a place to house the firm, an architectural gallery and apartments for rent. In 2005 their third brother Johnny McDonald and long-time family friend Howard Steinberg join the company, transforming the company into a development/design/build company. Their unique modular-housing business model consists of one over-arching corporation, Onion Flats (the Developer), with smaller subsidies that focus on their own discipline; Plumbob (the Architect); JIG Inc. (the Builder); G.R.A.S.S. (the Technologist); BLOX (the Fabricator); and the McDonald Group (the Speculator). This was a result of the vertical integration growth incorporating each discipline of the develop/design/ build company into their own company. Onion Flats has focused on sustainable design, gaining either LEED, Passive House, and Net-Zero Energy certifications on all projects.

TIM MCDONALD TEDx TALK As a ‘critique’ of contemporary architectural and building theory and practice, Onion Flats’ mission since 1997 has been fourfold: 1. To extend the imagination of the architect beyond the drawing board and into the building process. 2. To educate the public about the collaborative role of the architect in not only the making of buildings but of culture and meaning in contemporary society. 3. To reestablish a space of dialogue and respect between members of the architectural and building communities. 4. to empower a younger generation of architects, builders and craftsmen to continue to dream.

http://www.youtube.com/watch?v=kYgXs2WLZgk

While each branch of Onion Flats are distinct, the intention of the collective is to seamlessly integrate the process by which ideas about architecture, the city, and sustainable development go from construction to habitation. ONION FLATS 168

ONION FLATS : MOST RECENT CURRENT INDUSTRIAL ECOLOGY Sit

s s he stem y s i S n n Fi ndatio Fou

eW struc ork tion

Con

ain

JIG Inc. The Builder

m te

S ar

u od

G.R.A.S.S. Inc. The Technologist

Pat McDonald

ofs

o nR

ree

Tim McDonald

Howard Steinberg

Onion Flats Developer

its

it B

loc

Johnny McDonald

Aquisition

Rea

ltor

sig

m Per

THE ROLE OF THE ARCHITECT 169

Factory Un

The McDonald Group The Speculator

PLUMBOB LLC. The Architect

Client Interaction

BLOX The Fabricator

PENNSYLVANIA MODULAR INDUSTRY MAP AND SURROUNDING AREA

Philadelphia, Pop. PA 5,772,947

100 mi.

200 mi.

MODULAR NETWORKS KEY 600 mi.

500 mi.

400 mi.

300 mi.

Manufacturer

Metro Area

ONION FLATS 170

ONION FLATS : PARTIAL UPWARD VERTICAL INTEGRATION

PLUMBOB LLC. Onion Flats

Onion Flats

ONION FLATS : TIMELINE 1997

BLOX G.R.A.S.S. JIG, Inc. PLUMBOB LLC. Onion Flats

2005

2006

2007

2008

Thin Flats Panelized Row Housing Rag Flats Panelized Row Housing and Trinities Residential Garden Community

Formation of PLUMBOB, LLC. Licensed Architectural Firm Founding of Onion Flats Development Firm Brothers Tim and Pat McDonald founds Onion Flats through their first project, Market Flats. Creating their office space and Philadelphia’s first architecture gallery, FAARM. Pat steers the organization towards fundamentally “sustainable” modes of thinking, building and dwelling.

Sibling Johnny McDonald and long-time friend Howard Steinberg join the team and transforming the company into a development/ design/build company.

THE ROLE OF THE ARCHITECT 171

Formation of BLOX Sustainable Building Systems, LLC. Modular Manufacturing Facility Formation of JIG, Inc. Licensed Construction Company

The McDonald Group BLOX G.R.A.S.S. JIG, Inc. PLUMBOB LLC. Onion Flats

2009

2010

2011

2012

Belfield Homes Modular Row Housing

2013

2014

Stable Flats Modular Row Housing The Ridge Modular Apartment Complex

Formation of G.R.A.S.S. Inc. Green Roofs and Sustainable System Company Formation of The McDonald Group / Cityscape Philadelphia, LLC. Real Estate / Acquisition Company

ONION FLATS 172

ONION FLATS : CASE PROJECT LOCATIONS 1

Belfield Homes

The Ridge

Sch

uylk

ill 95

Onion Flats

Rag Flats ware

Dela

Stable Homes Sc

ylk

ill

Thin Flats

Highway

Railway

Water

Sites

THE ROLE OF THE ARCHITECT 173

Rive

ONION FLATS : NEIGHBORHOOD OF PROJECTS Rag Flats

Stable Homes

Thin Flats

Highway

Railway

Water

Sites ONION FLATS 174

CASE STUDIES MATRIX

2006 Name

Rag Flats

2008

Thin Flats

BLOX Sustainable Building Systems LLC.

Rowhouses

Modular Manufacturing

Prefabricated Panelized

Establishment of the modular manufacturing facility and company reshapes building techniques employed on projects after 2008.

Type

Rowhouses Triple Deckers

Construction Technique

Prefabricated Panelized

Cost

$500,000 for TD $130,000 for RH

N/A

Architects

Onion Flats and Minus Studios

Square Footage Per Unit

1,650 - 2,140

Target Client

Affordable

Onion Flats 2,255 Affordable

THE ROLE OF THE ARCHITECT 175

2012

2014

2015+

Belfield Homes

Stable Homes

The Ridge

Rowhouses

Apartments

Prefabricated Modular

$247,680

$749,900

N/A

PLUMBOB

Onion Flats

1,920

2,500

N/A

Very Low Income

Market-Rate

Affordable ONION FLATS 176

RAG FLATS, PHILADELPHIA, PA Onion Flats, Experimental Community Project Rag Flats was an experiment in sustainable forms of urban dwelling, re-conceptualized as a residential garden community made up of the typical housing types found throughout Philadelphia; the rowhouse, the trinity, the loft and the pavilion. The trinities are 3 bedroom, 3 bathroom and 3 stories tall, with a footprint of 20’ X 20’. The rowhouses are 2 bedroom, 2 bathrooms and are designed by Minus Studios. Onion Flats explores the relationship between density, intimacy, and privacy in any urban community.

^ Project Bird’s Eye View Project Top View v

At this time, Onion Flats was still too small of a firm to handle such a large project. Working with Minus Studios and Cover LLC. they formed a collaborative design/build team to work on the project.

THE ROLE OF THE ARCHITECT 177

Rag Flats Housing Type : Rowhouses, Trinities, Lofts and Pavilion Year Completed : 2007 Number of Units : 11-Units Number of Buildings : 5 Trinities, 2 Rowhouses, 2 Lofts and 1 Pavilion Price per Unit : $500,000 per Trinity $130,000 per Rowhouse LEED Certification : None Unit Size : 2,140 square feet per Trinity ($220/sqft) 1,650 square feet per Rowhouse ($79/sqft) ONION FLATS 178

RAG FLATS UNIT PLANS

THE ROLE OF THE ARCHITECT 179

ONION FLATS : BUSINESS RELATIONSHIP FOR RAG FLATS

Minus Studios

Row Homes Experiments

Cover LLC.

Steel Facade Experiments Trinity Experiments

O N I O N

Pavilion Experiments PLUMBOB LLC.

F L A T S

R A G F L A T S

Loft Experiments

G.R.A.S.S. INC.

Agents

Products

Taking on a project much larger than the firm could handle, Onion Flats enlisted the help of other companies to design and engineer specific building types within the project. This lead to a distribution

of the work with some branches having developed all the buildings and others focused on certain types. ONION FLATS 180

THIN FLATS, PHILADELPHIA, PA Onion Flats, Duplex Rowhouses Thin Flats consist of 8-units of rowhouses split between 4 duplexes. It was the first LEED-H Platinum multifamily residence in Pennsylvania. The skin is designed to allow any room to connect outside to a ‘periphery’ and remain within the skin. Although hampered by the thin dimensions of the rowhouse type, Onion Flats was able to flood the interior with light and air.

^ Project Bird’s Eye View Project Top View v

“A degree of density yet expansiveness uncommon to the thin space of the single family Row home emerges both programmatically and experientially.” (Onion Flats) This was one of Onion Flats’ key projects after the creation of their construction branch JIG Inc. expanding Onion Flats into a 4-branch company.

THE ROLE OF THE ARCHITECT 181

Thin Flats Housing Type : Duplex Rowhouses Year Completed : 2008 Number of Units : 8-Units Number of Buildings : 4 Rowhouses Price per Unit : N/A LEED Certification : LEED-H Platinum Rent : $3,250 per month Unit Size : 2,255 square feet ($1.5/sqft/month)

ONION FLATS 182

THIN FLATS UNIT PLANS

THE ROLE OF THE ARCHITECT 183

ONION FLATS : BUSINESS RELATIONSHIP FOR THIN FLATS

JIG INC.

O N I O N

General Contracting

Structural Engineering

F L A T S

Associated Engineering Consultants INC.

F L A T S

PLUMBOB LLC.

T H I N

Design Green Roofs

G.R.A.S.S. INC. Rainwater Harvesting

Agents

General Contracting

Products

Onion Flats has expanded to include construction within their repertoire of services. This gave the company more control of processes needed to construct a project as the company needed less

outside contractors. The service that they were lacking for this project was structural engineering which will be solved in the next project to come. ONION FLATS 184

ONION FLEX... MAJOR EVOLUTION TOWARDS MODULAR DESIGN The foundation of BLOX Sustainable Building Systems, LLC. provided a large paradigm shift for Onion Flats; expanding from their previously stick built and panalized systems towards a modular block focused design system. There are many benefits for this change stated by Onion Flats; 1. Prefabrication allows for more sustainable design from increased airtightness which result in a hyperefficient building envelope. 2. Use of prefabricated building components to achieve economic viability on projects. 3. Using this system cuts the time for buildings built by half and also doubles the energy efficiency of projects at equal or lower cost. Combining modular design with their other tenets, Onion Flats is able to engage their core principal belief that building sustainably does not mean building expensively. Following this core principal on all their designs, Onion Flats works with national, state and local initiatives and achieve results that are beneficial to everyone.

THE ROLE OF THE ARCHITECT 185

ONION FLATS : BLOX FACTORY TO SITES 476

BLOX

476

ylk

ill 276

276

Sch

uylk

ill

476 276

Belfield Homes

The Ridge 95 476 76

Onion Flats Rag Flats Stable Homes Thin Flats

Route

Sites

lki

Water

hu y

Philadelphia Border

Highway

iver

re R

Dela

ONION FLATS 186

PHILADELPHIA TYPICAL HOUSING TYPES

Rowhouse

Trinity

Apartment/Loft

THE ROLE OF THE ARCHITECT 187

PHILADELPHIA, PA INITIATIVES

The USDHUD is a national program working to expand home ownership and create affordable housing throughout the country. They provide; loans and subsidies to families for housing; grants for states and non-profit organizations to create affordable housing; and maintain a database of affordable housing for people to search. In 2014, Massachusetts has received over $126 million for public housing, homeless permanent housing, fighting housing discrimination and disaster recovery plans.

