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"A New Focus for FBS?"
The President's Message, September / October 2000
by Randall D. Holler, Manufactured Structures Corporation |
There has been some discussion about the practicality of converting Factory
Built Structures to an advertising media for our industry. Currently, the
magazine's audience is limited to MBI members and a few subscribing nonmembers,
not potential customers. And while copies of FBS go to some folks outside our
immediate industry, almost all articles are written by MBI members for MBI
members. Even if an issue or two per year were to focus on customers and
potential customers, FBS might prove to be an indirect advertising boost.
The MBI Board of Directors has commented that when and if we do change the
direction of the magazine, articles would need to focus on the positive aspects
of the business almost exclusively. Currently, many of the articles address
your concerns and while they are informative, they don't stress the advantages
of industry products.
What follows is a President's Message with a target audience of end users of
modular buildings, not MBI members. Please take a minute to read it, making
comments, and letting us know what you think. The more critical you are, the
more we learn about the potential of such an idea.
Construction Methods 2000
This article will briefly describe the current construction practices utilized
in the commercial modular building industry. Along the way you will receive a
few tips. But primarily this article will give you a process by which you can
compare your experience when purchasing a modular building.
There are four main phases in the construction procedures. These are 1) design
and approval, 2) assembly/module construction, 3) transportation to the site,
and 4) site erection.
Phase One: Design & Approval
While the time required and complexity vary from job-to-job, all buildings must
be designed prior to construction. Modular buildings usually go through three
separate design processes.
The first design process is for customer (user) approval. Plans are sent to the
customer and can be returned "approved," "approved with noted changes," or
"resubmit." It is usually best to make any corrections in red so that an item
is not overlooked. If you have not, you should begin a list of items you will
need to supply once the building is complete at this time.
Approved plans are what will be built. Therefore this is an important beginning
in construction of a building. Note that it is unusual for a building to be
drawn 100% correct the first time around. Please check carefully, changes asked
for after approval can be quite costly and delay a building's completion. The
quicker this approval process, the faster a building can be occupied.
Typically, the second phase of design involves submission of plans for review
by a governing authority. This may be the state, or it may be a state approved
independent third-party design-review firm. The building undergoes review of
the floor plan, structural details, electrical, mechanical, and plumbing
designs.
Most reviews assure the building complies with the latest edition of the
National Electric Code (NEC) and one of the major building codes such as
B.O.C.A., U.B.C., or S.B.C.C.
Often, this is an expensive and time-consuming process. Manufacturers will
normally wait until they have customer approval before investing in a state
approval. Changes made during or after state approval can easily double state
fees.
There are two important facts to note here. First, some states do not require a
design review. I would suggest you ask for an independent review in this case,
even if the cost was not included in your original quote. It can save thousands
of dollars and headaches later.
Second, local code requirements are frequently not included in your quote or
design. Commercial modular buildings are regulated on a state-by-state basis.
While your building should be quoted and designed to comply with state codes,
manufacturers cannot stay abreast of every municipal code in the county. While
state codes usually suffice, it is best to check with your local building
department.
The third phase of design is done for on-line assembly. Here, details are added
to facilitate plant purchasing and construction. Many companies do not start
work on this phase until the first two design phases are complete. One small
change can affect a multitude of dimensions and result in construction
problems.
Phase Two: Plant Construction
While this article will make it appear that site and line construction occur in
a steady progression of steps, this is often not true. Site work can occur at
the same time plant construction is occurring. This is one of the reasons
modular buildings are erected so quickly.
It is also true that line production can occur simultaneously. At a
conventional site you cannot set rafters until walls are up. In a modular
plant, a building's floors, walls, and roofs are built in adjacent areas. They
can all be built simultaneously.
Of course, all construction occurs indoors. This prevents material from being
damaged and production from being delayed by the weather.
Typically the following process occurs. Please note that various manufacturers
use varying techniques with great success. First, a chassis (frame) is
purchased or built. This is the underlying structural component of your
building.
Usually floors are built on this chassis. The load bearing of your building's
floor will be determined by the weaker of: the site foundation, the chassis,
the floor joists, or its decking.
The unit is then moved to the wall department. In this area walls are built on
tables. These are usually level and square. They stand about waist high making
the construction of walls relatively easy and ergonomically fit. These walls
are set on the floors by using overhead hoists or cranes. The wall design and
the attachment of the walls to the floor/frame assembly are part of the
structural design review.
