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Fabulous Pre-fab Applying Modular to Projects in Washington, DC

Abigail R. Brown, AIA Hickok Cole projects. site inWashington, DC,withtheintention ofintroducing thistechnology in future what canmodularbe? This research was tested withaspeculative designfor areal that drove theinvestigation: what’s modular?,why andwhy notuse modular?,and major .This documentrecords answers to thethree majorresearch questions and environmental benefitsitoffers andthesuccessful useofthe system inother system hasnotyet beenwidelyused inWashington, DC,despite thecost, schedule, constructed inafactory thenshippedto thesite andassembled onafoundation. This Modular construction isapre-fabrication system inwhichmodulesofabuildingare Applying ModularConstruction to Multifamily Residential Projects inWashington, DC.” This documentistheresult ofAbigailBrown’s iLabproject “Fabulous Pre-fab: entrepreneurship. to stretch conventional notionsaboutarchitecture, fabrication, work styles, and free timeto develop anideaorproject. Through thisexploration thefirmaims proposals, every employee votes, andthewinnersare awarded uninterrupted project- day to day work life to foster . The firmcrowd sources themost compelling internal research sponsored by Hickok Cole . The program creates agapin iLab exists to promote innovation and progressive anddesignthrough Hello! 2 1 What You’ll SeeHere Welcome to iLab Modular architecture with Jenga blocks;Hickok Cole Architects happy hour Tour ofmodularconstruction ; DeLuxe BuildingSystems 2 2 1

Hickok Cole Architects, Abigail R. Brown, 2014 Contents 2 1 Design &Construction Disruptive Innovation Interior Finishes MEP &Services Vertical Cir Exterior Cladding Roofing Installa Founda Tr Fact Appro Project Deliv St St Wood S Wha Wh Wh Wha ansportation eel Details eel y NotModular? y Modular? ory Fabrication t CanModularBe? t’s Modular? vals tion tions tructure culation ery

4 3 Resources &Credits Disruptive Application Ackno Illustr Bibliograph Modular inDC? Adv Project R Cos Modularization Sample UnitPlan Typical FloorPlan Section Comparison Project Sit t/Schedule Analysis antages &Challenges ation Credits wledgments eturn Analysis e y

Hickok Cole Architects, Abigail R. Brown, 2014 Disruptive Innovation

What’s Modular? Why/Why Not Modular? What Can Modular Be?

1 MANUFACTURE especially multifamily residential projects. receive thegreatest economic benefit. This includestallerurbanbuildings, almost any buildingcanbedividedinto modules,certain project typeswill an incredible variety ofspatial forms includinglarge spanspaces. Although exact repetition. Modulescancome together inanumberofways to create pushed by advances intechnology that allow mass customization to replace that were often banalandhomogenous.However, thisboundaryhasbeen was theonlyway to achieve economies ofscale. This resulted inbuildings repetitive planwere builtusingmodularconstruction since exact repetition constructed aheadofdelivery. Inthepast, onlybuildingswhichemployed a trailer. These unitsare lifted into theirfinallocation ona that is controlled conditions andtransported to theconstruction site onaflatbed Modular construction consists ofwholebuildingunitsprefabricated under What’s Modular? MANUFACTURE 1 Introduction TRANSPORT INSTALL INSTALL The Stack; Gluck+and DeLuxe BuildingSystems 3 3

Hickok Cole Architects, Abigail R. Brown, 2014 with unionlabor. construction isespeciallycost competitive against conventional construction built size andreduced schedule would still result inopportunitiesfor cost savings. Modular the event that factory workers are paidthesameason-site workers thesmallercrew a factory settingare typically lower thanonatraditional site aswell; however, even in amount ofwork canbedonewithasmallercrew size. Basewages for tradesmen in climate, factory organization, and optimized repetition oftasks.Inaddition, thesame Work doneinafactory canbedonequicker thanwork on-site dueto thecontrolled typically beinstalled at arate of6-10 modulesperday depending onsite conditions. and hoists are neededonasite isafurtherreduction ofoverall cost. Modulescan times canbecutupto 50%.Reducing thetimethat large expenses suchascranes modular construction project. DeLuxe BuildingSystems estimates that construction building construction simultaneouslyisthegreatest cost savings opportunity ona The shortened construction scheduledueto theabilityto perform site work and Why Modular? 2 1 Cheaper Labor Faster Schedule Site-Built Construction Construction ScheduleComparison Modular Construction , Engineering, Permitting, Permitting, Approval Approval Design, Design, Process Civil Engineering, Foundations Foundations Site Prep, Site Prep, 19 Site Installation & Finishing Site Construction Time Savings of 25%-50% Overall

Hickok Cole Architects, Abigail R. Brown, 2014 injuries including falls, ismuch higherinthefield. temperature extremes, precipitation, wind,and sunexposure. Safety risks,suchaspotential for Conventional construction workers regularly work in less thanideal conditions dealing with factory settingismonitored andcontrolled for proper airqualityandventilation. reduced withmodularconstruction since themodulesare assembled inadryfactory setting.The in theframing materials. The potential for highlevels ofmoisture trapped inbuildingmaterials is Many oftheindoorairqualityissues identifiedinnew construction result from highmoisture levels reduces thetimeneededto perform qualitychecksat theendofline. methodical andconsistent process performed at eachassembly station, whicheliminates error and construction allows for theabilityto more closelymonitor work quality. Qualitycontrol isavery who isconcerned withmany otheraspectsoftheconstruction process. Modular On atypicalconstruction site, day-to-day qualityistypicallyafunctionof thesuperintendent or interior space constraints. finishes have beenapplied. The work issurrounded by open factory space andnotsubject to many construction process, whichallows better access to agreater numberofbuildingcomponents after layers ofmaterials. Conversely, modulesexpose more surfaces andspaces throughout the On-site construction ischaracterized by theprocess ofconcealing previous work withsuccessive Why Modular? 5 4 3 Worker Safety Less Exposure to Weather Higher Quality DeLuxe Building Systems Materials andworkstations are located adjacent to assembly line; DeLuxe BuildingSystems Workers usepermanentwalkways andtie-offs; 5 6

Hickok Cole Architects, Abigail R. Brown, 2014 controversial orwithdifficult neighbors. the cityandbehindwalls ofafactory. This isanadvantage for projects that are highly Modular construction takes alotofless mess and noiseproduced by construction outof disturbance alsocomes inhandywhenasite haslimited for astaging area. areas to withinthearea immediately adjacent to thebuildingfootprint. The limited site which rewards construction techniques that limitsite disturbance andkeep disturbed the earningofLEED3.0 BD+C,SS Credit 6.1, Site Development -Protect andRestore Habitat, it agoodchoice for greenfield sites orurbaninfill. This construction technique can assist in The duration andimpactonthesurrounding site environment willbereduced, whichmakes Because buildingmodulesare fabricated off-site itispossible to achieve tighter site control. Construction Waste Management,whichaimsto reduce waste generated onsite. most applicableLEEDcredits to modularbuildingsisLEED3.0 BD+C,MRCredit 2.1 and2.2, safe from theftandexposure to theenvironmental conditions ofajobsite. Oneofthe helps to avoid material cost escalation. Bulkmaterials are stored inaprotected environment buy material inbulkandoften inadvance orimmediately uponcontract execution which creates adoublewall condition, cost control cancome from thefact that manufacturers while minimizingon-site waste. While there issomeredundancy since thejoiningofmodules Modular construction makes itpossible to optimize construction material purchases andusage Why Modular? 7 6 Less Environmental Disturbance Less Materials Waste Gypsum board installation; DeLuxe Building Systems Metal fabrication; DeLuxe BuildingSystems 7 8

Hickok Cole Architects, Abigail R. Brown, 2014 Why NotModular? heights. project. The result iseitherataller, widerbuilding,orshorter mate-lines thanwould typicallybefound inamultifamily residential also results inadeeperfloor structure andwider at module increases theacoustical ratings oftheassemblies. However, it some architectural benefits. For example, thedouble construction of amodularbuilding.These doublewalls andfloorsprovide another, there are someinherent redundancies intheconstruction since thesemodulesare stacked side-by-side andontop ofone Since eachmodulehasindependentwalls, , and ceiling, and 1 Deeper Structure CEILING HEIGHT CEILING HEIGHT THICKNESS WALL THICKNESS MATE-LINE WALL UNIT DEMISING& UNIT DEMISING UNIT INTERIOR FLOOR DEPTH FLOOR SLAB THICKNESS 8’-6” 9’-3” 4-7/8” 8-1/2” 8-1/2” 1’-6” 9”