Greenworks Philadelphia is a sustainability initiative created by the city of Philadelphia. It sets targets and directives for the city to try to attain throughout the year. This includes improvements and numbers to improve the environmental standards in Philadelphia and for buildings.

Raise of Hope Inc. was created by Habeebah Ali as a non-profit organization to provide social and educational services to enhance the quality of life for challenged communities. Their target population are the homeless, low and moderate income families and individuals, senior citizens, ex-offenders re-entering society and individuals in the Delaware Valley area.

ONION FLATS 188

BELFIELD HOMES, PHILADELPHIA, PA Plumbob LLC, Modular Rowhouses Belfield Homes is a subsidized housing project sponsored by a Philadelphia non-profit organization Raise of Hope Inc. through a grant from the US Department of Housing and Urban Development. It is the first Passive House Certified project in Philadelphia. Units are 4-5 bedroom rowhouses, built at a low cost with low upkeep while providing nicer living accommodations than many associate with low-income housing.

^ Project Birdâ&#x20AC;&#x2122;s Eye View Project Top View v

This is one of the cheapest and earliest housing projects built by Onion Flats through their modular branch, BLOX Sustainable Building Systems. This project used all the design/build branches of Onion Flats.

THE ROLE OF THE ARCHITECT 189

Belfield Homes Housing Type : Rowhouse Year Completed : 2012 Number of Units : 3-Units Number of Buildings : 3 Rowhouses LEED Certification : None Price per Unit : $5,000 per Rowhouse Unit Size : 1,920 square feet ($3/sqft) Other : Certified Passive House Very Low-Income Family Housing Net-Zero Energy Homes ONION FLATS 190

BELFIELD HOMES UNIT PLANS

THE ROLE OF THE ARCHITECT 191

ONION FLATS : BUSINESS RELATIONSHIP FOR BELFIELD HOMES

JIG INC.

Raise of Hope

O N I O N F L A T S

Modular Block

BLOX LLC.

PLUMBOB LLC.

H O M E S

Design

G.R.A.S.S. INC.

B E L F I E L D

Sustainable Systems Passive House Certification

Agents

Products

This is when Onion Flats established their current business model. With the establishment of their modular company BLOX, LLC. it allows Onion Flats to control most aspects of a project from design to completion. This allows Onion Flats to better predict

the timelines of projects, the costs, and services needed to be rendered. Furthermore, the use of modular helps to push many of the principles that Onion Flats adheres to. ONION FLATS 192

STABLE HOMES, PHILADELPHIA, PA Onion Flats, Modular Rowhouses Stable Homes is a development of 27-units of rowhouses designed to be the first Passive House community in the US; with a 90% reduction in energy consumption compared with the average for this type of housing. Everything is prefabricated including panelized foundation and modular superstructure. Each four floor townhouse unit will have 3-bedroom. This was a speculative project through a joint venture with Bodine Street LP dedicated towards Passive House and LEED-H Platinum Certification.

^ Project Birdâ&#x20AC;&#x2122;s Eye View Project Top View v

This was a market-rate speculative project designed and built entirely by Onion Flats, from design to sales of the units.

THE ROLE OF THE ARCHITECT 193

Stable Homes Housing Type : Rowhouses Year Completed : 2014 Number of Units : 27-Units Number of Buildings : 27 Rowhouses LEED Certification : LEED-H Platinum Price per Unit : $749,900 Unit Size : 2,500 square feet ($300/sqft) Other : Passive House Community

ONION FLATS 194

STABLE HOMES UNIT PLANS

THE ROLE OF THE ARCHITECT 195

ONION FLATS : BUSINESS RELATIONSHIP FOR STABLE HOMES

JIG INC.

O N I O N Domani Developers

F L A T S

Modular Block

BLOX LLC.

PLUMBOB LLC.

G.R.A.S.S. INC.

Agents

S T A B L E H O M E S

Design

Sustainable Systems

Products

With the current business model established, little changes in the processes from design to build but the element that does change is the actors that help to fund and/or hire Onion Flats to do a project. In

this example, the developer, Domani Developers are working in a partnership with Onion Flats on this speculative project. ONION FLATS 196

THE RIDGE, PHILADELPHIA, PA Onion Flats, Modular Apartment Complex The Ridge is a modular 126-unit mixeduse apartment complex. Each unit has 1-2 bedrooms and the complex focuses on alternative transportation options because there is less parking than there are units. Upon completion, it would be the first and largest multi-family Passive House certified Net-Zero Energy mixeduse community in the United States. Ground was broken in August, 2014 and the photos show the site at scale with the other case studies.

^ Project Birdâ&#x20AC;&#x2122;s Eye View Project Top View v

This will be the largest project Onion Flats has done to date. Partnered with a second developer for financial reasons, Onion Flats will develop/design/build the entire project. The entire building will be prefabricated by their modular branch, BLOX Sustainable Building Systems.

THE ROLE OF THE ARCHITECT 197

The Ridge Housing Type : Apartment Complex Year Completed : 2014+ Number of Units : 126-Units Number of Buildings : 1 Apartment Complex LEED Certification : None Rent : $1,300 - $2,000 Unit Size : N/A Other : Largest Passive House Community Net-Zero Project

ONION FLATS 198

THE RIDGE UNIT PLANS

THE ROLE OF THE ARCHITECT 199

ONION FLATS : BUSINESS RELATIONSHIP FOR THE RIDGE

JIG INC.

The McDonald Group

O N I O N F L A T S

Modular Block

BLOX LLC.

PLUMBOB LLC.

G.R.A.S.S. INC.

Agents

T H E R I D G E

Design

Sustainable Systems

Products

This is their first project that utilizes all aspects of the companies owned by the family. With the main speculator as The McDonald Group, their realtor company, Onion Flats is designing and building this

project based on their own ideals and principles utilizing the best of each branch of their corporation and creating a multi-unit modular complex. ONION FLATS 200

PHILADELPHIA VS. BOSTON : HOW DOES IT RELATE? Both Boston and Philadelphia are currently in a similar economic and social environment. Both cities are pushing for sustainable practices and affordable housing. Philadelphia is ahead of Boston as they have already embraced modular design within their new housing market, building to accommodate lower cost housing and denser housing. Furthermore, both cities have similar initiatives stressing affordable housing and also home ownership. Philadelphia is in an interesting situation where modular buildings are being built and embraced by the city. Modular projects, such as those done by Onion Flats, are well received by the neighborhoods. Modular construction was common in Philadelphia in the 2000s. A study on modular construction in Philadelphia has shown a reduction in cost per square-foot of about $22 compared to stick-built construction. This reduction in construction cost is relevant in Boston. A study by Econsult Corp has shown that Boston is one of three cities where the cost to build an average house is higher than the sale price when it comes to market.

Furthermore, both Philadelphia and Boston have similar housing types, the rowhouse, the triple decker (trinity), the loft and apartments. Other issues are the densification and sustainability of of housing stock. Barry Bluestone, one of the main advocates and researchers for Massachusettsâ&#x20AC;&#x2122;s Chapter 40R initiatives, expressed an interest in bringing modular housing into Boston along with streamlining the process through a city-owned modular fabrication factory. This integration of different industries would promote an interesting network of architects, engineers, builders and contractors that the Onion Flatsâ&#x20AC;&#x2122; business model already experimented with and optimized to allow for a cheaper, faster and more sustainable design/build process. Boston and Philadelphia both have sustainability initiatives, called Greenovate Boston and Greenworks Philadelphia respectively. Both initiatives strive to make buildings more weatherproof and to set environmental benchmarks for the cities to reach. With many of these similarities, Philadelphia can serve as a prototype for the direction and initiatives Boston can undertake to take advantage of the modular housing industry.

THE ROLE OF THE ARCHITECT 201

GENERALIZATION OF THE CASE STUDY Onion Flatsâ&#x20AC;&#x2122; unique business model creates an environment for the company to flourish. Through the integration of the multiple disciplines, it allows for a more viable business model which increases marketability and profit for other investors. This integration also allows the company to control the timeline, standards and local conditions of a project, allowing for better predictability. This allows for better estimation of profit margins, sale prices of units and the length of projects. As the units in projects increase, this changes the conditions in the factory as the same unit will be produced, making the system even more efficient and profitable.

Onion Flats produced an array of housing types to cover all typical housing needs found in Philadelphia, which are similar in type and size to those commonly found in Boston and other northeastern cities. Their key examples are the rowhouse, the triple decker and apartment complexes. Projects can be used as prototypes that can be undertaken and localized for Boston, carrying over ideas such as sustainability, affordable costs, and build time.

pushs the envelope for luxury and sustainability so that the upkeep of the homes are extremely low. Analyzing Onion Flatsâ&#x20AC;&#x2122; business model and their integration of the different industries layout a framework for redefining modular housing as a viable option for housing construction in the city.

Unlike the other case studies found in this book, which focus on second homes and luxury housing, Onion Flats provides an example for the design/build of affordable houses and

ONION FLATS 202

203

MACRO INITIATIVES

204

DISASTER RESPONSE DISTRIBUTION CENTERS INTERNATIONAL - UNHCR

Accra, Ghana; Amman, Jordan; Copenhagen, Denmark; Douala, Cameroon; Dubai, UAE; Isaka, Tanzania; Nairobi, Kenya

MACRO INITIATIVES 205

NATIONAL - FEMA

Cumberland, Maryland; Hope, Arizona; Selma, Alabama

9 206

DISASTER RESPONSE CAMP INTERNATIONAL - UNHCR

Al-Za’atari Refugee Camp May 4, 2013 Housing: 28, 243 Infrastructure: 1,662 MACRO INITIATIVES 207

NATIONAL - FEMA

11 208

MACRO INITIATIVES 209

3.1 INTERNATIONAL - UNHCR Every year millions of people around the world are forcibly displaced from their homes requiring both a rapid and long term solution. The politics are slowly and reluctantly beginning to address the issue of displacement beyond the temporality of its cause. Housing solutions need to be produced and distributed internationally, but implemented on a regional scale.

INTERNATIONAL-UNHCR 210

UNHCR INTERNATIONAL DISASTER RELIEF AID The United Nations High Commission for Refugees, or UNHCR, is an international agency that leads and coordinates actions to protect those who are forcibly displaced. The category of displaced primarily includes refugees and internally displaced persons. Others that would receive protection are those seeking asylum, those under the statelessness mandate, returned IDPs and refugees, and others of concern.

