MODULAR MUSINGS: There are single-family homes, and then there’s this home, an 11,120-square-foot-project built to house about 10 people for Boys Hope Girls Hope Baltimore. What are some of the challenges involved when designing a modular home of this size?

STEVEN SAFFELL: Excel Homes is equipped to build homes and structures from a few hundred square feet to 50,000 square feet or more, so the size was not a big deal for us. When we get into larger structures we simply increase the number of boxes to accommodate and size the supporting infrastructure like the foundation, electrical and plumbing to match.

One thing that does require more attention is the structural details. Great care is taken on every home to assure the loads are transferred correctly so the home will last, but with this home it took some extra effort. We worked closely with the architect and several structural engineers to make sure not only the loads of our structure were addressed correctly, but also to make sure the loads of the barrel vault roof that was built on site were addressed correctly when they interacted with our structure. It took a group effort.

MM: Please explain the “hybrid” approach used in this project.

SS: When we say this was a hybrid, we are not talking about electric cars, but it does have some solar technology incorporated into the design. When we say hybrid in this context we are talking about a hybrid of building technologies. In this case, we combine the best of what modular, panelized and stick built had to offer.

The foundation system was built by Superior Walls in an off-site location and brought to the site for fast assembly. This allowed Excel to set the modular portion of the structure within hours, not days or weeks. The modular portion consisted of 11 boxes that made up the outer ring of the structure and completed about 70 percent of the structure. Excel also provided panelized components to complete the floor of the great room and foyer, exterior walls for the two-story entry foyer, walls for the walkout basement and roof decks to complete the flat roof portions.

The barrel vault of the great hall was completed on site using traditional site built methods; but in retrospect, we could have completed that portion in the factory and lifted it into place in four sections like we did the floor deck of the room. Every time we build a project like this that challenges us to push the envelope of what people expect modular to be we find new ideas and are just that much more prepared for future requests.

MM: The interior of this home looks incredible. What was the biggest design challenge with this particular home?

SS: For this home it was the great hall. The architect and design team had a vision of a massive space over 40 feet long, 24 feet wide and two-and-a-half stories tall without any intermediate support columns for the roof. This was to be the center of the home and a major design feature, so we had to get creative.

The solution turned out to be simple and came together really well. The best ideas tend to be that way – simple. What we did was to create an outer wall, like a castle, and then we built and placed floor decks in what would be the center courtyard of the walls. The front of the home we sealed up with two-story panelized walls that closed up like a drawbridge. Finally, we capped the whole thing off with a barrel vault over the center section to create the massive room.

It is a solution we are all very proud of and one I am sure you will see on future designs.

To be continued. Check back on Friday for part two of our interview with Steven Saffell.

You can add the U.S. Navy to the list of people and organizations who have recognized the power and benefit of modular construction.

When the wooden housing units on the U.S. Navy outpost on Andros Island in the Bahamas had deteriorated after three decades of island weather and wear, the Navy decided against stick-built replacements and opted instead for concrete modular houses. The units were created by Royal Concrete Concepts in West Palm Beach, Florida, which specializes in “concrete alternatives to traditional building methods and materials” (although only about 15 percent of its U.S. work is residential).

Although modular construction has been proven to be stronger than stick-built building methods, the Navy’s new concrete modular homes are even stronger, making them much more resistant to hurricanes and coastal weather conditions. Other benefits, according to a Builder magazine article, are the units’ low maintenance and improved energy efficiency.

We talk a lot here on Modular Musings about residential modular projects, which means Excel’s commercial projects often get lost in the single-family shuffle. I guess it’s because houses are something we can all relate to, but we should also start relating to commercial construction because Excel Homes has done a lot of it in the past and will be doing a lot more in the future.

It’s worth mentioning that our commercial work should already be easy for people to relate to because, by definition, our commercial modular projects include townhomes, apartments, college dorms, hotels and other living spaces.

The reason commercial modular construction is on the rise (nationally and here at Excel) is that a lot of the same modular benefits that apply to single-family residential projects also apply to commercial projects. Less material loss and cost overrun mean a savings of 10 to 30 percent over site-built construction. Time is also saved. A skilled staff who knows their jobs and the modular process means fewer construction delays and a faster build overall.

The structure of the modular planning process provides a better indication of costs – and profit – up front, before the project is complete. That removes a lot of the uncertainty from a project which, if you’re a developer, is one of the biggest advantages of them all.