Standard enclosure dimensions; steel modularconstruction versus cast-in-place concrete CAST-IN-PLACE CONCRETE BEYOND MODULAR STRUCTURAL 10’-0” HEIGHT FLOOR-TO-FLOOR 10’-0” HEIGHT FLOOR-TO-FLOOR

Hickok Cole Architects, Abigail R. Brown, 2014 coverage are important,asthey influence theopinionsofpotential residents. rather like thanothermultifamily housingproject. Marketing messages andpositive media modular allows. Itisimportantthat modularhousingdoesnot“looklike” pre-fab ,but advantage oftheuniquearchitectural opportunitiesandincreased construction qualitythat and low-end . Combatting thisnegative perception requires showing clientshow to take perception ofmodularhousing,whichisoften associated withtrailer ,publichousing, A majorchallengeofintroducing modularconstruction to anew market isthenegative means modularmay notmake financialsenseinDCunless thelaborlandscapechanges. typically lower thanthoseinothermajorcitieswhere there isastronger union presence. This modular construction projects inrecent years. Unfortunately, laborrates inWashington, DC,are with unionlabor. For thisreason, citieslike New York andPhiladelphiahave seenanupswing in Modular construction isfinancially competitive when compared to conventional construction built Why NotModular? 3 2 Market Perception Cheap DCLaborRates Union membershiprates by state; 2013 How modularconstruction issometimes perceived 5.0-9.9% DC/VA: 10.0-14.9% PA/MD: 15.0-19.9% NJ: 20.0%+ NY: 10 9

Hickok Cole Architects, Abigail R. Brown, 2014 What CanModular Be? Innovative High-Rise Low-Rise Fabulous Iconic Local Student Housing Market-Rate Affordable Single-Family Wood High Quality Luxury Condos Traditional Mid-Rise Steel Sustainable

Hickok Cole Architects, Abigail R. Brown, 2014 Bethesda, MD;Robert Gurney, FAIA What CanModular Be? 1 •Manufactur •Allow •Made nocompr •All finishes,appliances, andmillw •Took 6monthsto complete after delivery ofmodules •Took 2weeks to build13wood frame modulesinfactory, 2days to install on-site •Cost $200/sf; typical Robert Gurney housescost $300/sf •5,000sf single-family BM ModularOne ed aclientwhohadbudgetandschedulelimitations to afford acustom er: Nationwide ,SandySpringBuilders omises interms ofqualitymaterials orconstruction ork were installed on-site 11 Single-Family Single family homebuiltwith modularconstruction; BM Modular One, Bethesda, MD:Robert M.Gurney Luxury Wood Home 11 11

Hickok Cole Architects, Abigail R. Brown, 2014 New York, NY; Architects Garrison What CanModular Be? 2 •Manufactur •Modules includesolarhotwa •Steel structure modulesare 15feet widex12feet x47 or57 feet long •Common chassis allowed modulesto bemodified for useas comfort stations, lifeguard •Deploy •Needed to bebuilt quickly(withinfiv •Built after Hurricane Sandydes •37 lifeguard andcomfort stations NYC BeachFacility Modules sta capable ofwithstanding futur ed to fifteen sites around New York tions, andoffices whilemeetinga varietyofsite conditions er: DeLuxe BuildingSystems ter heating, skylight ventilators, andPV panels troyed existing e extreme storms e months,by MemorialDay 2013) andhadto be 12 pods builtusingmodular construction; NYC Beach Restoration Modules, New York, NY: Architects Garrison

12 Iconic Facilities 12 12

Hickok Cole Architects, Abigail R. Brown, 2014 New York, NY; Architects Garrison What CanModular Be? 3 •Manufactur •Steel modulesare 12feet widex40feet long •A 3-st •Modules could bedeplo •Multi-st •Disaster housingprototype designedfor theNew York CityOffice of NYC Emergency HousingPrototype undergoing oc arrangements calibr Emergenc ory, 3unittest structure isinstalled inBrooklyn, NY, andiscurrently ory, multifamily interim housingdesignedto work across thecountry er: MarkLineIndustries y

Management cupancy tests 13 yed inless than15hoursandassembled invarious ated for challengingurbanconditions Low-rise emergency housing builtusingmodular construction;

13

Emergency Housing NYC Emergecny HousingPrototype, New York, NY: Architects Garrison Low-Rise Steel 13

Hickok Cole Architects, Abigail R. Brown, 2014 15 Philadelphia, PA; Interface Architects What CanModular Be? 4 •Manufactur •Used modularcons •One ofthelarges •Modular cons •Cost was approximately $135 persquare foot •Total of89 wood modularunitsto build72 oneandtwo- apartments •Includes ground floorparkinggar •80,000sf, 5-story buildingwas builtfrom excavation to completion in9months The Modulesat TempleTown er: Innovative Design&BuildingServices withExcel Homes truction helpedkeep costs down withoutcompromising quality t LEEDfor Homesdevelopment intheUS truction aspartofthebranding for thebuilding age and60,000sf ofmodularconstruction above 14 Mid-rise student housing builtusingmodular construction; 15

Student Housing The Modules at TempleTown, Philadelphia, PA: Interface Studio Architects Mid-Rise 14 Sustainable Wood 14

Hickok Cole Architects, Abigail R. Brown, 2014 Melbourne, ; AmnonWeber Architects What CanModular Be? 5 •Manufactur •Built withtheUnitisedBuilding(UB)Sy •Facade includesdoubleglazed andslidingprivacy screens •Building comprised of36modulesbuiltoff-sit •One andtwo-bedr •9-story, 34unitcondo buildingerected in5days inNovember 2013 One9 dev and ; cantile finishes eloped andusedinAustralia er: Hickory Group, Vaughan Construction oom market rate unitsincludehigh-grade contemporary 16 vered terraces onalllevels stem, amodularpre-fab system e complete withfacades, finishes, Mid-rise market rate condos builtusing modularconstruction;

16 One9 Apartments, Melbourne, Australia: AmnonWeber Architects Market-Rate Condos 16 16

Hickok Cole Architects, Abigail R. Brown, 2014 Brooklyn, NY; SHoPArchitects What CanModular Be? 6 •Manufactur •Includes 4,000sf ofgr •Housing willbe50%at mark •Estimated to trimconstruction schedulefrom 24 to 18months •60% ofwork doneinf •Had somedelay •As ofJune25thcons •32-story, 350 unittower willbethetallest modularbuildingintheworld Atlantic Yards B2 er: FCS Modular, Skanska andForest CityRatner s at the beginning,buttheprocess isspeedingup truction was upto theseventh floor 17 actory, 40%onsite ound floor andluxuryamenities et rate, 50%below market rate High-rise modular buildingcurrently underconstruction; 17 Apartments High-Rise Atlantic Yards B2Tower, Brooklyn, NY: SHoP Architects 17 Mixed-Use Steel 17

Hickok Cole Architects, Abigail R. Brown, 2014 What CanModular Be? Composed Pulled Textured Wrapped Pushed Subtle Dynamic Stacked Rotated Aggregated Dramatic Twisting Terraced Site-Specific Expressed Playful Iconic Irregular Moveable Innovative Traditional

Hickok Cole Architects, Abigail R. Brown, 2014 allows for uniquearchitectural expression andcontrolled variety across afacade. for eachproject. The Jengaexploration revealed multipleways that expressing themodules of thebuilding.Whether ornotto express themodulesisadecisionthat needsto bemade it becomes mucheasierto identifytheindividualmoduleswithininoverall composition encloses andcovers theexpression ofthemodules.Ifcladdingisinstalled inthefactory the factory. Installing thecladdingon-site allows thebuildingskinto actasawrapper that using conventional techniques, through itcanalso becompletely orpartiallyattached in the populargameJenga.Claddingfor modularbuildingsisusuallyinstalled entirely on-site question “What CanModularBe?” Multiplemassing studies were produced usingblocksfrom Hickok Cole was invited toahappy hour tohelpgenerate ideas responding tothe In keeping withHickok Cole’s mantra that “good ideascancome from anywhere,” theentire What CanModular Be? 7 “Play withyour architecture” Jenga blocks for building modules?; Hickok Cole Architects happy hour ENCLOSED MODULES Options for expression ofmodules; EXPRESSED MODULES enclosed or expressed

Hickok Cole Architects, Abigail R. Brown, 2014 What CanModular Be? 18 19 Precedents andJengamassing studies; stacked, pushed andpulled Pushed &Pulled Stacked 20

Hickok Cole Architects, Abigail R. Brown, 2014 What CanModular Be? 21 22 Unit Type A Precedents andJengamassing studies; rotated, terraced, courtyards Terraced Rotated Unit Type B Courtyards 22

Hickok Cole Architects, Abigail R. Brown, 2014 What CanModular Be? 23 24 Precedents andJengamassing studies; Aggregated Textured textured, aggregated, subtle Subtle 25

Hickok Cole Architects, Abigail R. Brown, 2014 What CanModular Be? 26 Precedents andJengamassing studies; twisting, dynamic,iconic 27 Twisting Iconic Dynamic 27

Hickok Cole Architects, Abigail R. Brown, 2014 What CanModular Be? 28 Precedents andJengamassing studies; irregular, dramatic, composed Dramatic Irregular Composed 29

Hickok Cole Architects, Abigail R. Brown, 2014 Design & Construction

How Does Modular Work?