Refugees (11,699,638)

Internally Displaced Persons (23,925,555)

UNHCR PERSONS OF CONCERN

Stateless Persons (3,469,235) Returnees (1,770,596) Asylum Seekers (1,168,273)

Other (836,052)

Information from UNHCR Data 2013

FORCIBLY DISPLACED

Syrians refugees crossing to Iraq Photo credit: AP/HO

There are typically two categories of forced displacement; displacement driven by natural disasters, and displacement driven by disasters of conflict. Both are unpredictable, and cause the displacement of millions worldwide. These people are forced to leave their homes, and often have nothing but the clothes on their back. When left homeless and vulnerable, UNHCR hopes to aid to their best abilities. But these situations should also evoke responses from others, who can help return to these persons a sense of dignity and security. MACRO INITIATIVES 211

Refugees and IDPs (in millions)

IDPs

15 10

Refugees

‘93 ‘95 ‘97 ‘99 ‘01 ‘03 ‘05 ‘07 ‘09 ‘11 ‘13

Information from UNHCR Data 2013

(in millions)

Conflictinduced

30 Disasterinduced

‘08

Aid distribution at Kibati IDP camp in North Kivu, DRC Photo credit: P.Taggart

‘09

‘10

‘11

‘12

‘13

Information from UNHCR & IDMC Data 2013

Somali refugees in a Dabaab refugee camp, Kenya Photo credit: UNHCR

INTERNATIONAL-UNHCR 212

NUMBER AND LOCATION OF INTERNALLY DISPLACED PERSONS

Information from IDMC Data 2011

> 1,000,000

500,000 - 1,000,000

100,000 - 500,000

MACRO INITIATIVES 213

10,000 - 100,000

< 10,000

NUMBER AND LOCATION OF REFUGEES

Information from UNHCR Data 2012

> 500,000

250,000 - 500,000

100,000 - 250,000

10,000 - 100,000

< 10,000 INTERNATIONAL-UNHCR

214

COUNTRIES MONITORED FOR INTERNALLY DISPLACED PERSONS

Information from IDMC Data 2011

Natural disaster driven

Conflict, violence, and human rights violation driven

MACRO INITIATIVES 215

Both

MAJOR SOURCE AND HOST COUNTRIES OF REFUGEES

Information from UNHCR Data 2012

Host country

Source country

Both INTERNATIONAL-UNHCR 216

MACRO INITIATIVES 217

ONE CAMP

4 Sectors 20,000 Persons

HOUSING DISPLACED PERSONS CAMP SUPPORT INFRASTRUCTURE

ONE SECTOR

4 Blocks 5,000 Persons

ONE BLOCK

MARKET

DISTRIBUTION POINTS

FEEDING CENTRE

HEALTH CENTRE

REFERRAL HOSPITAL

SCHOOL BLOCK

REFUSE DRUMS

WATER TAP

16 Communities 1,250 Persons

ONE COMMUNITY

16 Families 80-100 Persons

ONE FAMILY

LATRINE

4-6 People

Information from UNHCR Third Edition Handbook for Emergencies 2007

When housing displaced persons, there are several options. Those options are dispersed settlement, which include host families and individual accommodations; mass shelters or collective centres; and camps, which include self settled camps, planned camps, and transit camps.

such as UNHCR. When individual accommodations are not possible a planned camp is the most desired housing option to be deployed by organizations. Although planned and ran by an organization, a planned campâ&#x20AC;&#x2122;s demands grows and changes at the mercy of the disaster. It is a rapidly growing and changing situation. There are guidelines to what is necessary per camp, as is presented in the above diagram.

Not all displaced persons will be housed by organizations

INTERNATIONAL-UNHCR 218

1997

2002

2003

2006

2007

2009

2004

09_2012 Protests and an uprising against President Assad result in civil war in Syria, causing hundreds of thousands to be displaced. With more than 15,000 finding refuge at Al Zaâ&#x20AC;&#x2122;atari.

Tents Housing Unit/Shelters Support Infrastructure MACRO INITIATIVES 219

12_2012 With increased violence, the number of refugees at Al Zaâ&#x20AC;&#x2122;atari rises to 45,000 by December. The camp expands, with additional shelter and construction of infrastructure support.

GROWTH & DEVELOPMENT HOUSING DEMANDS

2005 Photos taken from Google Earth and Digital Globe/Getty Images

2004

2010

2011

01_2013 As of January 2013, over half a million Syrians are registered as refugees. The camp continues to expand; introducing more tents, housing units, and shelters.

02_2013 Assad refuses to succumb to international pressures to step down, war continues. The camp expands, and does groundwork in anticipation of further growth and accommodations.

On the right are several photos showing the growth of two developments. The first set shows the growth of Surprise, Arizona over a span of several years. The second set shows the growth of the Syrian refugee Al Za’atari camp in Jordan, over the span of just months. All photos are shown at the same scale, showing the same land area. The amount of development that took Surprise 5 years, only took Al Za’atari 5 months. This shows the urgency and rapidity of a disaster camp. The development of the Al Za’atari refugee camp includes the addition of tents, housing units, and various support infrastructure. The camp is the second largest refugee camp, behind the Kobe refugee camp in Ethiopia. As of September 2013, the camp took in 2,000 new refugees per day. At the dawn of the conflict there were 8,000 registered Syrian refugees (Dec 2011). As of November 2014 there are over 3 million registered refugees, over 6.5 million IDPs, and thousands of other awaiting registration and asylum. INTERNATIONAL-UNHCR

220

HOUSING OPTIONS

Tarp

Tent

Unit

6 months 2 years MACRO INITIATIVES 221

x40

x200

Barrack

Existing Structure 12 years 12 years INTERNATIONAL-UNHCR 222

DISASTER RESPONSE AND PROCESS When responding to disasters of climate, violence, and human rights issues, interventions must be carefully coordinated. The majority of those affected by disasters are already vulnerable, many already living in poverty or coming from informal communities, so to have the burden of a disaster only further exacerbates the feeling of helplessness. Responses to disasters must be sensitive to the persons in need, while at the same time providing adequate and timely support. UNHCR is a global coordinator in disaster relief responses attaining to refugees, internally displaces persons, and other persons of concern. However, they only implement action when they find it appropriate. The first preferred action is by the appropriate governments involved. That would be the native government of those displaced and/or the host government of those displaced. It is then after that first preferred action or lack of action that UNHCR will either join or take lead in the response. The primary role of UNHCR is to act

as the coordinator of actions. They lead their own organization in addition to supporting organizations and governments. In addition to roles of coordination UNHCR also provides physical materials of support such as CRIs (core relief items). CRIs would include: blankets, buckets, jerry cans, kitchen sets, mosquito nets, plastic rolls, sleeping mats, winterized kits, prefab warehouses, and housing materials (lightweight tents, plastic sheets, & family tents). As previously mentioned different housing options include: dispersed settlement, which includes host families and individual accommodations; mass shelters or collective centres; and camps, which include self settled camps, planned camps, and transit camps. As shown in the following flow charts the choice of housing has varied with time and by situation. However there has been an increase in interest around prefabricated shelters. Prefabricated shelters have not been the optimum choice for disaster relief responses implemented by UNHCR.

MACRO INITIATIVES 223

However, with the realization that the six month life span of a tent is far outlived by the tenants by years, there has been a shift in ideology. A refugee camp is never meant to be a permanent solution, and with refugees living in camps on an average of twelve years, new housing solutions need to be considered. The path of a refugee or IDP after entering a camp varies greatly. Whether they leave or stay, upgrade their accommodations or resettle in a new host country, it is vital that the time spent in a camp is as dignified as possible. Housing solutions in times of disaster should provide shelter, security, dignity, and possibilities.

MASS SHELTER

SELF BUILD

HOST GOV’T ACTION

WITH

LOCAL MATERIALS

SELF SETTLED AND PLANNED

DISASTER

CAMPS

UNHCR

SANCTIONED

TENTS

PREFAB SHELTERS

LED

ACTION

R E F U G E E S & I D P S

INDIVIDUAL ACCOMODATIONS INTERNATIONAL-UNHCR 224

SAME SHELTER MAKE SHELTER PERMANENT

STAY UPGRADE SHELTER

HOME

ORIGINAL LOCATION WITHIN STATE

I D P S

RESETTLE

NATIVE LOCATION WITHIN STATE

SPONSORING STATE

LEAVE

A HOST STATE RELOCATE NEW SETTLEMENT MACRO INITIATIVES 225

SAME SHELTER

STAY UPGRADE SHELTER

R E F U G E E S

LOCAL INTEGRATION

NATIVE STATE REPATRIATE

RESETTLE SPONSORING STATE LEAVE NEW HOST STATE RELOCATE NEW SETTLEMENT INTERNATIONAL-UNHCR 226

END OF VIETNAM WAR, 1975

BUILD

MASS SHELTER

BUILD

VARIOUS GOV’T ACTIONS

WITH

LOCAL MATERIALS

*9+

POST VIETNAM WAR PERSE CUTION

PLANNED TRANSIT

CAMPS

UNHCR

SANCTIONED

TENTS

PREFAB SHELTERS

LED

ACTION

*Countries Of First Asylum: Malaysia, Hong Kong, Indonesia, Thailand, Philippines, Singapore, Japan, Macau, Korea, etc.

INDIVIDUAL ACCOMODATIONS

MACRO INITIATIVES 227

V I E T N A M E S E R E F U G E E S

SAME SHELTER

STAY UPGRADE SHELTER LOCAL INTEGRATION

VIETNAM

INVOLUNTARY AND VOLUNTARY REPATRIATION

RESETTLE IMMIGRATE TO

SPONSORING STATE *11+

LEAVE

*Third Country: United States, Australia, Canada, France, UK, Germany, New Zealand, Netherlands, Japan, Switzerland, China, etc.

