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In this episode of Mainstream Modular, host Gabrielle interviews modular consultant Scott Murphy. Scott explains that as a modular consultant, he works with banks, developers, builders, and other parties to ensure that units being built in factories meet the standards and requirements of the project. His role involves monitoring the units throughout the construction process, reviewing architectural drawings, overseeing changes and modifications, and ultimately signing off on the units for shipment or payment. Scott shares that his experience in the industry over the past 10 years has allowed him to develop expertise in catching potential issues early on and eliminating site rework.
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In this episode of Mainstream Modular, host Gabrielle Bejarano interviews Nickolos Gomez, Principal Director of Modular Design and Construction at The AO, as they delve into the world of designing for the factory in modular construction. Gomez shares his expertise and industry insights, highlighting the main differences between conventional site construction and modular off-site construction. He emphasizes the importance of efficiency, collaboration with factories, and early involvement of the factory in the design process. Tune in to discover key tips for optimizing modular design and ensuring seamless integration between factory production and on-site installation.
Key Points:
Designing for conventional site construction involves maximizing the site envelope and working with flexible geometries.Optimizing Design: Modular construction presents challenges when dealing with angled corners or irregular site geometries, requiring creative solutions to maintain efficiency without compromising design intent.Collaboration with Factories: Early involvement of the factory in the design process is crucial for success. -
Modular construction has been a very popular form of construction for hundreds of years now. Of course, in modern times, modular construction is very advanced even with several cons. But a simple fact remains for real estate and construction companies opting for modular: choosing the right modular manufacturers. In deciding on a modular manufacturer, these companies often must weigh certain components to ensure seamless projects.
Why is choosing the right modular manufacturer so important?
On the latest episode of Mainstream Modular, host Gabrielle Bejarano interviewed MacKenzie Thorn, Director of Multi-Family at Aspen Starwood, on construction projects, modular manufacturers and the varying industry standards.
In this episode, Bejarano and Thorn further exploredâŠ
Thornâs current construction project: StruthersWorking with modular manufacturers and the potential challengesThe importance of having the right design team and tough lessons learnedâThere's been big lessons learned with that experience. We have had a design team that in different areas were told that they had modular experience, and the lesson learned was hearing that they've done it and maybe seeing a picture, but actually sitting down with them discussing who they worked with, what factory they worked with, how they built it, and then talking to other developers, is a lesson learned from me about really digging in on, âDo they have that experience building modular?â So, that was a key â will be a non-negotiable going forward as finding that pairing,â said Thorn.
She added that she seeks to partner with companies with readily available skills and tools. âAnd I think also having a modular manufacturer that has a strong design team in-house because the construction really has a lot of parameters around it, how the boxes are built, and only the factory can drive some of those parameters.â
MacKenzie Thorn is the Director of Multi-Family at Aspen Starwood. She is also the President of Aspen Dev Co., LLC. Having grown up a Lego enthusiast, Thorn found herself very interested in construction and real estate very early on. She attended the University of Denver and continued her graduate studies at NYU Schack Institute of Real Estate and New York University, respectively, where she received her Mastersâ degrees.
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California and New York are key leaders in modular construction in both multi-family modular projects and educational modular products. And five statesâCalifornia, Georgia, New York, New Jersey, and Pennsylvaniaâare responsible for almost half of modular construction for educational units.
What is driving the trends for modular construction in these states, and what changes have occurred in the industry over the years?
On todayâs episode of Mainstream Modular by Guerdon, host Gabrielle Bejarano speaks with Matt Mitchell, President at ProSet Modular, to discuss his path in the modular construction industry, growth in the industry, and which markets have been experiencing the most growth in modular construction.
Bejarano and Mitchell also discussedâŠ
Current manufacturing projects and history behind ProSetâs current 20 partnershipsHow Mitchell has discovered the greatest areas of modular construction growth and how ProSet has grown its Colorado presenceHow the modular construction industry is expanding and the influence of price pointMitchell explained the geographical industry trends: âIt seems like the cost of site build in different areas really drives where the modular industry works and where it doesnât work. And what weâre finding now is itâs working in a much broader area.â
He added, âIn the greatest areas of the market growth in the modular, California was a leader in that because it was the most expensive place to build site-built in the country, so we saw lots of modular working in the California area into the statesâŠbut what weâre seeing now is itâs expanding into other areas.â
Matt Mitchell is President at ProSet Modular and was previously a partner there. He has been in the construction industry for more than three decades and began his career as owner of High Mark Development.
