The University of Wolverhampton in England is making architectural history this month, as student residents move into Victoria Hall, a 25-story complex that entered the record books as the tallest modular building ever constructed. (At right is an artist’s rendering.)

Only the ground floor of the building is site built, with the other 24 floors being comprised of 383 individual modules built in Cork, Ireland. Each module weighs 21 to 29 tons and includes a steel frame designed to support the weight of the modules above it.

So, why did they choose modular construction over traditional methods? We’re glad you asked.

It seems Wolverhampton found itself in a predicament faced by many colleges and universities when its student population began to grow faster than the campus’s living quarters could support. In short, Wolverhampton needed dorms and needed them fast.

Enter modular construction.

The Victoria Hall project, which actually consists of three buildings, took just nine months to build. According to architect Gary West, using traditional methods, the project would have taken at least 24 months to complete.

Each student suite is comprised of multiple modules, which are pre-fitted with plumbing, fixtures, finishes, cabinets, and furnishings prior to being shipped. A glimpse of the suites can be seen on the right. Overall, the project is yet another example of the near limitless potential of modular construction.

Like we talked about previously on Modular Musings (here and here), there are many reasons why a modular home can be built faster than a stick-built home of similar design. Among those reasons is the efficiency of the factory construction process and the fact that while the modules are being built, the foundation and other site preparations can take place simultaneously.

This time savings becomes clear in a pie chart on the Modular Today website. As you can see on the right, the design phase of both modular and traditional homes takes the same amount of time, but the site prep time for the modular home has been combined with the construction time. Though it may be hard to tell, the construction time in the top chart is also slightly less than the bottom due to the efficiency of the modular construction process.

All of this adds up to the ability to build a modular home in 25 percent less time than a stick-built home.

We talk a lot about the factory process of building modular homes, and for good reason – it’s a huge part of what sets modular construction apart from other construction methods. But exactly are the benefits of building indoors? We’ll let Excel’s Liverpool, PA plant GM Harry Odum answer that one:

“Think about your job – whatever it may be – and ask yourself: Would you rather do it outdoors in 10 degree weather in January or during a rainy April or would you rather do it in a controlled environment indoors? And in which environment would you work more efficiently and produce higher quality work? Of course, I don’t have to be a mind reader to guess that most of you would rather work indoors.

“The same is true for building homes. Modular homes are built indoors, which not only makes for happier workers, but it also creates better homes. Here are a few of the many benefits of building under a roof:

• Eliminating weather from the construction equation means no weather delays. This means your home will be completed quicker. No delays also helps to reduce workforce costs.

• Keeping things dry also means no materials are lost to weather damage (another cost saving benefit) and greatly reduces the likelihood of mold developing in the cracks and crevices of your home during the construction process.

• A house built outdoors is susceptible to infestation by termites and other creepy crawlies. This isn’t the case with homes built in a modular plant. (I hate bugs with a passion. Always have, always will.)

• Working indoors allows Excel Homes to create an assembly line process in which all of our tools and supplies are readily available and always in peak working condition. This creates a more efficient working environment, resulting in faster construction times and a higher quality finished product.

• In the standard construction process, when the crew goes home at night, the job site is at risk for theft and vandalism. Obviously, this isn’t the case with modular homes. And, of course, eliminating theft and vandalism is yet another cost saving benefit.

• Finally, working indoors creates happier, contented workers, which means higher quality work.  

“In the end, all of these factors of the modular construction equation add up to one thing: A stronger, higher quality home for the homeowner. And no matter where you work for a living, I’m pretty sure we can all agree that’s the biggest benefit of all.”