NEW HOST STATE RELOCATE NEW SETTLEMENT PERMANENT OR TRANSITIONAL

INTERNATIONAL-UNHCR 228

SYRIAN CIVIL WAR, ONGOING MASS SHELTER

BUILD

HOST GOV’T ACTIONS

WITH

LOCAL? MATERIALS

SYRIAN UPRISING AND CIVIL WAR

REFUGEE AND IDP

CAMPS

UNHCR

SANCTIONED

TENTS

PREFAB SHELTERS

LED

ACTION

*Syria and Countries Of First Asylum: Lebanon, Jordan, Turkey

INDIVIDUAL ACCOMODATIONS

MACRO INITIATIVES 229

S Y R I A N R E F U G E E S & I D P S

SAME SHELTER MAKE SHELTER PERMANENT

STAY UPGRADE SHELTER

ORIGINAL

HOME

IN SYRIA

RESETTLE

NATIVE LOCATION WITHIN SYRIA

IMMIGRATE TO

SPONSORING STATE

LEAVE

*Third Country: New Zealand, Netherlands, UK, Switzerland, Germany, Canada, Australia, USA

A (NEW) HOST STATE RELOCATE NEW SETTLEMENT INTERNATIONAL-UNHCR 230

B D

JAPAN

earthquake idp’s SECTIONINITIATIVES MACRO NAME 231

TURKEY

earthquake idp’s

CASE STUDY 1 A

TOKYO, JAPAN

INDIA

earthquake idp’s

PHILIPPINES

SHIGERU BAN

B C D

UNHCR

LOCAL DONATIONS

A B

PAPER ROLL STRUCTURE

VOLUNTEERS VOLUNTEER ARCHITECT’S NETWORK

MATERIALS AND LABOR

PAPER LOG HOUSE

Shigeru Ban developed the paper tube structure which is used as the basis of the Paper Log Houses. He became a UNHCR consultant, and introduced the first iteration of the Log Houses to the Vietnamese refugees who were denied access to public temporary housing provided after the earthquake in Kobe, Japan. He has since developed 3 iterations for those displaced in Turkey, India, and the Philippines.

typhoon idp’s

INTERNATIONAL-UNHCR 232

MACRO INITIATIVES

Turkey 2000

India 2001

Photos: Shigeru Ban Architects

Japan 1995

233

Philippines 2014

CASE STUDY 1

community building workshop

PAPER LOG HOUSES foundation

Designer: Shigeru Ban (SBA) Organization: VAN, UNHCR Location: Japan, Turkey, India Philippines Date: 1995, 2000, 2001, 2014

paper roll structure

Price Per Unit: $2,000 max Area: 258-560 sf Weight: varies People Per Unit: 5 Assembly Time: 6 hours- ? days

preparing roof

Materials: varies per location; paper tube roll, beer crates, sandbags, tenting material, waterproof sponge tape, wastepaper and fiberglass, cardboard, rubble, woven cane mat, coconut wood, plywood, woven bamboo, nyla palms, plastic sheets

Photos: Shigeru Ban Architects

thatched roof

Philippine Log House Exterior

Features: insulation, ventilation, easily deconstructable and recyclable, mosquito repellent (India), specific to location

Philippine Log House Interior Pin Wong

INTERNATIONAL-UNHCR 234

MACRO INITIATIVES 235

SWEDEN

CASE STUDY 2 A B C

REFUGEE HOUSING UNIT

IKEA REFUGEE HOUSING UNIT

IKEA FOUNDATION UNHCR

The Refugee Housing Unit in Sweden sought a collaboration with IKEA to produce a refugee housing unit that could be mass produced. IKEA then created a partnership with UNHCR. Together they have developed the IKEA Refugee Housing Unit. It is currently being tested in Ethiopia and Lebanon.

ETHIOPIA

somali refugees

LEBANON

syrian refugees INTERNATIONAL-UNHCR 236

Somali refugee camp in Kobe, Ethiopia Photo: J端rgen Shrader

MACRO INITIATIVES 237

CASE STUDY 2 IKEA REFUGEE HOUSING UNIT Designer: Refugee Housing Unit, IKEA Organization: UNHCR Location: Ethiopia, Lebanon Date: 2013 Price Per Unit: $7,500 (in mass production: $1,000) Area: 188 sf Weight: 220 lbs People Per Unit: 5 Assembly Time: 4+ hours Materials: steel frame, polymer foam panels (Rhulite), aluminum and polyolefin strips (external net screen), solar panel (laminated on thin plastic film) Features: door, solar panel, built-in light, USB port, 3 year lifespan

INTERNATIONAL-UNHCR 238

A AUSTIN, TEXAS

MACRO INITIATIVES 239

CASE STUDY 3 A B C D E

MICHEAL MCDANIEL

VENTURE CAPITAL FIRMS

INDIEGOGO

EXO HOUSING UNIT

REACTION INCORPORATED FROG DESIGN MARAM FOUNDATION INTERNATIONAL NGO’S AND GOVERNMENTAL ORG’S

SYRIA

syrian idp’s

SEED FUNDING

FUNDRAISING

The Exo Housing Unit is the brain child of industrial designer Michael McDaniel. After witnessing the results of Hurricane Katrina he began to develop a prototype that could quickly respond in times of emergency. From this prototype he created the companyReaction Housing. They have raised funds via Indiegogo in hopes of sending prototypes to Syria through their partnership with the Maram Foundation. INTERNATIONAL-UNHCR

240

MACRO INITIATIVES 241

CASE STUDY 3 EXO HOUSING UNIT 20 Reaction Exos 80 People housed

2 Travel Trailers 8 People housed

1 Shipping Container 6 People housed

Designer: Michael McDaniel (Reaction Housing) Organization: Maram Foundation Location: Syria Date: 2014 Price Per Unit: $4,000 - $5,000 Area: 80 sf Weight: 400 lbs People Per Unit: 4 Assembly Time: 2 minutes Materials: aircraft grade aluminum, rugged composite skin Features: bunks, electricity, heating & cooling capabilities, energy efficient doors and skylights, insulated, digital door locks, aggregable

COMMUNAL PODS

INTERCONNECTED

ROWS INTERNATIONAL-UNHCR 242

MACRO INITIATIVES 243

3.2 NATIONAL - FEMA FEMA is a Federal organization in the Department of Homeland Security that has a focus on recovery in the wake of disaster and non-disaster events. They represent a strategy for the rapid production of homes for the relocation of large groups of displaced peoples. In recent years FEMA has begun to study ways in which they might be able to aid the process of transitioning people from temporary housing to permanent housing.

NATIONAL: FEMA 244

FEMA ORGANIZATIONAL STRUCTURE BRIEF HISTORY Although existing before the late 1970’s, the mission and scope of the Federal Emergency Management Agency (FEMA) has changed greatly over the years. As a branch of the Department of Homeland Security FEMA is responsible for the preparedness of the United States and its ability to respond to a disaster on a federal level. FEMA has had the same general purpose since President Carter accepted a proposal to increase the operational power of a National Response agency signed by all 50 Governors at the time. At the height of the cold war FEMA’s primary response to the potential attack against the United States on US soil by the Russians. This is still their primary directive. However in recent years they have been increasingly focused on the management of “non-disasters” or natural events. Annually FEMA has an operational budget well into the billions of dollars. With over twelve billion dollars going into non-disaster events annually. The majority of which is dedicated to the “Disaster Relief Fund” and covers

the cost of storing, purchasing and deploying Temporary Housing Units (THUs). Annually FEMA expects to deploy around 4,400 THUs, the only year since 2000 that could be considered abnormally large for demand is 2005. The area we may be primarily interested in, as architects, when considering trying to work with FEMA is in the area of preparedness grants. There are two types of preparedness grants, annual and congressionally appropriated. Annual Grants are typically distributed to state agencies with each state guaranteed a minimum sum. Congressionally appropriated grants are one-off projects that fall outside of the annual budget for FEMA and vary in size. One example of a congressional grant is the Alternative Housing Pilot Program FEMA initiated in 2007 to aid gulf states still recovering from Katrina. The grant totaled 400 million dollars and are focused on a variety of housing methods. The four end recipients represented manufactured housing,

MACRO INITIATIVES 245

modular housing, panelized housing, and pre-fabricated site-built housing. The Alternative Housing Pilot Program represents a change in the perceived mission of FEMA. Before Katrina and the 2005 storm season FEMA had the belief that they operated on an 18 month time line after an event and that after 18 months they would no longer be needed. At the time their housing solutions reflected this belief as well. Post Katrina FEMA has come to the realization that they need to operate on a much longer, indefinite, time frame. They now have four phases of response; immediate response, 1-6 months; short term goals, 6 months - 2 years; intermediate goals, 2-5 years; and long term goals, 5+ years. This format provides new opportunities for architects to work with FEMA on their intermediate and long term goals that are aimed at more permanent housing solutions.

FEMA MONETARY DISTRIBUTION

NATIONAL: FEMA 246

FEMA REASON & REACTION

Hurricane Tracks Since 2000

Every year in the United States there are dozens of natural occurrences that displace citizens from their homes. In 2014 alone there were hundreds of tornadoes in the spring, and although there have been few hurricanes to speak of we know that eventually there will be one that damages homes and destroys lives. Since 2000 there have been 105 recorded hurricanes, and 111 nonhurricane rated tropical storms, in addition to thousands of tornadoes, fires and earthquakes. Knowing that disasters will occur FEMA distributes hundreds of millions of dollars annually in the form of grants to states for the funding of projects aimed at preparations for disasters, natural or otherwise. Notably, although the highest risk area of the country is around Oklahoma and the gulf states, New York and California receive significantly more funding in annual grants from FEMA than any other state.

Tornado tracks since 1954

Source: NOAA Hurricane Tool

Source: UX Blog MACRO INITIATIVES 247

FEMA Regional Separation

Disaster Risk By County

Regional Capital National Capital

Presidential Disaster Declarations

Source: CNN

Emergency Management Preparedness Grant Distribution

Number of Declarations 0

Millions of Dollars 0 8 16 24 32 40 48 56 64 72 80

NATIONAL: FEMA 248

FEMA SCALE OF OPERATION REQUIREMENTS IN AN EMERGENCY During an emergency FEMA has extraordinary requirements for the production of temporary housing units. In the first month after a disaster event they require the production of 200 units from a single vendor, after the fist month they require 75 units per week until the termination of the contract. On the opposite page is a representation of the required size of a facility based on the production capabilities of Epoch Homes, in order to fulfill FEMA’s order with either 24 hour operation or standard 8 hour operation. What is evident is that FEMA’s scale of operation far exceeds that of the average modular or manufactured housing manufacturer’s capabilities to produce without increasing staffing and operational hours.

MACRO INITIATIVES 249

Epoch Homes

FEMA Qualified - Standard Operation

FEMA Qualified - 24 Hour Operation

NATIONAL: FEMA 250

SCALE OF PRODUCTION FEMA HOUSING POTENTIAL During periods of peak demand FEMA receives approximately 75 units per week, or about 300 units in a month from each activated contract. To the right are images showing the approximate size of development that one months production from one contract could produce. Figure 1, is a FEMA Temporary Housing Unit (THU) deployment site from post-Katrina outside of New Orleans. Figure 2 depicts a section of Somerville triple-deckers. The area inside of the red line represents the buildable area in one month. Discounting on site work one contract could produce 300 THUs or 50 triple-deckers.

MACRO INITIATIVES 251

NATIONAL: FEMA 252

SCALE OF PRODUCTION COMPARISON OF SCALE Though FEMA and the UNHCR both operate with similar goals, they operate at vastly different scales. The image to the right is a UNHCR refugee camp in Jordan. Shown below are a FEMA Housing Development (Right) and a block of Triple Deckers in Somerville (Left).