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Altruism is the idea or practice of having a selfless concern for the benefit of others. It may also be defined as a concern for others' well-being.
The adaptability and versatility of modular buildings are one of their main benefits. They are easily expandable and customizable to meet shifting needs or specifications, and they can be disassembled and moved to a different location if necessary. They can also be more affordable, especially for projects with constrained budgets and deadlines, and they are often more energy-efficient than conventional site-built structures.
Overall, modular buildings have gained popularity across a range of industries and purposes, from commercial and institutional buildings to temporary structures for disaster relief and remote labor sites, and they provide a number of advantages.
In this episode of Mainstream Modular by Guerdon, host Gabrielle Bejarano spoke at length with Matthew Mayoya, Senior Project Manager at Suffolk Construction about The 6th Place Project and its actionable industry insights.
They had a conversation about:
How Suffolk Construction was able to get on board the 6th Place Project and Matthewâs role in thisThe advantages and benefits The 6th Place Project will offer to the communityHow modular technology is playing a part in this initiativeThe challenges faced during the construction of this projectInsights into modular construction as opposed to traditional construction and its sustainabilityâItâs kind of like a beacon of hope as there are a lot of people out there that just need to get a place to stay and get off the street and this is part of what The 6th Place Project aims to provide,â said Mayoya.
Matthew Mayoya, who is currently the Senior Project Manager at Suffolk Construction, oversees the planning and delivery of construction projects. He ensures that work is completed on time and within budget. He also organizes logistics, delegates work, and keeps track of spending.
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Guerdonâs new CEO Tommy Rakes is taking modular to the next level. Tyler Kern hosted a conversation with Rakes about his background, his ideas for the future, and the proven performance methods he plans to implement.
A modular veteran, Rakes has been in the business since 1977 when he started out on a production line before moving to a managerial role. Rakes said, âIâve sat in just about every chair and touched every base thatâs involved in the industry and thatâs been a real value-added asset, to be able to feel the pinch-points and know what people are able to experience when we talk about something.â
Rake reflected on the beginning of his time in the modular industry and how it has evolved since. He said, on modular, âI saw us really being able to compete with any custom-site builder and being able to do the things that...placed us in a whole different ballgame at that time.â From then on, the industry has grown, and with his real-world experience and passion for the industry, Rakes aims to take Guerdon to the next level using a one-team, one-focus approach.
Guerdon is an industry leader in commercial modular with over 200 projects that has a firm commitment to customer satisfaction, something Rakes wants to expand on. He said, âI want to build upon that...There are so many things in the modular manufacturing that are proven processes and proven methods...with a forward-thinking mindset...weâre at a real growth period in our industry when we talk about modular manufacturing and what we can do from making our production lines an assembly line and not a construction line.â
Using the core principles and values which set the foundation for Guerdonâs structural integrity, Rakes aims to utilize automation for the next chapter in the industry. "This means", said Rakes, "creating a balanced production line that uses sub-assemblies to do more now than 20 years prior."
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The U.S. Department of Energy has sponsored an extensive, three-year study under an Advanced Building Construction Initiative (ABC) program grant to study how modular construction impacts energy efficiency. Professors at the University of Nebraska-Lincoln, and Colorado State University began the study in 2020 and expect to complete data collection and release final reports in 2023.
The research focuses on comparing modular to the traditional multi-family site build, specifically how modular construction methods impact energy performance. The study is broken down into two parts. First, it evaluates building compliance. Second, it measures energy consumption.
âItâs a Department of Energy project, specifically in the office of energy efficiency and renewable energies,â said Professor Jon Elliot, a Colorado State educator whose work focuses on the compliance side of the research.
The study compares multi-family construction between the advanced technology and practice of modular construction to traditional builds. âWeâre looking at twenty projects in compliance. So, ten modular and ten site-built. Another twenty or so in the consumption side, after occupancy,â said Prof. Elliott.