This unit is then moved into the roof area. Here, the entire roof is assembled
on a fixture or table. It is lifted in one piece and set on the load bearing
walls of the building. Again, the design of the roof and its attachment to
beams, columns, or walls is subject to independent design review.
At this point two more important points are worth mentioning. First, your unit
should be level during this process. It must be built in the same position it
will take after being set on the site foundation. We assume this will be level.
In other words, if walls and roofs are set plumb on an unleveled floor they
will not be plumb when the floor is leveled.
Second, modular units are built inside out, as opposed to conventional
site-built, outside-in construction. In conventional construction, siding and
roofing are applied as quickly as possible to prevent lumber and plywood from
getting wet. This also allows drywall finishers, finish carpenters,
electricians, plumbers, and others to work inside in inclement weather. Modular
plants do not have to make this accommodation.
At this point electricians and plumbers typically do their thing. Often they
are in and on a unit during these first three framing processes.
Now the unit moves into an area where the interior trim and exterior siding are
applied. Again, the unit should be level at this point.
The final station includes areas for the installation of windows and doors, a
thorough cleaning, and the loading of any site required finish materials.
All units go through a series of tests during the final stages of completion.
Plumbing supply and waste lines are tested. All electrical circuits are tested
for continuity. Electrical systems are energized and all fixtures and
receptacles are tested. Complete HVAC start up is also performed.
All aspects of construction are also subject to independent inspections by
state personnel or approved third-party agencies. A state or third-party label
affixed to your unit is verification that the unit was indeed inspected during
construction.
Plants today are subject to regular inspections from OSHA and loss-control
inspectors from insurance agencies. Fall protection, right-to-know, training
requirements, and other legal requirements are in place at most manufacturers.
As a side benefit to you, the above safety issues, worker's compensation
insurance, trash removal, unsightly restrooms, and parking spaces for
construction employees are not a concern at your site during this phase of
construction.
Phase Three: Transportation
It is best to let the source for your modular building arrange for
transportation. In many cases these are independent firms with established
relationships with your building provider. Modular units are large and heavy.
Regular over-the-road trucking companies do not usually transport modular
buildings. Shipping height, width, length, and weight are all concerns best
handled by experienced professional drivers specializing in this endeavor.
State and local laws govern when units can be shipped. Do not expect shipment
during holidays for example. Normally units can be on the roadway only during
daylight hours. However, some of the busiest thoroughfares can only be traveled
at night. What appears to be a short trip can last for many days because of the
circuitous routings required to meet height and width clearances.
You can help by checking to make sure that there is adequate access to the
building's site. Check clearance through gates, past trees, and look at power
line clearances. Streets might even need to be cleared of parked cars for a
short time.
Phase Four: Site Erection
This is another step best left to companies regularly engaged in the modular
building industry. However, with a small amount of assistance from a project
manager familiar with your manufacturer's product many general contractors have
successfully tackled large modular buildings.
If your building is large or if you have several buildings, a staging area
might be required. Normally the set crew would prefer that it be close to the
final site for ease of access and security purposes.
As at any construction site safety concerns exist. Please limit access to the
site, minimizing risks of accidents and speeding completion. To be safe, obtain
a copy of the erector's worker's compensation insurance certificate.
You should meet with your provider and obtain a completion schedule. While this
portion of the project is subject to the weather, a reasonable schedule may be
obtained. This is a good time to verify builder's risk coverage.
You should again go over a list of items that you will need to supply once the
building is complete. The modular building industry provides both turnkey
buildings and buildings with nothing but the structure (no utilities, no steps
or ramps, no fire alarms, no fire suppression, etc.).
Schedule a walk-through at the end of the project. Make a punch-list and then
inspect the building again to make sure all punch-list items have been
corrected.
Most manufacturers will provide a one-year warranty on their product, and many
of the building's appliances have extended warranties provided by their
respective manufacturers. Normal wear-and-tear and vandalism, of course, are
excluded.
Randy Holler
of Manufactured Structures Corporation in
Middlebury, Indiana was elected president of the Modular Building Institute in
March 2000.
Copyright © Modular Building Institute, September 2000. |