2 construction islimited to Type IIIorType Vconstruction. Building heightandgross floorarea are alsolimited by . Wood therefore canaccommodate large modulesizes. These are rulesofthumb: restrictions andwillvary by manufacturer. Wood isalightweight structure, and Dimensional requirements for modularconstruction are determined by transportation since thewood framing may notbeengineered to withstand transportation loads. after placement at thesite. Duringtransit, modulesoften require temporary bracing shipping, butappliances, millwork, andheavy finisheslike tileand stone are installed connection. Wood modulesare often finishedwithprimedgypsum wall board before Wood modularbuildingsare limited inheightandrequire adeepceiling to floor Wood modularisusedfor singlefamily homesandlow-rise multifamily . Wood Structure 3 2 3 3 2 2 1 •Estimated depthoffloormate-line: 2’-0” •Maximum buildingheight:3to 4s •Maximum moduleheight:12’-0” •Maximum modulelength:64’-0” •Maximum modulewidth:16’-0” Construction Type Module Dimensions Principles ofWood Modular tories Wood framing system; ZETA DesignBuild Wood moduleonsite; BMModularOne, Bethesda,MD;Robert M.Gurney 30 31

Hickok Cole Architects, Abigail R. Brown, 2014 restrictions andwillvary by manufacturer. These are rulesofthumb: Dimensional requirements for modularconstruction are determined by transportation or steel modules. before shipping.Modularconstruction manufacturers often specialize ineither wood wiring, ducting,finishes,appliances, andmillwork sothey are as complete aspossible transport. The modulesare finishedoutinthe factory withinsulation, infill framing, steel isstronger thanwood anddoesnothave to beunnecessarily over-structured for multifamily buildings. Steel frames are strong andrigidcanbeless stout since therefore become popularwithWest Coast architects andfor mid-riseto high-rise such astaller, high-performing, orseismic-designedbuildings.Steel moduleshave Steel modularisusedinbuildingsthat require amore robust structural system Steel Structure 3 2 2 1 •Estimated depthoffloor mate-line: 1’-6” •Maximum building height: 5to 12s •Maximum moduleheight: 12’-0” •Maximum modulewidthandlengthusing cement boar •Maximum modulewidthandlengthusingconcr Module Dimensions Principles ofSteel Modular •16’-0” x50’-0” •14’-0” x58’-0” •12’-0” x65’-0” •16’-0” x35’-0” •14’-0” x40’-0” •12’-0” x46’-0”

tories ete : d: Steel moduleunder construction; DeLuxe Building Systems Steel framing system; DeLuxe BuildingSystems 32 33

Hickok Cole Architects, Abigail R. Brown, 2014 joints between modulesare notrequired. isolation. Once on-site themodulesare bolted together insuchaway that expansion members are wrapped withmineral wool insulation for protection andnoise floor joists witha4.5” concrete deckasitstypicalmoduleassembly. All structural taller andlarger buildings than wood modular. DeLuxe BuildingSystems usessteel Steel modularconstruction istypicallyType IorType IIconstruction, whichallows for Steel Structure 4 2 3 •Higher qualitycons •High lev •Structure isshallower thanthat required for wood modular. •Mate linesare more structurally sounddueto easeofconnections andhigher •Rigid androbus •Higher fire r Advantages ofSteel Modular Construction Type as cheapcons High quality willhelpmitigat leads to gr Interior finishes,applianc winds. capacity ofconnections. P supports for tr lat may pr structur eral bracing, andmore designflexibility. Doesnot require temporary el ofprefabrication dueto thestrength andprecision oftheframe. esistance (Construction Type I&II)allows for tallerandlarger ove to becheaper thanacast-in-place concrete structure. es. Steel modularcould beusedfor a13-story DChighrise, and eater time savings. t structure allows larger openingspans, reduced needfor truction. truction thanbothwood stick-built andwood modular. ansit. es, andfixtures are installed inthe factory, which erforms well underseismicstress andhigh e thenegative market perception of pre-fab

Steel modulesunder construction; DeLuxe Building Systems 33

Hickok Cole Architects, Abigail R. Brown, 2014 Interior openings between modules be achieved by increasing thebeamdepthorwelding frames across themate line. as 9’-6”are possible withoutsignificant structural modifications. Ifaclearspanopeningisdesired, thiscan The framing ofatypicalmoduleresults in atypicalopeningdimensionof8’-0”;however, openingsaswide floor depth,and steel modulestypicallyneed1’-6”offloordepth. Floor thicknesses vary basedonmanufacturer andstructural system. Wood modulestypicallyneed2’-0”of framing, there canbenodirect soundtransfer through thelightgaugesteel framing into adjacent surfaces. Multi-unit modularconstruction isinherently insulating to sound.Becauseeachmodulehasitsown following are rulesofthumbassuming theuseoflightgaugesteel studs and5/8” gypsumboard: Wall thicknesses vary dependingonrequired fire rating andlocation ofthe wall withinthemodule. The Steel Details 3 2 1 •Interior walls notonamate-line shouldusetypicalpartitiontypes •When adjacent modulesmeetthere isa1/2” gapat themate-line •Exterior w •Interior wall onamate-line: 8” Openings Between Modules Floor Thickness Wall Thickness all (w/o cladding,w/ membrane): 93/4” 34

35 36 Junction of floor, exterior wall, andinterior wall Typical separating wall inasteel modularbuilding 38 37

Hickok Cole Architects, Abigail R. Brown, 2014 Typical plandetail at exterior wall Steel Details

8” 9 3/4” 39

Exterior wall section detail 1’-6” 40

1’-6” Typical mate-line wall section 8” 41

Hickok Cole Architects, Abigail R. Brown, 2014 an outsidearchitect asasubcontractor. contract inwhichthemodular manufacturer caneitherdothedesignin-house orhire In design-buildprocurement theclient andmodularmanufacturer enter into asingle constraints duringthedesign process. more accurate pricing,astheselected manufacturer’s standards are usedasknown of thedesignprocess. This delivery methodallows for maximum collaboration and a general contractor whoisteamed withamodularmanufacturer at thebeginning In anegotiated bidthearchitect andclientselecteitheramodularmanufacturer or design work once amanufacturer isselected). (which results inless architectural control ofthefinalproduct and requires additional bidding), orbiddocumentscanuseaperformance-based orprototypical system one manufacturer’s standard system asabasisofdesign(whichlimitscompetitive the production ofbiddocumentsbecomes tricky. Biddocumentscaneitheruse of modularconstruction; since modularmanufacturers have theirown systems, method doesnottake complete advantage ofthepotential collaboration benefits then selectsasubcontractor to provide themodularcomponents. This delivery andbidby competing general contractors. The selected general contractor Design-bid-build istheconventional methodinwhichaproject isdesignedby an bid-build, negotiated bid,anddesign-build. process ofconstruction procurement for modularconstruction. These includedesign- There are afew standard routes that aclientmay take whengoingthrough the Project Delivery 1 Delivery Methods Contract Documents produced by DeLuxe Building Systems given to amanufacturer to complete in-house. and 50%construction documents.DeLuxe BuildingSystems usesthismodel. then willbeginto produce drawings at astage inbetween finaldesigndevelopment then produces shopdrawings basedoffthisset. manufacturer may occur to prepare construction documents: There are three different ways inwhich collaboration between thearchitect and 2 If usingdesign-build,thearchit The manufacturer may beinvolved from thebeginninginanadvisingrole and The architect produces asetofconstruction documentsandthemanufacturer Construction Documents ect may produce “bridgingdocuments”that are 42