The builds are across the country, in California, Seattle, and Philadelphia. âWe proposed ASHRAE climate zones. But then, through the negotiation process, the program managers wanted to look at these three specific areas. Seattle and California because they are fairly progressive on their energy standards⊠and then Philadelphia, there's just a whole bunch of modular projects going on,â said Prof. Elliott.
To evaluate the compliance of the modular builds, Prof. Elliott starts by reviewing the plans. Then the team visits the factory to confirm the materials used in the construction are, in fact, the materials of the plans. Finally, thereâs an on-site visit to confirm the information when the building is complete or near completion. Once the buildings are occupied, the research will focus on consumption by gathering the data through energy suppliers and comparing it to existing consumption data from traditional multi-family construction.
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Modular construction is growing in popularity and use and for good reason. But not everyone starts off believing in or knowing about the quality build modular provides, including Vijay Patel, a modular construction expert. Host Tyler Kern sat down with Patel as he explained the key reasons he converted to modular construction for his builds and what advice he would give to those looking to make the switch.
A self-proclaimed âconstruction junkieâ Patel started his journey in the hospitality industry ten years ago, amassing a portfolio of hotels around the country. He was first introduced to a modular build in the 1980s, which is markedly different than the builds of today but which sparked an interest in the process. Patel said, â...I was intrigued at the idea that something could be built off siteâŠso the seeds were planted many, many years ago.â
When an opportunity to build modular came about, Patel knew he couldnât miss it. âI was definitely on board. I mean, to have all of our guest rooms completely furnished, from carpet to tile to vinyl, bedding. Everything is in there that would take months and months of hair-pulling during a construction project that having a complete unit sent to us was something that I thoughtâŠjust resonated with me,â he reflected.
With a hard-working team behind him, Patel said building modular took precision, âWe did our homework. We actually spent the time early on.â This is perhaps a key difference for most. With on-site and off-site work ongoing concurrently, doing early homework on the needs, designs, and construction process of the build is pertinent to a successful project.
For Patel, the off-site work needed to be of the highest standard, as quality in his industry is a key ingredient for success. With perfect finishes, modular construction offered excellent construction quality which âwonât bring us any further issuesâ.
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There is an inherent amount of waste generated by the construction process. However, building methods like modular construction can provide ways to reduce that statistic. To discuss this topic, host of Mainstream Modular, Tyler Kern, welcomed John Killingsworth, associate professor in construction management at Colorado State University, to explain how this is possible.
âNew construction produces well over 20% of the solid waste that goes into the landfill, and thatâs just the process of building,â Killingsworth said. âThat number gets significantly higher â in excess of thirty percent â when we consider the waste produced by demolishing old buildings when they reach the end of their useful life.â
Itâs no secret that the built environment utilizes many natural resources in the construction process. When buildings reach the end of their usefulness and demolition occurs, the materials end up in a landfill, and that waste of resources is a lost opportunity to recycle/repurpose. Sustainable building practices are essential, but often those solutions are not regenerative and could require updates or replacement parts down the road.
Extending a buildingâs lifecycle is critical, and a circular economic model attempts to achieve that goal through the design and production of products that will reduce waste in the manufacturing and construction process. Killingsworth emphasized, âAre we building in a way that we can keep the buildings in the economic cycle or in use, for longer than twenty, thirty, fifty years?â
Modular construction utilizes five principles that guide circular economics: building accessible layers, designing out waste, designing for adaptability, designing for disassembly, and material selection. According to Killingsworth, the material selection is at the core of circularity.
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Matthew Wickersham, a Principal with AMJ Construction Management, Inc., focuses on building projects for the affordable housing market. He joined Mainstream Modularâs Tyler Kern to discuss AMJâs history with modular construction and a recent undertaking in the city of Los Angeles, CA.
Wickersham began exploring modular construction as a solution to the housing crisis about five years ago,âIt presented an opportunity to bring to market occupiable units at a much faster rate than the LA market has seen before,â he said.
Several years of exploration and feasibility studies later, the 6th and San Julian project kicked off. This project replaces a three-story light industrial building with new six-story affordable housing. As a mixed-use building it will house up to 90 residential units for low, and very-low-income households as well as provide ground-floor commercial space.