MACRO INITIATIVES 253

FEMA HOUSING LAYOUT Actual FEMA THU Distribution

Planned FEMA THU Distribution

ACTUAL AND PLANNED To the right are drawings of how FEMA would like to place temporary housing units on site (Right), and how those units actually end up being deployed (Left). The proposed FEMA Plan is for neighborhoods of 50 units, this plan has been repeated to show the neighborhoods that could be built in one month of a FEMA contract. At approximately the same scale it becomes evident that the proposed plan would occupy less space. The plan however is less adaptable to the area and requires a large flat plane to work on. The actual distribution requires less consistent terrain and is thus more adaptable at the expense of overall area.

NATIONAL: FEMA 254

FEMA TEMPORARY HOUSING UNIT MANUFACTURED HOME In 2005 FEMA was hit with a demand for housing that it was not prepared to meet. In Mississippi alone over 50,000 families were displaced that year. Their response was to rush the production of manufactured houses and trailer homes. While solving the immediate need for housing several issues arose in the aftermath of living in those homes, such as high formaldehyde levels in trailer homes. Since that time FEMA has refined their emergency housing to only include manufactured homes. They maintain a stock of 2000 stored units for immediate deployment and have several active contracts for units from vendors.

0’

5’

10’

20’

FEMA THU: Two-Three Bedroom 924 sq.ft. 2000 unit storage Sold to Families after use

MACRO INITIATIVES 255

ALTERNATIVE HOUSING PROGRAM TRANSITION TO PERMANENCE The hurricane season in 2005 was the most damaging season in US history. Hurricane Katrina alone caused more than $100 billion in damages. Nine of the ten most damaging single storm events have occurred since 2004; Hurricane Andrew in 1992 is third. In light of that in 2007 FEMA initiated a 400 million dollar congressionally approved pilot program to examine alternative methods of housing that offer more permanent solutions for citizens displaced by disasters. Out of all applicants five proposals by four states were accepted. Three of those used either modular or manufactured housing, including both programs proposed by Mississippi and the program proposed by Alabama. Mississippi received the largest of the grants with 281 million dollars and Alabama received the least with just 15.7 million dollars.

Mississippi Emergency Management Agency Louisiana Recovery Authority

Texas Dept. of Housing and Community Affairs

Mississippi Home

Bayou La Batre

Mississippi Cotage

Luisiana Alternative NATIONAL: FEMA

256

ALTERNATIVE HOUSING PROGRAM STATE OF MISSISSIPPI As part of the alternative housing pilot program in 2007 the state of Mississippi received $281 million in grants from FEMA to deploy housing for affected residents. The development of housing types was not necessary as Mississippi had already developed prototype models. Their proposal was for the deployment of modified, pleasant, manufactured homes designed to house small families. They had two basic models, the Mississippi Home and the Mississippi Cottage. The new designs were both HUD certified, built to the standards of the 2003 International Residential Code and designed to withstand winds of up to 150 miles per hour. These were used to give permanent housing to families across the state that had been without a “permanent” home since 2005.

Mississippi Home

0’

5’

10’

Mississippi Cottage

20’

0’

Mississippi Homes: Two-Three Bedroom 617sq.ft. and 840sq.ft. Approx. $26,000 (Varies on income level)

MACRO INITIATIVES 257

5’

10’

20’

Mississippi Cottage: One Bedroom 396sq.ft. Approx. $17,000 (Varies on income level)

BAYOU LA BATRE Bayou La Batre is a small town in Alabama that was severely damaged in the 2005 storms. When FEMA published the grant availabilities the town put a proposal to use a modular housing manufacturer from Florida to create new, permanent housing for residents that met local building code and could withstand winds of 150 miles per hour. After receiving 15% less than requested, at approximately 15.6 million dollars, the project was reduced to 100 units with ten of them being prototype “Re-deployable” houses. The prototype houses were not attached to the foundation in a traditional method so they could be removed and transported to a new site if needed. The economic collapse in 2008 prevented the city from expanding the project leaving some still in FEMA Trailers. 0’

5’

10’

20’

Alabama Alternative: One-Three Bedroom One-Two Modules $200-$400 per Month (Varies on income level)

NATIONAL: FEMA 258

FEMA OPERATIONAL TIME LINE PRE AND POST KATRINA Preparedness

Short Term Goals: Pre-Katrina: 60 Days or Less Post Katrina: 6 Months or Less

Intermediate Goals: Pre-Katrina: 0-18 Months Post Katrina: 0-3 Years

FEMA has four classifications for disaster funding goals, preparedness, short term, intermediate, and long term. In 2005, after the events of Katrina, they began to realize that those time frames were inadequate and needed to be redefined. Short term goals were extended from 60 days to 6 months. The most notable change however is their realization that their intermediate goals, MACRO INITIATIVES

Five Years Post Event

Four Years Post Event

Three Years Post Event

Two Years Post Event

Pre-Katrina Post-Katrina

One Year Post Event

Disaster Event

Long Term Goals: Pre-Katrina: 3 Months-3 Years Post Katrina: 6 Months-5 Years or more

which included all temporary housing before Katrina, could not be completed in just 18 months. The new time frame for intermediate goals was up to 5 years, making them 2 years longer than the old long term goals, the new long term goals are classified as projects expected to last longer than 5 years.

259

PERSONAL HOUSING PATH TIME LINE State Shelter

Rented Shelter

Disaster Event

Large Shelter

FEMA Housing

Personal Housing In the case of a disaster event there are several paths that a person might take in terms of both their temporary and permanent housing. In the immediate aftermath of the event persons must evaluate their housing situation, if possible and safe you may stay in your own housing. If it is unsafe to do so you are sheltered in one of three places; large shelters such as stadiums, rented shelter such as hotels or apartments, or state shelter such as high schools and public meeting places. You remain sheltered until

there is available space in a temporary housing development, priority is typically given to those in larger shelters first as the conditions in such places deteriorate the fastest. Rented shelter is transitioned second due to the cost followed by those in state shelter. Once in temporary housing you begin the process of transitioning back to private housing either by repairing or rebuilding a personal home. In some cases, though not ideal, people may opt to purchase, and remain in the FEMA trailer they were placed in permanently. NATIONAL: FEMA 260

BOSTON NATURAL DISASTER RISK SEA-LEVEL AND HURRICANE The importance of planning is now more important than ever as it may soon Boston Hurricane Evacuation Risk Zones become imperative to have the ability to relocate large populations rapidly. There are two major risks to the city of Boston, hurricanes, and sea-level rise and flooding. The image right, courtesy of MEMA, shows the evacuation risk zones of the city of Boston. Though very little is at high risk of needing evacuation almost the entire city is at some increased level of risk and recent storms such as Sandy, or further back Andrew, have shown us that we are not out of the path of hurricanes. The image on the opposite, from Forbes, shows the flood map of Boston. It was created as an evaluation of sea level rise. What can be seen from the map is that with just a few feet of water much of the city could be flooded.

Zone 1

MACRO INITIATIVES 261

Zone 2

Zone 3

Source: Massachusetts Emergency Management Agency

Boston Sea-Level Rise Flood Map

NATIONAL: FEMA 262

263

4.0

MICRO INITIATIVES

264

265

4.1 MASSACHUSETTS INITIATIVES This section examines the current initiatives to be implemented in Massachusetts and in Boston: the Compact Neighborhoods Plan, and Boston Housing 2030. These initiatives provide the framework for the development of affordable housing, and the context for the topic of our studio. How can modular housing respond to these long-term plans of Boston and Massachusetts?

266

2030 Affordable Housing Boston & MA

267

SYNOPSIS

ì Among other measures, the group is exploring ways to lower construction costs with pre-fabricated modular homes...î 1 unit = 1.100 sf ed tur ac

ma nu f

building

10,000 units

ALLSTON

micro unit (2 people per module)

6,661 units building footprint

550 sf

mo du l

550 sf

rowhouse (4 people per 3 modules)

ROXBURY

73.3 mi

les

triple decker (9 people per 3 modules)

365 days

BOSTON

DORCHESTER

EAST BOSTON

East Boston Allston/ Brighton

middle-income

low-income

mid.inc. unassisted: non-senior 11,000

mid.inc. units released via dorm redu. 5,000 mid.inc. units inclusionary/assisted 4,000 mid.inc. units unassisted senior 2,500

city assisted low-income: non-senior 6,500 city assisted low-income: senior 1,500

22,500

Bosto n H o

Dorchester

8,000

10% low income

Roxbury

0 203 ing us

22,500

Compact Ne ig

NATICK NORWOOD SHARON EASTON LAKEVILLE DARTHMOUTH

oods orh hb

market-rate

locations of off-campus undergrad students

market-rate/unas. seniors/non seniors 18,500 market-rate for market stability 4,000

On-Campus Off-Campus

37,543 3,414

PITTSFIELD NORTHAMPTON HOLYOKE WESTFIELD

NORTH ANDOVER NORTH READING READING LYNNFIELD BELMONT CHELSEA BOSTON BROCKTON KINGSTON PLYMOUTH

36,538 33,226 3,132

AMESBURY HAVERHILL LAWRENCE

LOWELL LUNENBURG FITCHBURG

Boston

40,957

136,781 95,824

76.4% 52.0%

67.6% NY

78.2%

87.3% PA 66.7% IL

CA 86.8%

1950

1960

1970

1980

1990

2008 recession

2009

2011

2010

2012

2013

2014

2015

2016

2017

2018

2019

2020

2030

Metro-studio units-450sf min Metro 1 units-625sf min Metro 2 units-850sf min

AHNL>AHE=L 197,300 192,400 186,900 182,700 172,500 170,300 166,600 155,500 153,400 146,900 143,500 139,700 138,600 125,600

900,000

33,000 31,100

*.&*2

+)&+- +.&+2 ,)&,- ,.&,2 -)&-- -.&-2 .)&.-

Households in 2010

:@>

Households in 2020

801,444 800,000

730,000 700,000

645,000

630,000 600,000

500,000

62.2%

8000

5 or more unit

7000 6000 5000 4000

34%

single-family

3.9%

2-4 unit

3000 2000 1000

2008

2009

2010

2011

2012

2013

268

“Access to housing for middle and moderate income families is an important component in the Commonwealth’s continued growth to retain and build our young and innovative workforce.” Governor Deval Patrick 2013 MA Smart Growth Conference

“Only 63.6% of the 2008 graduating class were still living in New England one year after graduation-the lowest rentention rate in the nation. Recent graduates are leaving New England primarily for job-related reasons-not housing costs.” A.S.Modestino

However, governor Patrick and Walsh support part of the production of affordable housing to be targeted towards young professionals the ages 20-34, in an effort to keep them in Massachusetts after college graduation.

