MODULAR BUILDING DESIGN
It is clear to us at THINK! That modular construction is a building technology whose time has come and we have integrated this type of project delivery into the repertoire of design solutions and alternatives that we present to our clients when determining the right approach to site, budget and program. It is not right in every circumstance, but when it is, it affords signiďŹ cant advantages in terms of speed of erection, schedule based cost savings, quality and sustainability. From our ongoing experience we have come to understand that modular construction requires a collaborative team structure from the very beginning of design with the modular builder playing a major role.
14’-9” max.
3’-0”
flatbed
11’-0” max.
60’-0” max.
MODULAR DIMENSIONS
MODULAR CONSTRUCTION A successful modular project requires intense collaborative planning and project management. To ensure achivement of the best possible outcome, early engagement with a qualified modular builder who can guide the design process and assist on modular system options is neccessary.
PROS
CONS
Overall speed of construction • With good management, onsite and offsite work can be performed and completed simultaneously, accelerating construction schedules. • Less vulnerability to weather delays. • Offsite efficiency reduces building time.
Not necessarily cheaper than conventional construction on a dollar per sq.ft. basis
Less construction time allows for faster return on investment
Extra planning + extra coordination • Without intense collaborative planning and project management, gaining modular construction’s optimal advantage of the accellerated scheduling is not possible. • Careful coordination between offsite and onsite work is requiired, foundation design, logistics, site access, and mep connection are key factors.
Quality + consistency
Low waste and sustainability
Less time/laborers on site minimizes disruption to neighboring businesses and residents
Accelerated project schedule + cost predictability
Increased worker safety and productivity •All work is performed at the ground level within a controlled environment in the factory allowing for all trades to wo rk more easily with safety.
Less flexibility impacts design • Due to modular layout, transportation and manufacturing restrictions, modular size can be limiting and affect room layouts and overall desirability.
MODULAR DESIGN AND CONSTRUCTION PROCESS Design+ Engineering Predesign: Programming Preliminary Schedule Schematic Design Design Development Construction Documents
Permits + Approvals
Final Pricing + Schedule to Completion
Site Work
Plant Fabrication
Survey Demolition Excavation Grading Site Drainage Foundation Construction Utility Installation Podium Construction
Welded Steel Frame Decking+Insulation+Subfloor Stud Wall+Insulation MEP Exterior Finishes GWB+Painting+Interior finishes At the manufacturing facility a third party inspection agency is present to ensure that the modules are built in compliance with building code and construction documents.
Transportation The fabricated modules are transported by road. Coordinate parking, staging prior to erection, and street closures.
Installation A general contractor will coordinate with modular fabricator and is responsible for the installation of the modules and all final utility connections.
Site Completion Utility connections tested • sidewalks • curbs • paving •landscape
Site Completion Inspections performed to receive certificate of occupancy as-built drawings, maintenance manual and other documnents are provided by GC. Warranty period begins.
MODULAR VS CONVENTIONAL CONSTRUCTION Though not typically less expensive than conventional construction, a modular approach has several advantages. Factory-built modules are completed more quickly than conventional buildings. In addition, the contractor’s time on site will be a fraction of the duration for a typical job since much interior build-out and finish work can be done off-site. Both of these can have a positive effect on project cost. Finally, because modular buildings must be very precise, the quality control for this approach exceeds that of typical construction.
HSS column
[2] layesr 3/4” structocrete on metal deck min. 3 1/2” batt insulation 15”
W8 3/4” steel plate W6
8’-9”
1/2” GWB type C
TYPICAL MODULAR FLOOR/CEILING ASSEMBLY (UL DESIGN NO. H501) BASED ON 10’-0” FLOOR TO FLOOR
Because each module typically has both floor and ceiling construction the typical floor/ceiling sandwich dimension (15” to 16”) is considerably thicker than that of flat plate concrete construction or concrete on metal deck (6” to 8”). This increased thickness must be taken into consideration with regard to zoning limitations and desired floor to floor heights.