Hickok Cole Architects, Abigail R. Brown, 2014 modular buildingsare ableto receive buildingpermitsinWashington, DC. containers are adifferent kindofpre-fab thanmodular construction, thisproves that were assembled less thantwo weeks after thepermitwas issued. Though shipping story, four unitshippingcontainer apartmentbuildinginJuly2014. The containers In Washington, DC,Brookland Equity Group LLC was issued apermitfor athree modular components. as afinalwhole. However, drawings should still clearlydifferentiate site work from permit drawing set,modularandin-situcomponents shouldberepresented together again after assembly. Permits are alsooften runthrough athird-party system. Inthe the modularmanufacturing facility for inspectionsofthemodules,thenvisitsite inspectors, athird-party inspector system hasbeenestablished. Inspectors must visit Because modularbuildingsare constructed at adistance from municipal building Approvals 1 Permits &Inspections 43 SeaUA Apartments;Brookland, Washington, DC; Travis Price Architects 44 44

Hickok Cole Architects, Abigail R. Brown, 2014 Factory assembly line; DeLuxe BuildingSystems; Berwick,PA Factory Fabrication 46 1 •Previously worked withHickok Cole ontheunbuilt16th&Constitution project •Primary market sect •Capacity to pr •Metal fabrica •Nearly 400, •Two quarter milelongproduction lines,materials are procured locallywhenpossible •Founded in1965;beganusingsteel frame modulesinthemid-1980s Regional Manufacturer 000sf ofproduction andwarehouse facilities tion andconcrete plantonsite; roll own studs andstructural steel oduce 12.5millionsfperyear DeLuxe Building Systems, Berwick, PA ors are hospitality, student housing,apartments,andcondos 46

47 45

Hickok Cole Architects, Abigail R. Brown, 2014 Factory assembly line;DeLuxe Building Systems, Berwick, PA Factory Fabrication 48 48 48

Hickok Cole Architects, Abigail R. Brown, 2014 Factory assembly line;DeLuxe Building Systems, Berwick, PA Factory Fabrication 48 49 50

Hickok Cole Architects, Abigail R. Brown, 2014 Permit Office for furtherinformation on Oversize and Overweight . required for any carrying Class 1Explosives. Refer to DDOT’s PublicSpace feet-6 inches,longerthan75 feet, orthat weigh over 120,000 lbs.Police escort isalso escort isrequired for any vehicles andloadsthat are widerthan 12feet, taller than13 limitations (21,000 lbfor singleaxle, 34,000 lbfor double axle). Inaddition,police feet-6 inches,longerthan55feet, orthat exceed theDistrict axleandgross weight Permits are required for vehicles andloadswiderthan8feet-6 inches,higherthan13 typically considered 500miles. destination. For economic feasibility, themaximumdistance from factory to site is maximum weights. Modulescanbeshippedviatruck,railroad, orshipdependingon maximum dimensions,timesofday, roads, route reporting requirements, and additional regulations, whichmightincludepermitrequirements, police escort, and are limited by individualstate laws. Cityandcounty governments alsoimpose Maximum width,height,andweight ofmodulesare basedonshippingrestrictions appliances ormaterials must betieddown priorto shipment. polyethylene sheetortarpfor temporary weatherproofing. Inaddition,any loose All modulesthat are exposed duringtransport are covered by acustom made Transportation 3 2 1 Vehicle Permits inDC Shipping Transit Protection Temporary Weatherproofing; DeLuxe Building Systems NYC Emergency HousingPrototype; Architects Garrison Modules ready for shipment 52 51

Hickok Cole Architects, Abigail R. Brown, 2014 inaccuracies inthetop ofthe foundation. the foundations andgrouted andlevelled asnecessary to take upany Generally baseplates, steel strips, orcement particleboard are fixed to and fixingmechanisms to aidinthepositioningofunitson the foundations. Each manufacturer haddeveloped itsown proprietary system for locating for someadjustment inthefoundation orinthelegsofmodularunit. installation andalignmentofmodularunits.Often itisnecessary to provide The levelling offoundations or grade beamsiscrucialto thesubsequent modules placed above. the larger spansrequired for parkingandretail at thesite withtheresidential construction isagoodchoice for multi-family buildingssince itallows for foundations systems are more common for steel buildings.Concrete podium modules often produce apointload.Therefore, perimeter andpier generally place distributed loadsonfoundations whereas steel framed construction dependingonthe site andsoilconditions. Wood modules arrive onsite. Almost any foundation system canbeusedwithmodular In allcasesthefoundation must beprepared before themodulesbeginto Foundations 2 1 Tolerances andLevelling Foundation Types Modules placed onstepped concrete podium; Star Apartments: MichaelMaltzan Kullman BuildingCorporation Foundation Detail; 53 Kullman BuildingCorporation Foundation Types; 54 55 56

Hickok Cole Architects, Abigail R. Brown, 2014 capacity isgenerally required. Various typesofrigsare available to liftmodules. commonly kept on-site duringtypicallow-rise construction projects, asa40-75 ton Positioning ofmodulesoften requires acrane ofgreater capacitythanthose The typeofcrane required for placingmodulesisbasedonweight andreach. Installation 75-ton capacityluffingjib crane Methods of lifting 1 Crane andRigging 58 57 Craning site plan; Pierson College 59 Top: The Stack, ;Bottom: 38Harriet , SanFrancisco Installation ofmodules; 61 60 61

Hickok Cole Architects, Abigail R. Brown, 2014 modules together withblindrivets. 3/8” steel plate witha1-1/2” stiffening lip at the top andbottom then fastens the pin registers alignment inonedirection, andthe two floating pinsallow for error. A Building Corporation’s system, thetapered pinlocates themodulebelow, thediamond corner column whichfitsinto the ofthemodulebelow. Inthe Kullman accuracy andreduce setting time. In most cases apiniswelded to thebaseofeach modules to eachother;however, itistypicalto useainterlocking system to increase Each modularconstruction manufacturer usesadifferent system to connect the manufacturers caninstall 6-10 modulesperday, dependingonsite conditions. speed. Any jointsoropeningsare covered withatarpat theendofeachday. Most mph. Asmallgapbetween moduleframes allows theprocess to occur withgreater Weather conditions willprevent theplacingofmoduleswhenwindspeedsexceed 10 cranes are expensive. The maneuvering ofmodulesisperformed by guideropes. this process doesnotimpedethemaximumworkflow ofthecrane, as large An on-site crew guidesthemodulesinto place andmake theconnections. Ideally, Typically themodulesare lifted directly from theflatbed trailer into theirfinallocation. Installation 3 2 Fastening Hoisting and Positioning Kullman Building Corporation Setting pin section; Kullman BuildingCorporation Bind rivet section; 63 62 Kullman Building Corporation Stacking andfastening ofmodules; Kullman BuildingCorporation Setting pinidentification, undersideofmodule; 66 65 64

Hickok Cole Architects, Abigail R. Brown, 2014 Roofing residential buildings. was beyond thescope ofthisdocumentsince they are rarely usedfor multi-family of amoduleat thefactory ifitislow-sloping. Detailed research onpitched roofs installed onsite, constructed conventionally, orintegrated into theconstruction Pitched roofs canbeconstructed inthefactory asindependentmodulesthat are a moduleinthefactory orconstructed conventionally onsite. services withinthebuilding.Aparapet canbeintegrated into theconstruction of vertical service shaftsthat alsoaccommodate soil andvent pipesandothervertical Parapet wall detailsare possible. Roof drain pipescanbeincorporated into the can beaccommodated ontheroofs onmodularbuildings. engineered to accommodate a orassembly space. Itisunlikely that pools built upmembranes onsheathing laidonfurringstrips. The roof structure canbe all roof loads.Arange offlat roofing systems canbeused,includingsingle layer or either caseitisnecessary to ensure that thestructure isdesignedto accommodate roof structure that spansbetween thewalls ofthemodularunitsmay beused.In structure oftheuppermodularunitscansupportroof directly oranadditional All currently usedroofing systems canbeapplied to modularbuildings. The ceiling 2 1 Pitched Roofs Flat Roofs Roof moduleconfigurations 67 Roof deck;The Modules at TempleTown student housing Flat roof detailwithparapet 68 69

