We are living in a time of evolution in the construction sector. The industry is currently facing several unique challenges that make building homes not only costly but also time-consuming. A lack of skilled labor, increased materials costs, and unpredictable weather conditions are creating massive hurdles for the construction industry.
But guess what? A promising solution is now emerging from a somewhat unexpected source – the manufacturing industry! By borrowing ideas from the manufacturing sector, it’s becoming possible to offer a response to these homebuilding woes: modular construction.
Modular construction is no new kid on the block. However, its popularity is surging now more than ever. Why? Simply put, it’s because it presents a solid solution to the construction industry’s current problems. By creating modules or sections of a building off-site in a controlled environment, then transporting and assembling them on-site, this approach can mitigate many of the issues traditional construction methods face.
One of the most pressing issues in the construction industry today is the shortage of skilled labor. As a result, projects are often delayed, leading to missed deadlines and ballooning budgets. With modular construction, the need for on-site labor is significantly reduced. By constructing modules in a controlled factory setting, the process becomes more predictable and less dependent on the availability of skilled workers in a particular geographic area.
Weather unpredictability is another major hurdle for traditional construction. With the nation’s attention being focused on climate change, rain, snow, extreme heat or cold – all can disrupt the construction timeline significantly. With modular construction, a majority of the building process takes place indoors in a controlled environment, reducing weather-related delays. Even the current smoke from the Canadian wildfires is causing havoc with workers that build on-site projects.
The rising cost of materials is yet another obstacle that the construction industry is grappling with. Modular construction provides a means to better manage these costs. In a factory setting, materials can be ordered and used more efficiently, with less waste. This approach not only reduces cost but also aligns with the increasing demand for sustainable and environmentally-friendly practices.
FullStack Modular’s Roger Krulak
Roger Krulak, founder and president of FullStack Modular, describes the company as a “design, manufacture, construct solution for multifamily building focused on mid to high-rise … generally focused on dense urban environments.”
Affordable housing is too expensive in the United States because there’s just not enough of it to go around. Roger Krulak thinks he has a solution–manufacturing.
“We as a country are failing to provide attainable housing. Full stop,” says Krulak, owner of a company that builds homes in factories. “The conventional process that we’ve used for decades is inefficient, slow and expensive, so we need a set of answers, and industrialized construction, done correctly, is an answer to faster construction, cost-effective construction, predictable timing … As a result of that, both publicly and privately [modular] is getting a lot of attention.”
FullStack Modular recently moved its U.S. headquarters and manufacturing center from Brooklyn to Hamden, Connecticut. It also has a factory in Oregon to serve the West Coast.
As a fully integrated solution, FullStack Modular uses a design-for-manufacture (DFM) process, meaning elements are purposely designed in a way that optimizes the manufacturing process and reduces costs. DFM has the ultimate goal of “embracing the industrialized construction aspect, increasing economies of scale, speed and cost-effectiveness,” Krulak says.
Building homes on vacant lots is tough. The environment is chaotic and unpredictable, and virtually no processes are repeatable. The main advantage of modular is stability. It happens indoors in a factory where workers can follow standard procedures.
According to FullStack Modular, Krulak’s company in Connecticut, developers can anticipate 80% greater time and cost certainty, 20% to 50% faster development, and up to 25% lower building costs with modular.
Efficiency can also lead to sustainability benefits. “Integrating renewable energy, etc., is very easy in our process because we’re doing it in the same place,” he says. Krulak also touts the low carbon footprint. For example, FullStack Modular reports their process produces material waste under 5%, which is 67% less waste than conventional construction on a typical project.
Compared to traditional construction, Krulak says the job is more stable. “You come to the same place every day; we attract people with families.”
Game Changer
Modular construction is a game-changer. It’s not just a band-aid for the current problems in the construction industry but a sustainable, long-term solution. Its scalability and the ability to produce high-quality buildings faster and at lower cost is a winning combination.
While some may argue that the upfront costs of modular construction may be higher due to transportation and logistics, the speed, efficiency, and the ability to control costs throughout the process often offset these initial expenses.
The modular approach is not meant to replace traditional construction completely. However, by embracing this manufacturing-inspired solution, we can certainly make the construction process more efficient and less stressful for everyone involved. As we continue to evolve and innovate in the construction industry, modular construction is becoming a significant part of the solution to our homebuilding challenges. Who would’ve thought that the answer to the construction industry’s woes could come from its manufacturing cousin?
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Gary Fleisher, the Modcoach, author
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