Sources: New England Public Policy Center at the Federal Reserve Bank of Boston(2013) and Boston Globe, A.S.Modestino (2013) MICRO INITIATIVES 269

STATE RETENTION RATE FOR COLLEGE GRADUATES 76.4% 52.0%

67.6% NY

78.2%

87.3% PA 66.7% IL

CA NC

86.8%

% .4

% .2

% 7.3

66.

Source: Federal Reserve Bank of Boston MASSACHUSETTS INITIATIVES 270

HOUSEHOLDS INCREASE BY 2020 HOUSEHOLDS 197,300 192,400 186,900 182,700 172,500 170,300 166,600 155,500 153,400 146,900 143,500 139,700 138,600 125,600

33,000 31,100

15-19

20-24 25-29 30-34 35-39 40-44 45-49 50-54

Households in 2010

Households in 2020

MICRO INITIATIVES 271

AGE

Demographic Increase by 2020

Population Shift by 2020

“We are about to see a very dramatic shift in the overall demand for housing and the type of housing people will want. The housing demand over the next 8 years will be led by younger families with significant debt, and older people looking to downsize.”

• the region will attract and retain more people,especially young adults

Boston Globe, Barry Bluestone, 2012

young professionals / young couple

73,000

young professionals / young couple

single family

636,000 2014

709,000 2020 young professionals / young couple

single family

seniors / eldery couple

single family

• younger householders (born after 1980) will be more inclined toward urban living than were their predecessors, and less likely to seek outseniors / eldery single family homes couple

• an increasing share of seniorheaded households will choose to downsize from single family homes to apartments or condominiums

MASSACHUSETTS INITIATIVES 272

COMPACT NEIGHBORHOODS PLAN Mission:

Densification: A. Compact Housing Models

Encourage and create housing near workplaces, public transportation, and city and town centers Agendas: *The production of housing (apartments and condominiums) to be created near workplaces, public transportation and urban centers in accordance with other state initiatives like “smart growth” *The demand and type of housing is oriented towards middle and moderateincome families as Boston area is expected to expand by 120,000 households bewteen 2010 and 2020 *The creation of affordable and marketrate housing gears towards a more flexible condition for the public to rent or buy

1. Compact single family Detached 7-21 units/acre 2. Single family with secondary unit 17-24 units/acre 3. Multiple units, single family appearance 8-22 units/acre 4. Rowhouses 10-40 units/acre 5. Multi-family walkup flats and apartments 16-51 units/acre 6. Multifamily elevator apartments 21-236 units/acre

B. Compact Housing References Compact development (Chapter 40R)

*Along with the initiatives of Chapter 40R, it is stated to build more densely to promote a compact development that will meet the needs of an expected increase in population and employment

88 units / acre for single family homes units / acre for single family homes MICRO INITIATIVES 273

CHAPTER 40R: ACTIVITY MAP, MA

The towns that want to participate in the Compact Neighborhoods Plan. Source: Dept. of Housing and Community Development

AMESBURY HAVERHILL LAWRENCE

LOWELL LUNENBURG FITCHBURG

NORTH ANDOVER NORTH READING READING LYNNFIELD BELMONT CHELSEA BOSTON BROCKTON KINGSTON PLYMOUTH

Compact development (Chapter 40R)

PITTSFIELD NORTHAMPTON HOLYOKE WESTFIELD 8 units / acre for single family homes

ent

NATICK NORWOOD SHARON EASTON LAKEVILLE DARTMOUTH 8 units / acre for single family homes

12 units / acre for two and three family buildings

20 units / acre for multi-family dwellings 20 units / acre for multi-family dwellings

12 units / acre for two and three family buildings 12 units / acre for two and three family buildings

MASSACHUSETTS INITIATIVES 0-200

200-400

274

600-800

800-1,000

CHAPTER 40R: ACTIVITY MAP, MA

The towns and the desired number of units, modular industry, and main roads.

0-200

400-600

MICRO INITIATIVES 275

1,031

600-800

1,092

1,096

Brockton

730

Chicopee

678

Lawrence

675

Kingston

594

Fitchburg

North Reading Reading

578

Plymouth

Dartmouth

200-400

530

Bridgewater

434 458 482 526

Boston

319

Haverhill

296

North Andover

280

Easthampton

250

Holyoke & Pittsfield

249

Easton

244

Lowell

204 207 240

Amesbury

Natick

180

Grafton

Chelsea

167

Westfield

Marblehead

156

Lunenburg Lakeville

138

Lynnfield

125

Sharon

Northampton

15 18

Norwood Belmont

Modular Vendor

800-1,000

ZONED UNITS, POPULATION AND AGE

106,519

This chart indicates the population and median age of each town in Massachusetts, and are categorized in accordance with the range of the amount of the units that they desire to be developed, under the stateâ&#x20AC;&#x2122;s initiative; the Compact Neighborhoods plan.

60 ,8 7 9

61 7 ,5

34,032 N.Rea

Darthm ou

3 9 .6

ding 14,89 2 Rea d ing 43 Eas 24,7 tha 38 47 .5 mp H ton av 30 er 16, .8 hil 053 Bo l sto n

33,

45.7 Marb lehea d 31.8 Che lsea 41 Na tick 41.5

Belmont

Norwood

41.1

age

Pittsfield

Easton 39.5

owell 32.6 L

.7 43

38.3

fton Gra

field West

6 17,7

10 .6 44

n Ly

39.2

el nfi

g ur nb e n Lu lle evi Lak

6 9 ,5 11

r t h am pt on

28 ,54

006

35,1

19,8

24,729

28,602

0-200

43 .3

ar on

17 ,61 2

cities

,4 56

er at w ge 318 id 40, Br th u mo Ply rg .4 1 bu 4 itch 29 F 12,6 7 34. n o t s K in g 42.3 ence Lawr 30.5 icopee 40.1 Ch 35.9

Brockton

76,377

00 800-10

units population

.7 36

3 ,56 26

00 0-8 60

,0 10

2 ,60

00 0-4 20

23,112

94 41,0

44,737

400-6 00

55,298

93,810

MASSACHUSETTS INITIATIVES 276

COMPLETED PROJECTS Projects completed and/or in progress, throughout MA and the region of Boston.

Housing Units Constructed in Chapter 40G Districts in MA

Highland Woods, Williamstown, is a new construction project sponsored by Berkshire Housing Inc. When completed, Highland Woods will offer 40 units of housing for seniors, all of which will be affordable. Howland Jr. House, New Bedford, is the adaptive re-use of a historic building in New Bedford. The project is sponsored by the Waterfront Historic Area League. When completed, Howland House will offer seven units of housing, five of which will be affordable. 181 Washington Street, Somerville, is a new construction project located in Union Square, Somerville and sponsored by the Somerville Community Corp. The development will also receive funding from the city of Somerville. When completed, 181 Washington will offer 35 units of affordable family housing. Tritown Landing Phase III, Lunenberg, is a new construction project sponsored by Great Bridge Properties. When completed, Tritown will offer 32 units of affordable housing for families. Shoe Shop Place, Middleborough, is the adaptive re-use of a historic mill building. The project is sponsored by The Neighborhood Corporation and Neighborhood of Affordable Housing. It will also be supported by funding from the town of Middleborough and the Greater Attleboro and Taunton HOME Consortium. When completed, Shoe Shop Place will offer 24 units of housing for families, all of which will be affordable.

Fitchburg Yarn Mill Phase III, Fitchburg,

is the adaptive re-use of an historic mill building sponsored by Winn Development. When completed, the project will offer 38 units of affordable housing for families.

MICRO INITIATIVES

277

75 Amory Ave., Boston in the Jamaica Plain neighborhood and sponsored by Jamaica Plain Neighborhood Development Corp. When completed, the project will offer 39 affordable units for families.

Chapin School Veterans Housing, Chicopee, is the adaptive re-use of an historic school building. The project is jointly sponsored by Soldier On Inc. and the OíConnell Development Group and supported by funding from the city of Chicopee. When completed, Chapin School will offer 43 affordable units of housing for veterans.

RTH Riverway, Boston, is a new construction project located in the Longwood Medical Area and sponsored by Roxbury Tenants of Harvard. When completed, the project will include 60 affordable units for families.

Village at Lincoln Park, Dartmouth, is a new construction housing project to be built on the site of a former amusement park. It is the first of several phases to be built on the site which received a Chapter 40R designation. Other planned phases include an elderly rental project, as well as single family homes. The town has contributed $100,000 to this phase of the project. This phase will consist of 36 family units.

Whittier-Lyndhurst-Washington, Boston, is a part preservation, part historic re-use and part new construction project located in the Dorchester neighborhood and sponsored by Codman Square Neighborhood Development Corporation. When completed, Whittier-Lyndhurst-Washington will offer 44 affordable units for families. Port Landing, Cambridge, is a new construction project located in Kendall Square sponsored by Capstone Communities and Hope Real Estate. When completed, the project will include 20 affordable units for families.

Island Creek Village North Age, Duxbury, is a new construction project sponsored by Beacon Communities. When completed, the project will offer 94 units of affordable housing for residents aged 55 and older. Christopher Heights, Northampton, is a new construction project sponsored by The Grantham Group. When completed, the project will offer 83 units of Assisted Living housing for seniors, 43 of which will be affordable. Leeds Transitional Housing, Northampton, is a new construction project sponsored by Soldier On. When completed, the project will include 16 units for women veterans and their children.

Kendrigan Place, Quincy,

Dalton Apartments, Pittsfield, is a preservation project and sponsored by the Berkshire Housing Development Corporation and Rees-Larkin Development. When completed, Dalton will offer 100 affordable units for families.

189 Broadway, Revere,

Stable Path Rental Housing, Provincetown, is a new construction project sponsored by the Community Housing Resource. When completed, Stable Path will offer 23 units of housing for families.

Kenwyn Quadrangle, Springfield, is the preservation of two historic buildings that house low- and moderate-income families. Kenwyn Apartments completed its 15-year Low Income Housing Tax Credit compliance period in 2010; Quadrangle Court completed its 15-year LIHTC compliance period in 2013. The buildings need recapitalization and additional historic, life and safety improvements. Together they comprise 60 units of housing.

is a preservation project located in Quincy and sponsored by NeighborWorks of Southern Massachusetts. When completed, 78 units of affordable housing will be preserved.

is a new construction project for seniors sponsored by The Neighborhood Developers. When completed, 189 Broadway will offer 39 units of affordable housing for adults aged 55 and older.

Leyden Woods Apartments, Phase I, Greenfield, is a new construction and preservation project sponsored by The Community Builders. When completed, the project will offer 113 units of affordable housing for families.

Outing Park II, Springfield, Outing Park Historic District and is sponsored by the First Resource Development Co. When completed, the project will offer 118 affordable units for families, with 12 units reserved for families earning less than 30 percent of area median income.