Hickok Cole Architects, Abigail R. Brown, 2014 Exterior cladding; details. The external claddingmust bedetailedto fitaround the openings withappropriate waterproofing required itmay benecessary to incorporate hotrolled steel elementsinto thestructure oftheunit. permitted inany onemodularunitislimited onlyby structural requirements. Iflarge openingsare is similarto otherforms offramed construction. The numberofopeningsandarea ofglazing anddoorframes are generally fitted into themodularunitsin factory andtheirdetailing rainscreen panelsattached to sub-framing ordirectly to thestructure. the foundations andlaterally by thestructure), cementitious panelsappliedto rigidinsulation, and attached inthefactory. Typical claddingmaterials includebrick(whichissupported vertically by entirely on-site usingconventional techniques, through itcansometimesbecompletely orpartially the units,oritcanbesupported entirely by themodularstructure. Claddingisusuallyplaced Cladding for modularbuildingscanbeselfsupportingvertically andonlysupported laterally by Exterior Cladding 2 1 69 Windows & Wall CladdingInterface The Modules at TempleTown, Lehman ChildCare Center, Atlantic Yards B2 70 71 Architects Exterior installation; The Modules at TempleTown; Interface Studio Exterior installation; The Stack, New York City;Gluck+ 69 72

Hickok Cole Architects, Abigail R. Brown, 2014 individual project. shaftsandstairs canalsobesite built. Elevator shaftsandstairs canbeconfigured into modules to suitan Vertical Circulation Integrated stair modules; DeLuxe Building Systems 1 & 73 73 Possible stair andelevator configuration; Kullman Building Corporation 75 74

Hickok Cole Architects, Abigail R. Brown, 2014 enclosures canbeintegrated withthebuilding’s finishes. on-site once theservices are inplace. The designofaccess pointsand chase connections canbemadeeasily. Corridor lightingandfinishesare theninstalled The corridors withinthemodularunitsarrive to thesite unfinishedsothese made through removable flooror wall panels. ofthecorridors, whichrequires adropped ceiling. Hookups canalsobe the finisheswithinapartments.Horizontal distribution isoften runthrough the duct andwithouttheneedto enter theunit.This minimizes potential damageto corridors outsidetheunit,whichallows services to beconnected on-site withinthe terminate at thevertical duct.Access to theservice ductisgenerally madefrom and pipework. The services withineachunitare installed inthe factory and vertical service ductisincorporated ineachunitto accommodate vertical drainage largely beachieved inthefactory whilefinal connections are madeon-site. A Installation ofelectrical,,andheating services inmodularbuildingscan systems andmakingfield connections. central plant.Decentralizing alsoavoids someofthecomplexities ofrouting the eliminates theneedfor deepductwork required to transfer conditioned airfrom a Decentralized mechanicalsystems are often usedinmodularbuildings.This MEP andServices 2 1 Hookups &Distribution Decentralized Systems Service duct; modelunit Service hook-up diagram UNFINISHED CORRIDOR FINISHED FINISHED ATTACH UNIT UNIT UNFINISHED CORRIDOR FINISHED FINISHED ATTACH UNIT UNIT 76 DUCT SERVICE DUCT SERVICE Typical service duct; axon andplan 77

Hickok Cole Architects, Abigail R. Brown, 2014 Single family homeinterior; BMModular One, Bethesda, MD:Robert M.Gurney be installed on-site for greater control andwithouttheneedto account for jointsat modulemate-lines. installed inthefactory by trained craftsman. Finishesinmarquee spaces, suchaslobbiesandamenities,can Quality offinishesare not restricted by modular construction. Any grade offinishescanbeselected and order to cover themate-line inthefloorseamlessly, thoughthis requires more on-site labor. detailing thesefinishtransitions at mate-lines. Alternatively, floorfinishescanbeappliedentirely on-site in lines thefinishesneed to be stitched together inthefield. Therefore, designersshould pay close attention to interior spaces that are builton-site, andthejointsbetween modules.When openingsoccur at modulemate- finish work always needs to bedoneonsite. This includesthe corridors after MEPhook-ups are made, any The goalofmodularconstruction isto complete asmuchpossible inthefactory setting.However, some Interior Finishes 2 1 Quality ofFinishes Schedule ofCompletion 78 Unit interior; 38Harriet Street, Panoramic Interests Unit interior; NYC Emergency HousingPrototype; Architects Garrison 80 79

Hickok Cole Architects, Abigail R. Brown, 2014 Disruptive Application

Modular in DC?

3 Modular in DC?

Conventional vs Modular

Non-Union vs Union

Wood vs Steel ????????? offer rental unitsinamixofunitsizes from juniors to two bedroom units. floor. This proposal aims to develop anew multifamily residential buildingthat will site, andtheproject proposal incorporates a replacement facility ontheground west ofthesite. The ’s existing Kiss &Ridefacility islocated onthe The Brookland-CUA Metro station andWMATA busloopare immediately to the Development Solicitation that was released inNovember 2013. south parcel intheWashington Metropolitan Area Transit Authority (WMATA) Joint in theNortheast quadrant oftheDistrict ofColumbia, anditwas includedasthe The site islocated adjacent to theBrookland-CUA Metro station ontheRed Line Washington, DC. applied to aspeculative designfor areal site intheBrookland neighborhood of better understand theconstraints andchallenges,thepreceding research hasbeen any large-scale modularconstruction projects inWashington, DC.Inorder to and thesuccessful useofthesystem inothermajorcities,there have notyet been the expedited schedules,higherquality, andenvironmental benefitsofmodular, but developers have beenshy to adoptmodularconstruction techniques. Despite Multifamily residential construction iscurrently boominginthenational’s capital, Project Site 2 1 Speculative Project Site Disruptive Application Project site location; Brookland WMATA JointDevelopment Site, Northeast Washington, DC N

MONROE ST NE

METRO STATION METRO MICHIGAN AVE NE BROOKLAND-CUA BROOKLAND-CUA LOOP WMATA

BUNKER HILL RD PROJECT BROOKS

NEWTON ST SITE

10TH ST NE

OTIS ST

Hickok Cole Architects, Abigail R. Brown, 2014 decision: not becompetitive inWashington, DC.Below isalist ofmajorfactors that drove this Construction) itquicklybecameapparent that wood modularconstruction would limitations ofwood modularanddiscussing thecosts withalocalcontractor (Davis built construction over asite-built concrete podium.However, after researching the speculative project was therefore assumed to befive stories of wood modularor stick- concrete podium,whichisacommon construction typeinWashington, DC.The use ofmodularconstruction to replace wood frame stick-built construction over a The initialconcept oftheapplication phaseofthisstudy was to investigate the Comparison 1 •Wood frame stick-built construction isvery affordable inthe Washington, DC, •The negative market perception ofmodularconstruction ismore pronounced •Less work canbedoneinthefactory since wood modulescannot support •Wood modularrequires avery deepceiling to floor connection (2’-0”minimum) •Wood modularrequires temporary supportsfor transit loads •Wood isless rigid thansteel, andthuslimitsopen spansandrequires more •Wood buildingsare limited inheightandgross square area by buildingcode Initial Concept modular costs 3 mar with wood. St the samesavings benefitofmodular cons heavy applianc later ket. Early pricing studies by Davis Construction have shown that wood al bracing eel modularisgenerally perceived ashigherquality. es, millwork, andfinishesduringtransit. This reduces 5% more thanconventional wood framing. truction.

*Approximate overall buildingcost; basedon 2013 by Davis Construction WOOD FRAME CONCRETE PODIUM SITE-BUILT CONCRETE PODIUM SITE-BUILT MID-RISE CONVENTIONAL SITE-BUILT MODULAR MID-RISE MODULAR WOOD UNITS UNITS 5 STORIES 5 STORIES $149/SF* $110/SF*

Hickok Cole Architects, Abigail R. Brown, 2014 including afloorplan,modulesections,sampleunitandmassing study. Brookland WMATA site that were usedto generate thecost andschedulecomparisons, an abbreviated setofthebasicdrawings ofamultifamily residential project for the pro-forma to compare the project returns for eachoption.The following pagesshow using bothunionandnon-unionlabor. Allfour estimates were thenpluggedinto a We compared bothtotal buildingcost andconstruction schedulefor bothoptions stories ofmodularorconventional construction over asite-built concrete podium. same site andfloor planastheinitial concept, the study was revised to compare nine modular construction to aconventional cast-in-place concrete building. Usingthe During earlydiscussions Davis Construction expressed interest incomparing steel Comparison backs for balconies. The building skinwas assumed to beinstalled on-site. modular optionfor thisstudy usesastraightforward stacking approach with someset- take advantage oftheinteresting architectural opportunities that modular allows. The to beexisting whenconstruction ontheupperfloors started structure over aconcrete podium concrete podium. The following are theassumptions that were taken into account for theestimates:

2 3 •To make thisstudy anapples-to-apples comparison thebuildingform doesnot •The site-built concrete podiumisidenticalfor bothoptionsandthat isassumed •The conventional optionconsists ofninestories ofcast-in-place concrete •The modularoptionconsists ofninestories ofsteel modularover asite-built Revised Concept Assumptions CONCRETE STRUCTURE SITE-BUILT CONCRETE PODIUM SITE-BUILT HIGH-RISE CONVENTIONAL CONCRETE SITE-BUILT MODULAR HIGH-RISE MODULAR UNITS STEEL UNITS 9 STORIES 9 STORIES COST ? COST ?

