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Modular Concrete Design

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Manufacturing

A Modular approach in the construction profession is an emerging trend of educational thinking that shifts the traditional method of construction to a new paradigm.

Modularization is based on the principle of dividing the end into small modules or units that can be fitted with ease typically in a short duration.

This holds that a project is designed in a modular fashion where the different sections, making up the whole, are manufactured off-site and installed with an experienced installation team at a certain point.

The advantage hereof is that there is a saving in time (manufacturing of modular products with other construction) and manufactured in a production line leading to savings in cost (comparative advantages) but more importantly saving in time with less manpower on site.  The figure below indicates where saving in time is possible.

 

 

 

Comparison with traditional construction methods:

 

Modular design concepts start with standard approved material used in the construction industry already complying to SANS.  The only difference is that prior to construction, even in the design phase the standard building blocks are manufactured  with only some special design items manufactured after approval are obtained from the local authority. See items 1 and 2 below.

 

In item 5 above the modular systems are delivered and install as it has been manufactured off-site.  The installation period is short and as the modular systems are pre-manufactured it has as a result that the snag lists are non-existent comparing to traditional building methods.

 

As depicted on the right-hand side of the table above site restoration needs to take place adding additional time to the project.  Using a modular system there is minimal waste and clean-up is quick.

 

The additional advantage is that the walls are prepared in the factory to the desired outcome leaving the project with no further work after installation cutting out plastering, rhinolite, paint including all the time delays within the process.

 

PRACTICAL  3D LAYOUT OF STRUCTURE

The designed structure is shown in a 3d.  Form the image it is clear that the whole structure (from foundations to roof) is pre-manufactured in a controlled environment.

 

 

 

 

 

ARCHITECTURAL DESIGN

An individually designed end product is done providing the benefits of traditional modular block systems in a bespoke architectural environment

 

 

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Benefits from Using Concrete Modular System:

  • Speed of construction:
    Modular building projects can be completed 30-50% quicker than traditional construction methods. By choosing to build modular, the indoor construction process can take place alongside site and foundation work and there’s no need to worry about weather delays.

 

  • Speed of construction:
    Modular buildings are constructed off-site in modules and are then brought to your site in panels, ready to build. Building off-site is transforming the construction process, ensuring better construction quality management and less disruption.

  • Minimal impact on existing operations:
    The modular process removes more than 80% of the construction activity away from the actual site location – the current operation running smoothly with minimal impact and disruption.

  • Eco friendly:
    Modular buildings are kind to the environment – all manufacturing is localized in one factory minimizing waste and using less concrete and steel in comparison with traditional methods. A saving of more than 56 % on the weight of concrete is a typical saving.  By introducing fibers as part of the Engineer's design process the use of steel is also minimized. For isolation, perlite is used which on its own is an eco-friendly product providing the client the option to choose a cost-effective product. The off-site construction process ensures less waste, of at least 20% of the raw materials, too. This is mainly obtained because the manufacturing takes place in a controlled environment. One of the benefits that you can be sure that you are investing in a sustainable construction process from start to finish.

  • Eco Friendly:
    Modular constructions are very cost-effective, with flexible payment options available and a shorter construction time. The design service is often included too so you don’t need to worry about architect costs on top of building expense.

  • Architectural design:
    Thanks to innovative and practical design, using the best quality sustainable building materials, modular constructions are an extremely attractive addition to various end-users such as a school, business, or residential property. One of the main advantages of building modular using this concept is the use of high level 3 d design packages (Revit) with Lumion for 3 d rendering, which provides to each client a tailored-made design. Gone are the days where a matchbox design is used and any design forced into this box. Modular buildings can truly be custom-designed to fit the client’s exact space and budget requirements.

  • Flexibility:
    Thanks to the bespoke design, modular buildings are extremely flexible. Whether you need extra space for a garden room, office, studio, school classroom, music room, or a house  modular buildings can meet your requirements with the perfect flexible extra space. As shown by our case studies, many clients use modular buildings for more than one purpose and they can be designed accordingly. The use of wooden “wendy” structures that may not be used for residential purposes are now eliminated and replaced with a structure that complies with all the SANS regulations, even if only erected as a temporary structure.

  • High quality:
    The nature of indoor construction means that quality and safety are guaranteed and the building materials are protected from moisture and weather during the construction process.

  • Durable materials:
    Modular buildings are constructed with the most durable materials to ensure that your modular construction is built to last.