Tenney Place Apartments Phase I, Haverhill, is a new construction project sponsored by Dakota Partners. When completed, the project will offer 72 affordable units.

278

MASSACHUSETTS INITIATIVES

COMPACT NEIGHBORHOODS PLAN COMPLEMENTARY INITIATIVES

Chapter 40R/40S

These statutes provide a financial incentive to implement "smart growth zoning districts." These districts promote higher density housing and mixed-use development in appropriate places - city and towns centers, transit stops, and other highly suitable locations. Staff from the Department of Housing and Community Development as well as other Development Cabinet agencies will aid communities in understanding and adopting smart growth districts pursuant to Chapter 40R.

Smart growth is a principle of land development that emphasizes the mixing of land uses, increases the availability of a range of housing types in neighborhoods, takes advantage of compact design, fosters distinctive and attractive communities, preserves open space, farmland, natural beauty and critical environmental areas, strengthens existing communities, provides a variety of transportation choices, makes development decisions predictable, fair and cost effective, and encourages community and stakeholder collaboration in development decisions.

The Massachusetts Smart Growth Alliance (MSGA) promotes healthy and diverse communities, protects critical environmental resources and working landscapes, advocates for housing and transportation choices, and supports equitable community development and urban reinvestment. MICRO INITIATIVES 279

PARTIES INVOLVED IN THE COMPACT NEIGHBORHOODS PLAN

BRA

Chapter 40R

plan formation

data/reports

programs / tools

partners

state agents MASSACHUSETTS INITIATIVES

280

BOSTON HOUSING 2030 Desired urban settings, building types, and densification tactics for Boston Housing 2030.

AFFORDABLE HOUSING On October 9, 2014, Mayor Martin J. Walsh released “Housing a Changing City: Boston 2030,” the administration’s housing plan. By the year 2030, Boston’s population will reach more than 700,000 residents, a number the city has not seen since the 1950’s. Boston 2030 is the city’s strategy to responsibly plan for that growth by creating housing across demographics and neighborhoods.To accomplish this goal, the city is going to help create 53,000 new units of housing at a variety of income levels: -44,000 units of housing for the work force -5,000 units of housing for the senior citizens -4,000 units to stabilize the market and bring prices under control

MICRO INITIATIVES 281

PROPOSED SITES FOR BOSTON HOUSING 2030 DORCHESTER, ROXBURY, EAST BOSTON, ALLSTON/BRIGHTON:

Neighborhoods for growth, where there is sufficient public transit and availiable building sites.

M edian H ousehold Incom e

ity Survey 5-Year Estimates

(in the past 12 months, in 2009 inflation-adjusted dollars)

ncom e

sted dollars)

East Boston Allston/ Brighton

Roxbury

BOSTO

2 Miles Dorchester

BOSTON

Median Household Income

Median Household Income by census tract

$87,400$143,819

$66,250$87,464

Median Household Income

$52,433$66,250

$10,250$24,717

$24,717$37,274

$37,274$52,433

$87,464.01 - $143,819.00 $66,250.01 - $87,464.00

MASSACHUSETTS INITIATIVES 282

DESIRED HOUSING UNITS 44,000

workforce

16,000

dorm beds

5,000

seniors market-rate units to support market-stabilizing vacancy rate

4,000

2013

2030

MICRO INITIATIVES 283

DIVISION OF UNITS PER INCOME 8,000

low-income city assisted low-income: non-senior 6,500 city assisted low-income: senior 1,500 22,500

middle-income

mid.inc. unassisted: non-senior 11,000

53,000

mid.inc. units released via dorm redu. 5,000 mid.inc. units inclusionary/assisted 4,000 mid.inc. units unassisted senior 2,500

22,500

market-rate

market-rate/unas. seniors/non seniors 18,500 market-rate for market stability 4,000

MASSACHUSETTS INITIATIVES 284

PROJECTION OF BOSTON HOUSING INITIATIVE Map of existing urban conditions, typical building type, and density projection desired by the Boston Housing 2030 initiative, per neighborhood.

DORCHESTER ALLSTON

ROXBURY

building

250 FT

Characteristic building type of Roxbury: brownstones/Victorian row houses Characteristic building type of East Boston: 3 or more story houses

Characteristic building type of Allston: small apartment buildings Characteristic building type of Dorchester: large apartment complexes

MICRO INITIATIVES 285

rtment complexes

EAST BOSTON

building

250 FT

ALLSTON

250 FT

Characteristic building type of Allston: small apartment buildings

Characteristic building type of East Boston: 3 or more story houses

Characteristic build

MASSACHUSETTS INITIATIVES 286

BOSTON, MODULAR HOMES, AND EPOCH

ALLSTON

MICRO INITIATIVES 287

Epoch Homes

73.7 miles 1 hour 18 mins

MASSACHUSETTS INITIATIVES 288

“...higher demand for condos and lower demand for single-family homes.” Boston Globe Barry Bluestone 11/16/2014

MICRO INITIATIVES 289

HOUSING PERMITS BY STRUCTURE TYPES

Modular Housing Delivery Systems is capable of meeting the increasing demand for multi-family (5 or more units) housing.

MASSACHUSETTS INITIATIVES 290

BOSTON HOUSING 2030 STUDENT HOUSING Goals for the production of undergraduate and graduate housing: *Create 16,000 new undergraduate dorm beds to accommodate growth while reducing the number of undergraduates living off campus in Boston by 50 percent *Create dedicated housing for 2,500 graduate students to mitigate the impact of graduate students on the housing market *Improve living conditions for off campus students through vigorous enforcement of housing codes and improved communication with students and families

student villages *Work with the community to establish approved locations for both on and off campus student housing facilities *Work collaboratively with Greater Boston area college leaders and mayors to address student housing issues in the region *Utilize the updated University Accountability Ordinance to obtain more complete information from institutions of higher education.

Actions: *Partner with colleges and universities to set specific student housing commitments, creating clear plans and timetables for every institution to achieve its housing goals *Explore public-private partnerships to create off campus dorms and MICRO INITIATIVES 291

LOCATIONS OF DORMS AND OFF CAMPUS UNDERGRADUATES While students are spread throughout Boston, the majority of off campus undergraduates are clustered in three neighborhoods: Allston/Brighton, Fenway/ Kenmore, and Jamaica Plain/Mission Hill.

locations of off-campus undergraduate students 2,000 beds (dorms) 1,000 beds (dorms) 200 beds (dorms)

MASSACHUSETTS INITIATIVES 292

3,132

36,538 33,226

40,957

136,781

15,684

Boston 36,284 20,600

37,543 3,414 49,792 46,032

Off-Campus

95,824

On-Campus

40,957

ON-CAMPUS AND OFF-CAMPUS STUDENTS IN MA AND BOSTON

95,824

STUDENT PERCENTAGES LIVING OFF AND ON CAMPUS total in MA

total in Boston

undergrad

graduates

MICRO INITIATIVES 293

OFF-CAMPUS STUDENTS BY COLLEGE/UNIVERSITY

MASSACHUSETTS INITIATIVES 294

What is the role of pre-fab in the state’s and the city’s initiatives?

MICRO INITIATIVES 295

“Among other measures, the group is exploring ways to lower construction costs with pre-fabricated modular homes and apartments, or using timber instead of more expensive materials such as concrete and steel.” Mayor Martin J. Walsh First major real estate development initiative Boston Globe, May 2014

“Time: Pre-fab modular fast construction will contribute to expedite Boston’s plans for affordable housing and meet the announced demands” Barry Bluestone, Dukakis Center Interview, 2014

MASSACHUSETTS INITIATIVES 296

11/16/2014

MICRO INITIATIVES 297

“Real estate industry officials support a key factor in the low inventories of homes for sale/rent is the notoriously slow rate of new housing construction in MA, often blamed on overly restrictive local zoning laws.” Boston Globe, The Warren Group (Real Estate and Financial Information) 11/16/2014

“Even though we all know we need more housing in this state, we aren’t building enough housing.” Boston Globe, Brad Campbell Executive Director of Homebuilders Association of MA 11/16/2014

MASSACHUSETTS INITIATIVES 298

BARRY BLUESTONE: INTERVIEW Barry Bluestone Interview The role of pre-fab in the initiatives?

Demographics Increase -increase of population in Boston (By 2030, the population of Boston will increase by 15%, to 709,000 people)

TIME (Barry Bluestone)

Housing Typology * micro units ex. 380ft the smallest

small bedrooms, but larger common spaces like kitchen, living room bathrooms, balconies * ì Millennialî Villages (residential complexes) mixed-used housing (inclusion of retail) 5-6 storey buildings: that incorporates other programs: ex. daycare, gym,incubator spaces for start ups, convenience store, laundry stores, etc.

Demographics Shift -young professionals stay in Boston

(Boston now is expanding as a tech hub)

-eldery couples move in the city

Densification (high-density housing) transit accessible

It's the kind of housing that will make a big difference for grad students to medical interns to line chefs; pretty much any young professional who might be strapped on cash and time.

*Apartment style

kitchen and bathroom not common

Dorms for student housing

Densification tactic as:

construction of 16,000 units of student on-campus housing

Suggestions: -building manufacturing factory close to Boston that could undertake this plan, the production of 10,000 per year until 2020 -housing units to assemble/disassemble in lieu of the Olympics 2024 -portion of dorm development to not be dependent on the institution -universities and hospitals be part of the ì Millennialî Villages

Types of Densification (ex. city center, university campus,etc.)

apartments complexes accessory apartments triple deckers duplexes large family houses

ì the quicker we create housing, the faster we stabilize the marketî (Walsh, Boston Globe)

will open up about 5,000 units to non student renters

MICRO INITIATIVES 299

BARRY BLUESTONE: SUGGESTIONS * micro units (i.e. 380ft the smallest with small bedrooms, but larger common spaces) *ì Millennialî Villages (residential complexes) 5-6 stioty mixed-used housing buildings with the inclusion of retail and other programs (i.e. daycare, gym, incubator spaces for start ups, convenience store, laundry stores, etc.)

* building a factory close to Boston that could undertake this plan, the production of 10,000 units per year until 2020 and the production of 53,000 units until 2030 89

95 93

Epoch Homes

*housing units to assemble/disassemble in lieu of the Olympics 2024

2024 Olympic Village: temporary housing for the athletes in Japan for 2020

MASSACHUSETTS INITIATIVES 300

DEMAND OF HOUSING UNITS AND SUPPLY BY EPOCH HOMES

units

10,000 9,000 8,000

7,000 6,000 5,000 4,000 3,000 2,000 1,000

1 YEAR

MICRO INITIATIVES 301

UNIT DEFINITION BY EPOCH MODULES

1 unit = 1.100 sf

2 modules (boxes)

550 sf

4 people

MASSACHUSETTS INITIATIVES 302

303

4.2 TACTICS + IMPLEMENTATION The modular industry has historically addressed the single-family home as its primary market. Recently, architects have begun to investigate the limits of the scale of modular housing, from single ultra-small accessory units to the modular highrise. While the most extreme examples of this investigation have not yet been proven feasible, there exists a mid-range scale of development that is optimal both for the modular industry and the densification efforts of Massachusetts.