Hickok Cole Architects, Abigail R. Brown, 2014 Building Section CONCRETE PODIUM SITE-BUILT UNITS MODULAR STEEL East/West Building Section;1/8” =1’-0” Key Plan

Hickok Cole Architects, Abigail R. Brown, 2014 large spansandirregular room geometry. amenity roof . The amenityspaces are site-built dueto the include aClubRoom andaFitness Center, bothwithaccess to an The buildingfeatures residential amenitiesonthesecond floorthat equipment andlighting,storm water retention systems. design strategies, suchaswater-reducing fixtures, energy efficient will strive for LEEDcertification and feature many sustainable units perDCInclusionaryZoning requirements. The building juniors to two bedroom units.The proposal willoffer affordable The speculative project offers rental unitsinamixofunitsizes from Typical FloorPlan UNIT MIX 1 BED+ 1 UNITTYPE JUNIOR TOTAL 2 BED 1 BED Program Elements AV SF 1224 888 519 715 L02 28 15 4 2 7 L03 34 17 5 5 7 L04 34 17 5 5 7 L05 34 17 5 5 7 L06 34 17 5 5 7 L07 34 17 5 5 7 L08 34 19 4 6 5 L09 34 19 4 6 5 L10 34 13 11 4 6 TOTAL 300 149 60 50 41 N 2BR 2BR 2BR 1BR 2BR 2BR TERRACE AMENITY 1BR BELOW 1BR 1BR 1BR 1BR 1BR 1BR 1BR 1BR 1BR+D 1BR 1BR+D JR JR JR 1BR JR 1BR+D JR 2BR 1BR+D 2BR 1BR 1BR 1BR 1BR 1BR 2BR Typical Floor Plan; 1/8” =1’-0”

Hickok Cole Architects, Abigail R. Brown, 2014 Sample UnitPlan MATE MATE LINE LINE JR

16’-0” UNITS 1BR JUNIOR 480 SF 30’-0” E1 MODULES C1 D1 MATE MATE LINE LINE 1 BEDROOM 720 SF 35’-0” Sample Junior and1Bedroom UnitLayout; 1/4” =1’-0”

11’-6” 12’-6” LINE MATE LINE MATE LINE MATE N

Hickok Cole Architects, Abigail R. Brown, 2014 Modularization 1BR JR 2BR UNITS 2BR 1BR 1BR E1 Z1 Z2 MODULES Z3 Z4 Z5 A2 D1 B2 C1 N Z31 Z30 Z29 Z28 Z27 Z1 Z2 Z3 B2 Z4 A2 Z5 A1 B2 B1 A2 B2 A1 A2 B1 Z26 B2 Z25 Z24 Z17 Z6 Z13 Z14 E1 Z12 E1 E1 E1 Z23 1 Z11 Z7 Z22 Z19 Z21 Z16 Z15 D2 D1 Z18 Z20 C2 C1 D2 D1 C1 C2 D2 D1 C1 Z10 Z9 Z8 Module Plan; 1/8” =1’-0”

Hickok Cole Architects, Abigail R. Brown, 2014 Modularization MODULE AXON LEGEND MODULES SET BACK FOR BALCONIES *LENGTH DIMENSIONISAPPROXIMATE; VARIES AS DIMENSIONS VARY MODULES STACK VERTICALLY; JUNIOR MODULE,16’-0”x30’-0” BEDROOM MODULE,11’-6”x35’-0”* LIVING ROOMMODULE,12’-6”x35’-0”* BEDROOM MODULE,11’-6”x65’-0”* LIVING ROOMMODULE,12’-6”x65’-0”* SITE BUILT BELOW GRADEPARKING SITE BUILT PODIUM

Hickok Cole Architects, Abigail R. Brown, 2014 UNION NON-UNION

Davis Construction dated 9Oct2014. Conceptual estimates basedoncost analysis by DeLuxe Building Systems and construction onthetower started. and escalation. This study assumes that thepodiumwas already builtwhen general contractor’s fee, gross receipts tax,performance andpayment bond, general conditions, contingency, contractor , buildersriskinsurance, *Total BuildingCost perGSFincludesdirect construction cost, unionpremium, UNION NON-UNION Cost/Schedule Analysis 1 CONVENTIONAL MODULAR CONVENTIONAL MODULAR TOTAL BUILDINGCOST PERGSF* How much? CAST-IN-PLACE CONCRETE MODULAR 50 CAST-IN-PLACE CONCRETE MODULAR 50 100 100 0 150 0 150 $175.07 200 $175.07 $204.55 200 $217.97 $219.58 $204.55 $217.97 $219.58 250 250

UNION NON-UNION 3 2 CONVENTIONAL MODULAR CONVENTIONAL MODULAR LENGTH OFCONSTRUCTION •Modular is22weeks f •Modular is9weeks f •Modular is$1.61/ •Modular is$29.48/

Summary UNION NON-UNION How long? 10 CAST-IN-PLACE CONCRETE MODULAR 10 CAST-IN-PLACE CONCRETE MODULAR 20 sf less thanconventional whenusingunionlabor sf more thanconventional whenusingnon-unionlabor aster thanconventional whenusingnon-unionlabor aster thanconventional whenusingunionlabor 20 30 30 40 0 43 WEEKS 43 WEEKS 40 50 0 43 WEEKS 43 WEEKS 52 WEEKS 50 60 52 WEEKS 60 65 WEEKS 70 65 WEEKS 70 80

Hickok Cole Architects, Abigail R. Brown, 2014 80 company assessing thedeal. depend onproject size, investment requirements, andportfolio size for theindividual while othersmay notbeaskeen to thebefirst to theparty. The decisionwillalso at anew potentially ground breaking opportunitywithhigherrisk/reward potential, depends ontheinvestor/developer riskappetite. Someowners may bequickto jump are highenoughto justify theincreased riskassociated withanew construction type with conventional construction built withunionlabor. Whether ornotthosereturns labor. However, modularconstruction produces slightlyhigherreturns whencompared construction isnotcompetitive against conventional construction builtwithunion multiple, IRR,andstandardized yieldoncost), itbecomes clearthat modular Through thecomparison ofseveral metricsmeasuringreturn oninvestment (equity models to test thefour scenarios priced by Davis Construction. speculative project, alocaldeveloper (CityInterests) agreed to runseveral pro-forma In order to test thefinancial feasibility ofusingmodular construction for the Project Return Analysis The following are theassumptions that were taken into account for theestimates:

1 2 •The onlyvariables are thelengthofconstruction and thetotal building cost/gsf •The construction loaninterest rate is4.50% •The landacquisition price is$10,000,000 •The project includes300unitsrented at $3.00/sf Is itworth it? Assumptions

UNION NON-UNION It doesnottake into account thetimevalue ofmoney. expected to receive theiroriginalinvestment backover thelife oftheinvestment. An equitymultipleisametricthat describesthe numberoftimestheinvestor is 3 EQUITY MULTIPLE CONVENTIONAL MODULAR CONVENTIONAL MODULAR Equity Multiple MODULAR CONVENTONAL 0.5 1.0 1.13x 1.17x 1.17x 1.5 1.9x 2.0

Hickok Cole Architects, Abigail R. Brown, 2014 UNION NON-UNION

UNION NON-UNION Project Return Analysis 4 CONV. MODULAR CONVENTIONAL MODULAR INTERNAL RATE OFRETURN(IRR),UNLEVERAGED MODULAR CONVENTONAL Internal Rate ofReturn MODULAR CONVENTONAL 5 5.15% 6.10% 5 5.15% 6.10% 8.94% 10 8.94% 10 15 15.03% 15 15.03% 20 20