This project could pave the way for more modular construction affordable housing in the LA market. Wickersham was part of a task force to figure out all the various planning, coding, and permit issues and work with all the city departments to ensure a modular undertaking of this magnitude would make a good fit. Currently, there are six different modular affordable housing construction projects underway in Los Angeles that will take place over the next couple of years.
Wickersham said the modular approach makes it possible to do these projects faster. And one of the challenges was finding a partner that could deliver the project with tight deadline demands.
âGuerdon came in at a time when we desperately needed a factory partner that was going to be able to deliver this project,â Wickersham said. âThey stepped in and took control. We went through some redesign with them to optimize the project for their assembly line. Ultimately, Guerdon brought a huge amount of experience to the team to get the product on the line into construction. We look forward to setting those units here in the next couple of months.â
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he modular construction industry has seen record growth since 2015. Once considered a lower quality and cheaper alternative to traditional construction, the industry has found a new life as a viable solution to construction needs. Tom Hardiman, executive director of the Modular Building Institute (MBI), spoke with Tyler Kern about the past, present, and future of modular construction.
As the executive director of MBI for more than 15 years, Hardiman has noticed an increase in popularity in the industry. âIâd say the state of the industry is strong. Everyone Iâve talked to said they are extremely busy. One of the busiest years theyâve had in a long not, if not the busiest year,â said Hardiman.
This rise in interest clearly has an impact on MBI as itâs the international non-profit trade association for the modular construction industry with approximately 450 member companies throughout the world. Hardiman highlighted that itâs a âportal or hub for anyone who wants information on modular construction.â
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Building safe and secure housing is often a foundational base for every architectâs designs. Modular consultant of Cairn Consulting, Weston Bierma, certainly holds this close at hand in the Burlingame Ranch Phase 3 build in Aspen, Colorado. He spoke with host of Mainstream Modular, Tyler Kern, about the perks of modular building and the planning and construction of the project.
For the City of Aspen, Burlingame Ranch Phase 3 will provide 79 affordable housing units consisting of 120 modules on a typically difficult build site. Bierma highlighted one of the main perks to modular building is the impact, or lack thereof, of building on the neighbors.
According to Bierma, âplanning is everythingâ when it comes to modular construction, and field-time is quicker and more efficient than other typical construction sites.
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When Matthew Laase, Principal at Jackson | Main Architecture, worked overseas doing architecture projects in Russia and the Middle East, he noticed something about housingâit was readily available. Once returned to the U.S., Laase saw Americaâs housing shortage as a problem worth fixing. He spoke about these housing challenges and what he sees as the solutions with Mainstream Modularâs Tyler Kern.
âMany of the communities that Iâm involved in are tens of thousands to hundreds of thousands behind in providing the kind of housing they really need to support the community,â Laase said. âItâs something I think about whenever we do a project. Itâs how can we make sure that these are good, livable spaces because people need places to live.â
Jackson | Maine is a champion of modular construction because of its value to a housing project. Modular makes these construction projects more accessible to the industry, from workforce housing to affordable homes.
Laase said it could be easy to get lost in the headlines on some advantages modular construction brings to a project. It is critical to keep one thing in mindâmodular is a different building approach with a different perspective in design.
âDecisions have to be made much earlier in the process,â Laase said. âYou canât have the project under construction and decide, âI want to change out all the sinks or something else.â Or âI donât like these refrigerators; letâs get a different one.â All those decisions are made early in the process.â
Another thing Laase said a builder must consider with modular construction is some costs require payment upfront due to the nature of the work done ahead of assembly. Paying 50% or more of the expenses at the beginning of the project may be a new procedure for some builders. Planning and researching a modular construction project is the key to success.
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The current affordable housing crisis in the U.S. impacts both the traditional single-family home market as well as the commercial multifamily space. Years ago, when the country faced a similar demand, modular construction rose to the challenge for single family homes and is now being called on as a solution to also help in the multifamily arena. For perspective on the situation, âMainstream Modularâ Host Hilary Kennedy reached out to an expert with more than 25 years of manufactured construction experience, Joe Uhlenkott. Uhlenkott, a business development manager with Guerdon, has a wealth of experience in manufactured and modular homes, and vertically constructed buildings.
