Tsogo Sun’s hi-MONTE hotel

When two well established construction entities, Ohlhorst and Tiber Construction, wanted to change the face of construction in South Africa, they found the concept of modular building very enticing.

Modular construction, also known as ‘prefabrication’ or ‘offsite construction’ in the moduBiLD case, is a method of constructing 3D volumetric units out of galvanised steel off-site, with full fixtures, and then putting the units together in minutes on-site.

Rui Lavarinhas of moduBiLD explains, “Modular construction is a more affordable construction method because there are areas of repeatability – you follow the pattern and make the same module in the same way multiple times. The amount of design for one module is then effectively spread across a number of units. We’ve also ensured that the modular approach is not a compromise – it’s an increase in quality for the finished product.”

In 2017, after working on modular construction ideas for years, things got exciting for the partnership. “The CEO of Tsogo Sun said he was interested in creating a modular hotel range, especially as they had a capped amount they could spend per room for the hotel to be viable,” says Lavarinhas. “We decided to partner with them to create prototypes. The completion of the hi-MONTE project was such a success that Ohlhorst and Tiber decided to create a dedicated modular business.”

In 2019, construction on the first hotel at Montecasino in Fourways, Johannesburg, commenced using this cutting-edge construction method. Rooms were constructed in a factory setting – with furniture, fittings, plumbing and electrics all included. The completed modules were then put together to create the hotel. Due to its lightweight construction, the hotel was partly built onto an existing two-storey parking structure at Montecasino.

Tsogo Sun not only achieved budget on cost, but also saved considerable time.

Lavarinhas explains, “We start constructing before the design is finished. You’re almost working on a need-to-know basis, and you keep designing as you go. Quite often you are waiting for that information, and that can be a roadblock. But in modular construction, your design is completed much higher up in the project timeline, and much more is done at the front end. It was a challenge to get the team on board for this, but we overcame that and the team understood our methodology, and in the next project we won’t have that challenge.”

Modular construction also offers some serious environmental advantages. Firstly, steel is 100% recyclable. The material used for walls, floors and ceilings is also suitable for reuse. Because of the use of these recyclable materials (much more recyclable than cement and brick), a more energyefficient construction process and very little wet works like concrete and mortar, the immediate environment is less impacted.

The minimal use of concrete delivers a lighter structure, which in turn ensures a light foundation, and logistical efficiency leads to less traffic movement and transport costs.

This concept is energy efficient and is well suited for the application of heat pumps and solar panels.

Says Lavarinhas, “For the vast majority of the building, there’s no bulk cement, bulk sand, concrete and other materials that affect the immediate environment considerably. Because the units are made in a factory, they arrive at site on a truck and can be offloaded and rigged in position in minutes. Traditionally, construction material deliveries would affect the immediate site environment to a far greater degree and for longer. In our method, the trucks can arrive out of peak time and in a matter of minutes, and the units are placed in the building, completed. You can schedule the construction to not interfere with the environment at all.

“A number of things made this project a success,” he continues. “Delivering to your client on cost and on time is always a win. In modular construction, you have greater control than you have in traditional construction because there are fewer variables involved.

In modular construction, you do the design up front so your pricing is more certain, and you’re not learning as you go along.”