304

POPULATION DENSITY Somerville Boston

14482

Cambridge

14236

Providence

8620

Hartford Portland

Somerville

18681 persons/mi 2

6828 3493

Somerville is the most population dense city in New England. The fact that it surpasses its more urban neighbors is initially surprising. The city lacks entirely the residential high-rise, and more closely resembles a typical suburb than a city. However, Boston and Cambridge also include this type of residential fabric, although that is not their primary association. It is the way that the regularized parcel of the suburb is occupied that affects Somervilleâ&#x20AC;&#x2122;s population so drastically. While Boston and Cambridge exceed Somerville in their densest areas, they quickly drop to a more sparse population outside the city center. Somerville, by contrast, is occupied very homogeneously in density, and almost exclusively by one building type: the triple decker.

Boston

Cambridge

MICRO INITIATIVES

Density maps: Bostonography.com 305

TACTICS + IMPLEMENTATION 306

DENSIFICATION WITHIN THE PARCEL WATERTOWN: THE SINGLE-FAMILY HOME The triple decker is an icon of New England housing, dating back to the late 19th century. It is a highly systematized building type, using balloon-frame construction to rapidly increase the housing supply. Today the type is just as much of an asset in the increasingly competitive housing market of the greater Boston area. The details of occupancy have changed in the densest areas of the city. The initial concept of the triple decker was that it be owner-occupied on one floor and rented to two other families. Today, triple deckers are rarely owner-occupied and increasingly being rented to groups of students and young professionals rather than families. Yet, the basic idea of the structure remains the same: to take the same plot of land that might be occupied by one family, and to fit as many people onto it as possible. This strategy allows population density that is not limited to city centers or apartment complexes, but dispersed throughout.

Units / Building Units / Block

MICRO INITIATIVES 307

SOMERVILLE: THE TRIPLE DECKER

Units / Building Units / Block

TACTICS + IMPLEMENTATION 308

THE MODULAR TRIPLE DECKER 81 BRENT STREET, DORCHESTER

Dorchester

Westchester Homes

Triple Decker 6 modules - 3,300 SF

The triple decker is a type to which modular construction adapts quite easily. The typical dimensions - roughly 25 to 35 feet in width and 50 to 60 feet in depth - translate well to the dimensions used by most wood frame modular builders - generally 14-16 feet by up to 60 feet, as defined by the limitations in the delivery process as well as the construction process. A full triple decker comprises six standard size boxes. Certain variations from the box, such as bay windows or dormers fit within the typical modifications made in the factory, while others, such as porches, are added on site. MICRO INITIATIVES 309

In 2011, Bostonâ&#x20AC;&#x2122;s first modular triple decker was built in Dorchester. The boxes were shipped from Westchester Homesâ&#x20AC;&#x2122; manufacturing facility in New York, over 180 miles away. The house was built to LEED Platinum standards for a total cost of $450,000, after accounting for environmental credits and incentives. The modular triple decker is a type that could become increasingly common in the replacement cycle of aging homes. In turn, this scenario moves Boston a step closer to achieving a market demand for modular construction consistent enough to justify its expansion in the area.

THE SITE

Delivery Route: Trucks arrive by Brent Street

1 Building site 2 Siting area: street

Crane Positioning: Street closed to traffic

Photos: 81Brent, flickr.com

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AGING HOUSING IN MASSACHUSETTS In mapping the oldest housing in Massachusetts, areas of especially old buildings happen to correlate strongly with the most population dense areas. In New England, this type of density generally suggests a prevalence of triple deckers or similar multifamily houses, and this holds true in those cities most greatly affected by their aging housing. There is a large percentage of triple deckers in Massachusetts that are reaching the end of their shelf-life. This replacement provides a potentially large and reliable market for the modular industry to expand into.

LAWRENCE

SOMERVILLE WORCESTER

HOUSING BUILT BEFORE 1940 100%

90%

80%

70%

60%

50%

MICRO INITIATIVES

40%

30%

20%

10%

0% Data: city-data.com

311

Somerville

Lawrence

Worcester

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SUBURBAN INFILL TACTICS OF DENSIFICATION

REPLACEMENT TRIPLE DECKER

ROWHOUSE

ROTATED ROWHOUSE

COURTYARD HOUSE

Typical New England

City of Toronto Recommendation

b9 architects Seattle

Lawrence Dodd Toronto ALLEY

STREET

Existing Units New Units

MICRO INITIATIVES 313

STREET

Although the triple decker is unique in the extent to which it dominates the New England urban fabric, it is only one building type that is representative of a more general strategy. The idea of densifying within the parcel, as opposed to the apartment block or high-rise, is a strategy with an unlimited number of solutions. These particular methods of densification can be sorted into two categories: those which substitute for or replace the single-family home, such as the triple decker, and those which supplement the existing single-family home.

ADDITION ACCESSORY UNIT

LANEWAY HOUSE

MEWS HOUSE

INFILL INFRONT

Stephanie Dyer Portland

Lanefab Vancouver

Typical London

Adams Massoud Unbuilt

STREET

ALLEY

STREET

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PREFAB TECHNIQUES IN THE ACCESSSORY UNIT IN-FACTORY

PRODUCT

SIPs are manufactured in factory

Structurally Insulated Panel

Pods are built in place within the factory

Fully Finished Pod

LANEFAB LaneFab is a Vancouver firm that specializes in the laneway house. In response to the problem of building while the main home is still occupied, the firm has chosen Structurally Insulated Panels (SIPs) as a way to minimize the time required for construction while minimizing the complications of a full-sized crane assembly on the site.

GREENPODS Greenpods, a Seattle firm, takes a different approach to the accessory unit. Due to the small size of the unit, Greenpods manufactures mostly singlepod homes, which allows full interior and exterior finishing inside the factory, without the complication of components matching up between boxes. The single box also minimizes on-site construction time to the absolute minimum: the only finishing done on site is at the connection between the pod and its foundation. MICRO INITIATIVES

Photos: greenpoddevelopment.com, lanefab.com 315

ON-SITE

Individual panels arrive on site by truck

Panels are assembled using a small crane

Construction time is reduced, but all finishing occurs on site

Single-module home arrives on site fully finished

Units are positioned using a full size crane

Site work is reduced to the absolute minimum: connection between pod and foundation TACTICS + IMPLEMENTATION

316

THE VISIBLE ADU INFILL INFRONT / ADAMS MASOUD Drew Adams and Fadi Masoud challenge the popular understanding of the accessory unit in their unbuilt proposal, Infill Infront. While the accessory unit is typically viewed as a method of increasing density with the minimum impact to the existing home, both in terms of physical construction and in terms of experience of the community, particularly from the street, Adams Masoud inverts that goal by radically redesigning the streetscape of the typical American suburb through the accessory unit. The project retains the goal of increasing density without demolition, but instead of maintaining the suburban street condition, replaces it with a potentially more active streetscape.

Typical ADU: Back yard Preserves streetfront

Infill Infront: Front yard Redefines streetfront Selection of key streets for redesign

MICRO INITIATIVES 317

EXISTING

PROPOSED TACTICS + IMPLEMENTATION

Photos: adams-masoud.com 318

TRANSPORTATION + DENSITY MBTA COMMUTER RAIL + POPULATION DENSITY in

-m

tra

LINCOLN WESTON

CANTON

MICRO INITIATIVES

Density map: Bostonography.com 319

UNDER-UTILIZED INFRASTRUCTURE Many of the state and city initiatives toward increased density place a high priority on access to transportation, particularly public transit and methods not reliant on the car. This comes from an environmental motive, as well as a practical consideration for the needs of the residents the program aims to house - those in the affordable housing category who may not have access to a car.

Lincoln

Massachusetts has a strong public transit system, relative to that of the country. Many towns have taken specific advantage of their access to the commuter rail, building denser housing types in closest proximity to the station. However, pockets of low density surround certain stops. This under-utilized infrastructure leaves a gap in which a densification effort might most effectively build.

Weston

Canton

TACTICS + IMPLEMENTATION 320

SCALES OF URBAN MODULAR ASSEMBLY As important as it is to consider densification within the defined parcel system of a city, the apartment block and highrise do offer significant increases in areas where they are feasible. The combination of these building types with modular construction has recently become a topic of interest to architects as well as developers and policy-makers. The scale of applications of modular has seen a gradual increase from many mid-rise projects not substantially structurally different from the scale of a triple decker to a few tentative steps toward a modular high-rise. The most ambitious of these projects by far is the B2 Tower of Atlantic Yards, designed by SHOP architects at an unprecedented 32 stories. Currently the construction on the tower has been halted, and the eventual outcome is not yet clear. No other project of a similar scale has successfully been built. As of now, the modular highrise is still deeply in testing, but the modular midrise is developing a growing collection of successful projects.

BUILT

7 STORIES

3 STORIES

NEHEMIAH SPRING Alexander Gorlin Brooklyn

5 STORIES

4 STORIES

SMARTSPACE ZETA DesignBuild San Francisco

THE RIDGE Onion Flats Philadelphia

MICRO INITIATIVES 321

THE STACK Peter Gluck Manhattan

32 STORIES

UNBUILT

10 STORIES

MY MICRO n ARCHITECTS Manhattan

B2 TOWER SHOP Manhattan

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URBAN SITE LIMITATIONS THE STACK / PETER GLUCK “There are a lot of infill sites that are very difficult to develop traditionally.”

- Peter Gluck Architects

The Stack, by Peter Gluck Architects is a 7-story apartment building in Manhattan, testing the limits of modular construction’s vertical reach. The project embraces modular as a construction method and a design aesthetic, with a facade that highlights the shift between boxes. One of the reasons stated by the architects for choosing modular construction was the difficulty of conventional construction on such a tight urban site. By moving much of the construction off site, the on site process might be simplified. However, in the process of construction, it becomes clear that modular construction is as much a liability on a small sight as it is an advantage. Though the apartment sits on a small site, it uses the vacant site next door as a siting area for the crane and modules. Without access to this site, construction would likely have shut down traffic, if not being entirely impossible. In the end, particular site conditions are just another variable in which modular is not a magic bullet for all of the problems of conventional construction, but rather a single option that may end up being the best solution.

1 Siting area: vacant lot 2 Building site

MICRO INITIATIVES 323

Photos: gluckplus.com

TACTICS + IMPLEMENTATION 324

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