UNION NON-UNION for how debtimpactsthe cashflow (includinginterest anddebtpayments). lending environment (asifitwere acashdeal),whereas leveraged IRRaccounts competing investments. Unleveraged IRRassesses aproject independentofthe money, whichthereby provides theinvestor abenchmarkby whichitcanevaluate valuable metricbecauseittakes into account allcashflows andthetime value of both negative andpositive) from aproject orinvestment equalzero. AnIRRisa An IRRistheinterest rate at whichthenetpresent value ofall thecashflows CONV. MODULAR CONVENTIONAL MODULAR INTERNAL RATE OFRETURN(IRR),LEVERAGED

UNION NON-UNION MODULAR CONVENTIONAL 4.24% 5 MODULAR CONVENTIONAL 6.45% 4.24% 5 6.45% 10 10 13.34% 15 13.34% 15 20 20 25 26.16% 25 26.16% 30

Hickok Cole Architects, Abigail R. Brown, 2014 30 UNION NON-UNION

UNION NON-UNION Project Return Analysis 5 STANDARDIZED YIELDONCOST, UNLEVERAGED CONVENTIONAL MODULAR CONVENTIONAL MODULAR MODULAR CONVENTONAL Standardized Yield onCost 2 MODULAR CONVENTONAL 2 4 4 0 6 0 6.67% 6 6.72% 7.11% 6.67% 6.72% 8 7.11% 8.14% 8 8.14% 10 10

UNION NON-UNION payments). cost accounts for how debtimpactsthecashflow (includinginterest anddebt of thelendingenvironment (asifitwere acashdeal),whereas leveraged yieldon of development cost. Unleveraged yieldoncost assesses a project independent income expected to begenerated from adevelopment property asapercentage The yieldoncost isameasure ofcashflow return that measures thenetoperating STANDARDIZED YIELDONCOST, LEVERAGED CONVENTIONAL MODULAR CONVENTIONAL MODULAR

UNION NON-UNION 1 MODULAR CONVENTIONAL 1 MODULAR CONVENTIONAL 2 1 2 3 1 3 4

4 5 5 6 6.15% 6.22% 6 6.59% 7 6.15% 6.22% 6.59% 7.51% 7 8

Hickok Cole Architects, Abigail R. Brown, 2014 7.51% 8 Modular inDC? and sothefuture ofmodularinthenation’s capitalisrichwithpotential. modular construction isincreasing inothermajorcitiesaround thecountry, terraces andaccess to individualexterior space for renters. The useof unit designmay reveal interesting new unittypesbasedaround increased module onafacade. Inaddition,studying thepotential opportunitiesfor a worthwhile endeavor to demonstrate thepossibilities ofexpressing the developing theJengamassing studies found inthisdocumentwould be clients andthepublicaboutmodularconstruction anditsbenefits.Further use ofwell designed,highqualityprecedents isimportant,aseducating opportunities andincreased construction qualitythat modularallows. The that architects canhelpsolve by showing clientstheuniquearchitectural negative market perception ofmodularconstruction. This isachallenge A majorchallengeintheWashington, DC,market iscombatting the be abetter opportunity. presence inothernearby citieswithstrong unions,suchasBaltimore, may comparison undertaken through this iLab suggests that increasing modular’s and theproject must bebuiltwithunionlabor. The speculative project a high-risethat would conventionally bebuiltwithcast-in-place concrete, this writing,theanswer isonlyundercertain conditions. The project must So doesitmake senseto usemodularinWashington, DC?At thetimeof 1 Moving Forward Manufacturing Unions Time Money Efficiency Expression Quality Perception Factory Fabrication Future? Competition

Hickok Cole Architects, Abigail R. Brown, 2014 Challenges Advantages 1 5 14 13 12 1 6 5 4 3 2 1 Reduces site constraints suchasstaging, weather, andsecurity Reduces site environmental impactsdueto reduced material waste, pollution,dust, andnoise Better construction sequencingandfewer conflicts increw scheduling Alters traditional design/documentation process andfinancing structure Must recognize thenature ofmodularbuildings andtheirconstraints duringthedesign process Cost savings isnotasbig inWashington, DC,asinothermajorcitiesdueto lower laborrates Negative market perception that modularconstruction ischeap, ugly, andofinferior quality Increased riskfor first project due to uncertainty by lenders Controlled factory conditions increase thepredictability ofquality, cost, andtime Potential reduction intotal project cost whenbuiltwithunionlabor;more accurate cost estimating Up to 50%reduction inproject scheduledelivers product to market faster

Hickok Cole Architects, Abigail R. Brown, 2014 Resources & Credits 4

Hickok Cole Architects, Abigail R. Brown, 2014 Architecture Center, Washington, DC.19July2014. Gurney, Robert. “25Architects: ModularHomes”Presentation. District 2014. P302). The Steel Construction Institute, 2001. Web. Accessed 18June Light Steel Framing: DesignofResidential Buildings(SCIPublication Gorgolwski, MT, Grubb, PJ, andLawson RM.ModularConstruction using Accessed 07 April2014. Kullman BuildingsCorporation Architects, andGarrison 2008.Web. JamesandTweedie,Garrison, Aaron. ModularArchitecture Manual. Accessed 17June2014. Development. Thesis. Massachusetts Insitute ofTechnology, 2007. Web. Benefits andLimitations ofModular Construction Methods for Multi-family Cameron, P. andDiCarlo, N.PiecingTogether Modular:Understanding the Presentation. Hickok Cole Architects, Washington, DC.27 March 2014. Brough, Denise. DeLuxe BuildingSystems. “ModularConstruction” Construction. Web. Accessed 12August 2014. Productivity intheConstruction .” 2011. McGraw Hill Bernstein, Harvey M,ed.“Prefabrication andModularization: Increasing University ofWashington. Web. Accessed 17June2014. Constraints andOpportunities.PNCCRE Technical Report #TR002. 2013. Azari, Rahman.ModularPrefabricated Residential Construction: Bibliography Hoboken: JohnWiley &Sons,,2011. Smith, R.E.Prefab Architecture: AGuideto ModularDesignandConstruction. Polytechnic Institute andState University. 2012. Web. Accessed 17June2014. Barriers to DesignInnovation for ModularConstruction. Thesis. Virginia Schoenborn, J. ACaseStudy Approach to IdentifyingtheConstraints and Steel Construction Insitute, 1999. Web. Accessed 18June2014. using LightSteel Framing: AnArchitect’s Guide(SCO Publication P272). Lawon, RM,Grubb, PJ, Prewer, J, andTrebilcock, PJ. ModularConstruction 19 June2014. Building Rating System.” 2009. ModularBuildingInstitute. Web. Accessed Kobet, Robert J. “ModularBuildingandtheUSGBC’s LEEDVersion 3.0 2009 McGraw Hill,2004. Methodologies are Poised to Transform theBuilding Industry. New York: Kieran, S.andTimberlake, J. Refabricating Architecture: How Manufacturing Print. Hawthrone, Christopher. “Prefab Grows Up.” Architect February 2014: 64-69. The

Hickok Cole Architects, Abigail R. Brown, 2014 construction.” Page 23. chartcomparisonGantt between construction schedulesfor modularandin-situ Kullman BuildingsCorporation Architects, andGarrison 2008.“Figure 1.7.1: 2014. Accessed 19June2014. Accessed 19June2014. Architecture Center, Washington, DC.19July2014. One inBethesda,MD. “25Architects: ModularHomes”Presentation. District Presentation. Hickok Cole Architects, Washington, DC.27 March 2014. membership rates by state, 2013 annualaverages.” Web. 29Oct2014. Members-2013. 24 Jan2014. Bureau ofLaborStatistics. “Chart1:Union 2014. 4. 3. 2. 1. Illustration Credits 13. 12. 11. 10. 9. 8. 7. 6. 5.