Design
Permit
Site Construction Modular Factory Built
Logistics Installation Site Restoration Time Savings
Modular Construction Schedule
Conventional Construction Schedule Design
Permit
S i t e
C o n s t r u c t i o n
Site Restoration
193 HENRY STREET 193 Henry Street is an 11,200 sf six-story multi-use building located in Manhattan’s historic tenement neighborhood on the lower east side. The building consists of: below-grade community facility and utilities, ground level retail and residential lobby, 5 full-floor residential units and a roof terrace. The project is Manhattan’s first, mid-range luxury, residential modular building made of 22 steel-frame modules sitting on a site-built ground floor, basement and foundation. The modules were pre-fabricated by modular steel systems in Bloomburg, Pennsylvania and shipped to New York where the building was erected in 6 days. Modular construction dramatically reduces construction time, contractor time on site and ensures exceedingly high construction quality.
Category Residential
Client 193 Henry Street LLC
Location New York •New York
Size 11,200 sf
Status Completed September 2019
Modular “A” (5 units) 12’-7”W x 35’-2”L x 10’H Modular “B” (5 units) 10’-11”W x 35’-2”L x 10’H Modular “C” (5 units) 10’-11”W x 21’-6”L x 10’H Modular “D” (5 units) 12’-7”W x 21’-6”L x 10’H Modular “stair+elevator” (1 unit) 8’-4”W x 23’-5”L x 10’H Modular “elevator” (1 unit) 8’-4”W x 10’-5”L x 5’H Modular Box 22,000-30,000 LBS 22 Modules Total
Chassis components, connections and lifting details vary from modular builder to modular builder.
Even though most of exterior siding can be installed in the factory, for this project THINK! chose to ďŹ nish our brick facade onsite to minimize the appearance of modularity.
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02
03
07
08
09
13
14
15
04
05
06
10
11
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Modularity is not an impediment to creativity.
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201 EAST BROADWAY 201 East Broadway, currently going up on this busy Lower Eastside street, is comprised of eight floor through and two penthouse units designed for the high-end of the Manhattan condominium market. The 65 modular boxes sit on a structural steel podium which provides clear span space for the buildings ground floor retail spaces with a sound recording studio and spaces for an audio engineering school at the cellar level. The foundations and first floor podium are reaching completion and the modular units, being manufactured in Turkey are ready for shipment.
Category Residential
Client 201 EB Development III LLC
Location New York •New York
Size 23,340 sf
Status Under Construction
Modular “A” - “N” Modular Box 22,000-30,000 LBS 65 Modules Total
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3
5
7
9
6
8
10
11
2
4
TYPICAL MODULE FLOOR
581 GRANT AVENUE 581 Grant Avenue is the first HPD sponsored project to require the use of modular construction. Consistent with its mission and Mayor De Blasio’s initiative to increase the production of affordable and supportive housing for New Yorkers, this project has been conceived of as a test-case to illustrate the ability of modular construction to bring quality units to market as quickly as possible. While individual modules differ in their interior layout (depending on their function), all modules are of a standard dimension to streamline the fabrication process. THINK! has worked in close collaboration with Fullstack Modular, the project’s designated modular builder to maximize the modularity of all of the project components, minimize the number of unique conditions and still come up with an impactful design that will improve the quality of life in this Brooklyn neighborhood. In addition to the project’s 174 residential units, which range from studios to four bedroom apartments, 581 Grant Avenue will have a full range of tenant amenities, generous spaces for the programs of community partners and an abundance of landscaped outdoor space for tenants and the community at large.
Category Residential
Client Thorobird Companies, LLC
Location East New York •New York
Size 155,610 sf
Status Schematic Design
Facade Type1
Structure Grid
1 Bedroom Unit: 2 Modules
Bathroom + Bedroom Fitout
Facade Type2
Structure Grid
Kitchen + Living Room Fitout
MODULAR UNIT TYPES
a
b
c
d
e
f
g
STUDIO
a
b
1BEDROOM
c
d
2BEDROOM
b
c
d
3BEDROOM
b
e
c
f
4BEDROOM
b
e
c
g
f
TYPICAL FLOOR PLAN
Alex Severin Architectural Photograph is responsible for the architectural photography in this book.