Getting the Facts on Modular: The real truth on how to get started with a modular hospitality project

Words and photos courtesy of Metric Modular

Groundbreaking technology, materials, and designs have revolutionized the modular construction industry. Around the world, leading hotel brands have recognized the benefits of modular construction.

Considerations for Modular Construction

Modular construction is still a new direction for many project developers, owners, architects, and franchisees, and the major barrier to adoption is the lack of knowledge on how to undertake a modular project.

Hospitality developers often see the risks associated with undertaking a new construction method without recognizing the benefits and solutions offered.The key is obtaining early project guidance from experienced modular construction companies on the viability of modular for use in the proposed project. Many of the modular industry providers are willing to provide early unbiased feedback on the viability of a project with little or no cost to the owner.

When choosing an experienced modular provider to assist with modular feasibility, the provider should be able to walk the owner and team through the modular construction process and explain the differences between modular construction and typical site construction. The modular provider should also be able to bring in and recommend partners that are familiar with modular construction to assist the owner in early project assessment.

One of the keys to successful modular development is multidisciplinary collaboration at the earliest stage of planning. This typically occurs at the schematic design stage of design development. With a site survey, an experienced architect or modular builder can provide some early modular feasibility planning and building massing to understand whether modular is the right construction method for the proposed project.

If evaluation of modular construction is brought in too late in the design process, architectural and consultant time and money will have been squandered to properly evaluate modular. If design has gone past the point of modular decision making, it’s recommended that the project continue down its chosen construction method path.

The decision can be made at the Schematic Design stage. Armed with a modular feasibility study and rough order of magnitude (ROM) on construction costs, the owner will be able to decide whether modular is the right method for their project. When modular development is adopted at the onset of a project, it provides solutions to common construction industry problems such as schedule and cost overruns, and compromised quality, including:

• Design errors and scope change

• Schedule and delivery delays

• Uncoordinated contractors

At the onset of modular development planning, it’s important to involve all project partners at the table in an integrated project development model. When the owner, the architect and consultants, site contractor and modular builder are all at the table during planning, it ensures an efficient process of engagement, accountability, and decision making.

It’s important to note, at this stage all decisions related to the construction of the project are decided upfront and in advance of beginning any construction. This includes integration of any brand and design guidelines as well as requirements and responsibilities for furniture, fixtures, and equipment (FF&E).

Modular Construction Reduces Costs

One of the most clear and immediate benefits of going modular is cost certainty. A reduction in labour costs, construction time, and material waste saves at every level of a modular construction project.

• Consistent availability of labor and task repeatability increases efficiency, which can result in a cost saving of 20-30 percent.

• The lean manufacturing process ensures increased human productivity and a decrease in potential rework costs.

• Hospitality projects are among the most likely types of modular builds to deliver the greatest cost savings, since they have the highest proportion of labour-intensive activities and the greatest levels of repeatability.

• Bulk buying and early decision making can result in cost reductions of 5 – 10 percent on materials.

While traditional construction planning takes place in stages, modular construction pre-plans every detail upfront. All required building permits and materials are identified at the earliest stages, and site preparation and foundations can be completed concurrently with off-site modular construction to compress timelines.

Additionally, manufacturing can meet exact specifications of components and subassemblies, which reduces preparatory work and the need for large subcontracting crews on site to finish assembly of electrical and plumbing components.

Modular Construction Saves Time

Modular construction’s production process boosts productivity. The ability to mass-produce ensures greater expediency, accuracy, and consistency. The higher quality of prefabrication in a controlled environment lowers rework and reduces waste, cost, and time of construction.

• Offsite manufacturing facilities can cut traditional site construction timelines by up to 50 percent.

• Modules can arrive on the worksite up to 90 percent completed, advancing occupancy dates and ensuring earlier hotel opening, which leads to faster ROI.

• The standardized, automated and controlled environment can double productivity above traditional builds.

A modular construction manufacturing facility is fully staffed with fully trained employees, which reduces time delays due to labour shortages or unskilled workers. And in a controlled environment, two to three shifts can be scheduled in a workday, increasing capacity and throughput times.

The manufacturing facility has the capability to preinstall smart technologies, fire suppression and sprinkler systems, plumbing, electrical, flooring, and furnishings, reducing the quantity of onsite subcontractors and potential scheduling delays.

Modular Construction Guarantees Quality

The best way to ensure the quality of construction is to build in a clean, controlled environment with stringent quality assurance (QA) and quality control (QC) procedures. In a manufacturing facility all quality assurance processes for inspection, review, and approval take place in a welllit, controlled environment, which allows for closer and consistent inspection.

Non-conforming work or products can easily be detected, and the quality representative can quarantine and correct the work immediately. When it comes to evaluating quality control,

ask your modular manufacturing partner about the following items:

Do they have:

• A detailed photographic record and quality assurance sign-off procedure for every module as it progresses down the production line.

• Detailed inspection and test plans used to verify a scope has been completed to the necessary quality standards.

• A quality control manual and a document control process to ensure all essential documents affecting quality and construction are reviewed and approved prior to release for use.

• Access to a factory with third party oversight from an independent testing agency.

Modular construction also provides quality and flexibility in design. The scope can range from single components in a building to multiple modules for multistory structures. The ability to mass-produce a diverse range of designs in a controlled environment ensures adherence with strict brand guidelines.

Modular Construction is Sustainable

Modular construction can be constructed to comply with the highest energy codes and certifications. Passive House, LEED, and Netzero specifications are easily achieved using modular construction.

• Modular construction has the potential to reduce 90 percent of construction waste through streamlined processes, increased accuracy, and efficient use of materials.

• Compared to an equivalent traditionally built project, up to 67 percent less energy is required to produce a modular building.

• Testing of envelope and mechanical systems can occur prior to arriving on site, thus reducing risk of re-work to achieve energy modelling requirements.

Modular manufacturing can integrate recycled materials, superior insulation, water barriers, and smart technology to reduce energy use and provide high performance buildings. Additionally, with a modular build, site disturbance is minimized reducing noise and waste pollution.

Leading hotel brands are choosing modular construction for the guaranteed consistency in design and quality and speed of construction, which results in a faster return on investment. Moreover, modular construction offers a more sustainable approach to building, with less disruption and less pollution and waste, which helps owners make the responsible choice when it comes to construction. ▪