While single-family modular construction plays a more prominent role in rural markets, commercial modular is critical in urban areas where affordable housing is most needed today.
While Uhlenkottâs vast experience in the single housing market didnât make him an automatic fit for Guerdonâs commercial work, he fell in love with multifamily living right away. âWhen that [Guerdon] opportunity became open, I was like, âWow, I am going to learn something so new and so fantastic,ââ he recalled. âBack seven years ago when I started, modular commercial was still pretty new. Itâs been around a long time, but not a lot of people have been utilizing it, especially in the Western U.S.â
Planning and timing are two of the most significant differences between single-family housing and commercial multifamily projects. What typically took one to two months to complete in the single-family market can take upwards of a year or more in commercial multifamily.
âItâs taking that whole concept of manufacturing but involving a whole team into the process,â Uhlenkott said.
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DCI Engineers, a structural and civil engineering services company based out of Seattle, Washington, since 1988 partnered with Guerdon on several modular construction projects. Troy Bean, Principal/Director at DCI, spoke with Mainstream Modular on some of the engineering considerations for modular construction.
Bean said traditional and modular building construction are similar from an engineering standpoint. Still, modular offers speed-to-market due to the controlled environment of modular construction building practices.
Bean noted that at DCI, they strive to be the change leaders in the industry and advance new methods and technologies. âWeâre spending our R&D time trying to make it easier for the contractor to construct it, for the inspectors to inspect it, and to get a better-completed structure.â
Although DCI is no stranger to modular construction, each project provides learnings that Bean takes with him for future builds.
âA lot of it has to do with the supporting structure that gets site built before the modules are brought in,â Bean explained. âAnd the construction tolerances that need to be followed, the design criteria that need to be in those members; they can present a challenge. The boxes are stacked so fast the buildings donât have an opportunity to shim and straighten, so everything needs to be really tight once you start.â
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On this episode of Mainstream Modular, host Daniel Litwin focused on modularâs relationship with the hospitality industry. To ground modularâs collaboration with hospitality and provide the insights and trends driving that relationship today, Mahesh Parekh, Executive Director of Business Development for Foliot Furniture and Founding Director & Former Board Member of AAHOA, joined the discussion.
Parekh, a storied executive and leader providing more than 30 years of business development and sales experience in hospitality, brought his wealth of knowledge and stories to the show.
âThe (hospitality) industry is a fantastic industry,â Parekh said. âI mean, itâs an industry for a community. Itâs a service industry where we service people.â
And what started as small mom-and-pop motel operations today expands beyond into a much larger, more scalable process. In terms of the built industry and its collaboration with hospitality, Parekh said that modularâs addition into the equation makes it a whole new ballgame.
âModular, if you look at it, is done much faster,â Parekh said. âAnd it is much easier for us, also. We manufacture FF&E (furniture, fixtures, and equipment) in Last Vegas and Montreal. So, when they asked us to be part of it, it was very easy. There was no difference putting the FF&E in the rooms.â
With the hospitality industry in a growth trajectory and a growing need to complete projects efficiently, Parekh believes the modular building is no longer a trend but the future for hospitality.
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Why is demand for modular construction growing today? To find out, James Kent spoke with Michael Merle, Guerdonâs Vice President of Business Development. Guerdon has been a leader in modular construction for the past 20 years, and there are many reasons why modular makes sense for many modern construction projects.
The landscape for modular is much different than it was in the past.
âTwenty years ago, there was very little in the way of commercial modular fabrication,â Merle said. âGuerdon was one of the pioneers in the industry, certainly on the west coast.â
With over 200 completed projects in various markets, including multifaceted family workforce housing, hospitality and assisted living, Guerdon continues to see entry into new industries every single year.
Even as commercial modular construction continues to gain in popularity, Merle said it is still an ongoing education process to educate people on the benefits of going modular.
âWhile itâs not rocket science, there are still some nuances that need to be understood to ensure you have a successful project,â Merle said.
There are many reasons why people are turning to modular solutions for their commercial building projects.
âCost certainty, particularly in todayâs volatile market,â Merle said, is one reason. âItâs the ability to take a large portion, 40, 50, 60% of your overall project, lock that down with a fixed contract, and know that you are not going to have substantial overruns and that type of thing on at least that portion of the scope.â
