Modular Multi-Family Case Study: The Graphic

Make the most of the individual boxes.

Utilizing individualized MEP systems where possible will reduce difficult connections between boxes. Because the double structural floor/ceiling system limits the available dimension between the boxes or through the framing to the corridor, it is imperative to minimize ductwork runs. To meet the state energy code requirements for fresh air ducting, we used the 4” interstitial space between boxes to tie bath and kitchen exhaust from the units through corridor ceilings into vertical shafts (2 per floor) to the rooftop ERV. As these connections were extremely tight in the corners of the corridors, we employed an all-electric system for in-unit HVAC.

Collaborate for condensed coordination.

The Graphic team met three times a week during the design development and construction documentation phases to ensure that mechanical systems fit into the modular boxes and that the connections from the boxes to building systems were well coordinated. Working through virtual design and coordination digitally cannot be emphasized enough: share the BIM file with the team regularly. Scope delineation between what is completed in the factory and what is completed at the site is a critical list of items on which everybody should agree. One of the benefits from this process includes simultaneous construction. As an example, the factory installed the modules’ finishes and cabinetry at the same time the onsite team constructed the podium.

Spend time at the factory.

The Architect/Engineers of Record and contractor/installers on site are ultimately responsible for closeout and affidavits. Our General Contractor maintained oversight of the boxes in the factory during construction, with observation from the representative of the state review board. The mechanical contractors also visited the factory so they were aware of exactly what was coming to the site. Additionally, visiting the factory allowed the team to see the benefits of modular construction firsthand: construction jobs are created in a safe, controlled work environment, with less waste and no exposure to weather.

Design with modular construction can be beautiful!

Modular is a tool. The process may be thought of as a spectrum that ranges from stick-built, to 2D panelization, to 3D volumetric modular forms. The design team may welcome what is initially viewed as design constraints and reframe how the typical building elements may be subdivided into smaller pieces that can be manufactured off-site and assembled on-site. For an architect, the constraints become design opportunities. The Graphic project, on a tight urban site in the Charlestown neighborhood of Boston, has no right angles. Our design embraced the geometry of these street edges, combining custom wedge-shaped boxes that crossed multiple apartments with separately constructed additive bay elements. These additive volumes create depth and interest on the regular planes of the façade.

ICON’s design team has incorporated these lessons, among others, into modular projects that are “on the boards”. Modular construction is not a silver bullet. It requires additional framing, so it does not save materials, and it requires more coordination at the beginning of the project. However, the modular process minimizes on-site labor by building off-site and lowers cost through the significant amount of time saved. As industry professionals gain familiarity with this tool, designing with open collaboration, this innovative construction method can lead to more efficient and creative applications of modular technology.

This article was first published in the Modular Advantage - May/June 2021 Edition.