Problem, Challenge, and Opportunity: The term "modular buildings" covers
a wide variety of building styles and configurations. As diverse as our
construction industry, each project presents unique challenges and
opportunities. When viewing a potential project, all must be considered.
The Problem
The Isaac School District in Phoenix, Arizona had an existing campus with
wood-framed modular classroom buildings constructed in 1996. The
buildings had multiple problems, possibly related to civil engineering flaws,
installation and detailing, and/or settling under the structures which caused
the surrounding pavement to be higher than the wooden floor line of the
building.
 As rooftop water ran down
the ends of the structures, it soaked sill plates and walls, and met concrete
paving that sloped toward the buildings in several places, allowing surface
water to saturate critical structural elements. Incidentally, building
foundation vents were replaced with solid panels as student vandalism was
repaired further increasing rot potential. Wood rot and accelerated
deterioration was the eventual result, adding health and safety issues as a
concern.
The Challenge
Isaac School District holds classes year-round, so a solution to the
deteriorating classrooms had to be implemented while school was in
session. Funding to complete the project was also tight.
The Solution
Modular replacement buildings with shorter construction times minimized
disruption to faculty and students. A team approach was selected and the
architectural firm of Orcutt-Winslow Partnership provided planning and
schematic design of the new modular buildings manufactured by Modular
Technology, Inc.
Located at Osborn and 39th Avenue on a five-acre lot surrounded by a crowded
community, the building was designed as a two-story structure to provide the
vitally needed classrooms for its students. Adjoining an existing 52,000
square foot two-story multi-purpose facility, the new modular addition greatly
improved the architectural effects of the entire campus, and simultaneously
offered greater energy-efficient amenities. Utilizing an elevator in the
existing building allowed optimal design goals while meeting accessibility
requirements.
Completed in just 120 calendar days, students and teachers are making good use
of the modular 48,000 square foot structure that features 30 classrooms, a
spacious library, two computer laboratories, and administrative area.
School districts with accelerated construction schedules are becoming more the
norm today in order to meet stringent timelines and tight budgets for the
facilities completion by school year commencement. Modular design
expedites the construction and jurisdictional requirements in ways that are not
possible through conventional construction methods. Construction
schedules are further optimized by the concurrent production of the building
modules at a manufacturing facility and simultaneous development of the job
site. This factory-built process also reduces scheduling impacts and
conflicts created by the usual convergence of construction activity.
Energy Efficiency/Opportunity
The Isaac School District project is an all- steel construction system, using
fully insulated metal studs, with the insulation R-value supplemented by using
an EFIS exterior application of one-inch polystyrene insulating board. It
should also be noted that this EFIS system is appropriate for and offers good
performance in Phoenix's hot-dry climate. The roof systems employ R-30+
batt insulation, while each classroom has individual heat pumps/coolers.
 Wherever possible, the
electrical designs include three phase systems to reduce electrical
consumption. This includes electrically matched HVAC units utilizing
scroll compressors. The energy efficiency package uses one-inch annealed
tinted solar glazing on all products. This project was complete at the
end of June 2002 and early indications reveal that this facility is saving
Isaac School District approximately $2,000 each month in utility bills.
The real opportunity in replacement buildings can come in improving the
performance in areas of health and energy efficiency. Although budgets
are tight, an integrated design approach can reduce utility bills while
increasing indoor air quality and comfort. In examples provided by the US
Department of Energy, some new site-built schools are coming in at about the
same or slightly less cost than conventional construction with up to a 40%
higher energy efficiency. The cost of replacement buildings can be repaid
over time where the previous facility was built to lower energy standards for
performance.
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