Garrison, JamesandTweedie,Garrison, Aaron. ModularArchitecture Manual. Gluck+. The Stack. 2014. Web. Accessed 04February 2014. McCarthy, Peter. “ModularArchitecture withJengablocks.” 12September Perkins, Devon. “DeLuxe BuildingSystems factory tour.” 13June2014. Garrison Architects.Garrison NYC Emergency HousingPrototype. 2014. Web. Architects.Garrison NYC Parks BeachRestoration Modules.2013. Web. Robert M.Gurney, FAIA. Sketches andphotographs ofBMModular Brough, Denise. DeLuxe Building Systems. “ModularConstruction” U.S. DepartmentofLabor. New Release USDL-14-0095: Union Perkins, Devon. “Gypsum board installation.” 13 June2014. Perkins, Devon. “Metalfabrication.” 13June2014. Perkins, Devon. “Materials andworkstations.” 13June2014. Perkins, Devon. “Workers usepermanentwalkways andtie-offs.” 13June October 2014. October 2014. October 2014. October 2014. 2014. Accessed 30 October 2014. October 2014. of BritishColumbia Pharmaceutical Sciences Building.2012. Web. Accessed 30 2014. Accessed 03 August 2014. 28. 27. 26. 25. 24. 23. 22. 21. 20. 19. 18. 17. 16. 15. 14.

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Hickok Cole Architects, Abigail R. Brown, 2014 Residential Buildings (SCIPublication P302). Page 37. compartment wall.” ModularConstruction usingLightSteel Framing: Designof Steel Construction Institute, 2001. Web. Accessed 18June2014. Light Steel Framing: DesignofResidential Buildings(SCIPublication P302). Manual. Page 39. Architecture Manual.Page 39. Systems.” 13June2014. Presentation. Hickok Cole Architects, Washington, DC.27 March 2014. Harriet Street. 2014. Web. Accessed 06June2014. Architecture Center, Washington, DC.19July2014. in Bethesda,MD. “25Architects: ModularHomes”Presentation. District Web. Accessed 31October 2014. Typical separating wall inamodularbuilding.” Page 36. 39. 38. 37. 36. 35. 34. 33. 32. 31. 30. 29. Illustration Credits Architecture Manual.Page 39.

“Figure 2.4.6:Typical plandetail.” ModularArchitecture Manual. Page 41. “Figure 3.5:Compartment floor at junctionwtih external wall and Gorgolwski, MT, Grubb, P J, andLawson RM.ModularConstruction using “Figure 2.4.4:Cross sectionshowing clearspan.” ModularArchitecture “Figure 2.4.2:Longitudinal sectionshowing clearspan.” Modular “Figure 2.4.1: Longitudinal sectionshowing typicalopening.” Perkins, Devon. “Steel modulesunderconstruction at DeLuxe Building DeLuxe BuildingSystems. Steel framing system. “Modular Construction” Panoramic Interests andZETA Design+Build.Fabrication ofmodulefor 38 Robert M.Gurney, FAIA. Installation ofmoduleat BMModularOne Adrian Smith+Gordon GillArchitecture. ChengduGreat CityMaster Plan.

“Figure 3.8: Modular The Accessed 02 February 2014. Page 45. Accessed 19 June2014. Washington Business Journal.21July2014. Web. Accessed 10August 2014. in Caldwell, NJ. 31May 2006. Page 43. 56. 55. 54. 53. 52. 51. 50. 49. 48. 47. 46. 45. 44. 43. 42. 41. 40.

Ewing, James.Michael MaltzanArchitecture. Star Apartments.2013. Web. “Figure 2.4.12: Perimeter basementfoundation.” ModularArchitecture Manual. “Figure 2.4.11: Pilotifoundation.” ModularArchitecture Manual.Page 45. “Figure 2.4.10: Foundation detail.” ModularArchitecture Manual. Page 45. Perkins, Devon. “Temporary weatherproofing.” 13June2014. Architects.Garrison NYC Emergency HousingPrototype. 2014. Web. Perkins, Devon. “Temporary weatherproofing installation.” 13June2014. Perkins, Devon. “Millwork construction.” 13June2014. Perkins, Devon. “DeLuxe BuildingSystems assembly line.” 13June2014. Perkins, Devon. “Concrete padsready for installation.” 13June2014. Perkins, Devon. “Metalfabrication plant.” 13June2014. Perkins, Devon. “DeLuxe BuildingSystems factory.” 13June2014. Lawton, Joanne. “Brookland’s ShippingContainer Apartments.” The Travis Price Architects. SeaUA. 2014. Web. Accessed 10August 2014. DeLuxe BuildingSystems. Typical ApartmentFloorPlansfor Caldwell College “Figure 2.4.8:Typical Mate-line sectiondetail.” ModularArchitecture Manual. “Figure 2.4.7: Typical sectiondetail.” ModularArchitecture Manual.Page 412.

Hickok Cole Architects, Abigail R. Brown, 2014 Architecture Manual.Page 68. Accessed 03 August 2014. Page 66. Light Steel Framing: DesignofResidential Buildings(SCIPublication P302). 68. 68. at 38HarrietStreet. 2014. Web. Accessed 18June2014. 2014. Construction” Presentation. Hickok Cole Architects, Washington, DC.27 March construction.” ModularArchitecture Manual.Page 65. 69. 68. 67. 66. 65. 64. 63. 62. 61. 60. 59. 58. 57. Illustration Credits Architecture Manual.Page 60. Publication P302). Page 75. Construction usingLightSteel Framing: DesignofResidential Buildings(SCI

Interface Studio Architects. The Modules at TempleTown. 2010. Web. “Figure 4.21:Flat roof detailwithparapet.” ModularConstruction using “Figure 2.4.9: Roof Types.” ModularArchitecture Manual. Page 44. “Figure 3.2.15: Fastening ofmodules.” ModularArchitecture Manual.Page “Figure 3.2.14: Stacking ofmodules.” ModularArchitecture Manual. Page “Figure 3.2.12: Settingpinidentification, undersideofmodule.” “Figure 3.2.11: Settingpinsection.” ModularArchitecture Manual.Page 68. “Figure 3.2.12: Blindrivet section.” ModularArchitecture Manual.Page 68. Panoramic Interests andZETA Design+Build.Installation ofmodularunits DeLuxe BuildingSystems. Installation ofmodularunits.“Modular “Figure 3.2.1: Craning site plan:PiersonCollege, New Haven, CT.” Modular “Figure 5.3:Various methodsofliftingmodularunits.” Modular “Figure 3.2.7: 75 ton luffingjib crane, commonlyusedinmodular Modular

2014. Web. Accessed 06June2014. Accessed 19June2014. Washington, DC.19July2014. MD. “25Architects: ModularHomes”Presentation. District Architecture Center, Page 67. using LightSteel Framing: DesignofResidential Buildings(SCIPublication P302). Page 46. Modular Architecture Manual.Page 47. Presentation. Hickok Cole Architects, Washington, DC.27 March 2014. Construction” Presentation. Hickok Cole Architects, Washington, DC.27 March 2014. June 2014. 80. 79. 78. 77. 76. 75. 74. 73. 72. 71. 70.

Panoramic Interests andZETA Design+Build. Unitinterior of38HarrietStreet. Architects.Garrison NYC Emergency HousingPrototype interior. 2014. Web. Robert M.Gurney, FAIA. Photographs ofBM ModularOneinBethesda, “Figure 4.22:Typical service ductinamodularhotel.” ModularConstruction Perkins, Devon. “Service shaft.” 13June2014. “Figure 2.4.13: Possible elevator configuration. ModularArchitecture Manual. “Figure 2.4.14: Possible stair configuration (facing wall removed for clarity). DeLuxe BuildingSystems. Stair modules.“ModularConstruction” DeLuxe BuildingSystems. Installation ofmodularunits.“Modular SHoP Architects. Atlantic Yards B2Tower. Web. Accessed 03 August 2014. Architects.Garrison Lehman ChildCare Center. 2013. Web. Accessed 19

Hickok Cole Architects, Abigail R. Brown, 2014 Robert M.Gurney, FAIA Saul Zapata, SeniorTechnical Designer Page Fran Doherty, Assistant Relationship Manager US BankCommercial Chris Furlong,Associate CityInterests Steven Phillips,Vice President -Estimating James Davis, President Davis Construction Denise Brough, Director ofBusiness Development DeLuxe BuildingSystems colleagues whoparticipated intheJengaarchitecture happy hour. McDermott, Katie Klos, Matt Starr, Fanny Gonzalez, and allofmy Afshar, Kate Maxwell, LuciaTang, JohnLang,Walter Ploskon, Charu Perkins, ElbaMorales, Jessica Sticklor-Lipson, Erika Miller, Mercedes Mike Hickok, Yolanda Cole, JohnBisch,MarkRamirez, Devon Hickok Cole Architects Acknowledgments

Hickok Cole Architects, Abigail R. Brown, 2014