Our first green observation comes from the Earth Advantage Institute, which last month released its list of 10 green trends to watch for in 2010. Below are four trends that caught the attention of Excel’s designers.

• Smart grids and connected homes – In-home displays will show real-time home energy use, both overall and by individual appliance. That’s smart because you can’t fix what you can’t see.
• “Rightsizing” of homes – Smaller homes have become a more attractive option and it looks like that trend will continue into 2010. We predict it will extend well beyond the current year, as it goes hand-in-hand with the green movement, which we all know isn’t going anywhere anytime soon.
• Net zero buildings – These über green houses generate more energy than they use over the course of the year, allowing some homeowners to sell unused energy back to the electric company.
• Financial community buy-in to green building – Lenders and insurers are finally seeing the light when it comes to green construction and will continue offering lower interest rates and more affordable insurance packages to green homeowners. That’s green saving green, which is always a good thing.

Habitat for Humanity of the Chesapeake in Baltimore is using modular homes to fill a vacant lot in East Baltimore. Another perk inner city Habitat chapters are realizing is that modular construction can be used to fill narrow vacant lots quickly and more efficiently than stick-built construction methods.

The excerpt below from the Baltimore Sun summarizes one of the biggest benefits of modular construction: shorter construction schedules.

Habitat expects that all nine houses will be in place by Saturday morning. The painting, landscaping and other finishing work will be done by volunteers over nine days, the last scheduled in October.

Compared to the rowhouse renovations that Habitat typically does in Baltimore, that’s light speed.

Today’s entry on the Excel Drawing Board takes a page out of the Frank Lloyd Wright playbook and his prairie style designs. It’s one of the homes in our Starting Line Up series, a collection of smaller homes with all the style of what is typically found in a larger floor plan designed specifically with the first-time home buyer in mind.

The Excel Drawing Board is a blog showcasing some of Excel’s more forward-thinking designs, which readers are encouraged to comment on. Check out today’s entry for yourself and let us know what you think.

All renderings are for illustration purposes only. See engineering documentation for specific configuration.

Inspired by the prairie style designs of Frank Lloyd Wright, the Prairie View is an open plan with spaces defined by the manipulation of the floor and ceiling rather than walls in most cases. This modern design gives the impression that the lower unit is connected to the upper unit by only a ribbon of glass. When combined with builder constructed leveled decks, the lines between indoors and outside are blurred, creating larger space that makes the home a part of nature. This home is perfect for locations such as waterfront property or sites with grand views.

The Prairie View uses large windows and lots of glass to bring the outdoors inside. Murphy beds and hideaways could sleep six to eight adults comfortably.

SPECIFICATIONS:

SQ FOOTAGE: 945 sq. ft.
# BEDROOMS: 1
# BATHROOMS: 1
SPECIAL FEATURES: Designed to accommodate one to eight adults; modern design with long, low features help it blend with the natural environment, weather-tight set service included in standard cost
MISC: Inspired by the prairie style designs of Frank Lloyd Wright. Home is shipped ENERGY STAR and green ready.

Like it? Don’t like it? Think something should be changed or added?
Please feel free to comment on this design by leaving a comment below.

Thanks, Coach! It’s always nice when people take notice of the things you’re doing to improve your company and your product. And to return the favor, to anyone interested in modular construction we’d recommend adding Coach’s blog to your reading list.

Today’s entry on the Excel Drawing Board is a small bungalow that draws its inspiration from the kit homes of the 1940s. It’s one of the homes in our Starting Line Up series, a collection of smaller homes with all the style of what is typically found in a larger floor plan, designed specifically with the first-time home buyer in mind.

The Excel Drawing Board is a blog showcasing some of Excel’s more forward-thinking designs, which readers are encouraged to comment on. Check out today’s entry for yourself and let us know what you think.

All renderings are for illustration purposes only. See engineering documentation for specific configuration.

The Craftsman Cottage is a reverse two story home with the bedrooms on the first floor and the main living space on the second floor. This promotes privacy, allows for grand views and offers something a little different from other homes at this price point.

The front stairs and kitchen are basked in sunlight from the large palladian style windows. The open floor plan of the second floor allows the space to flex as needed to fit the desires of the homeowner, making this 945 square foot home feel and live larger. With a basic footprint of only 15’-9” by 30’-0” and the second floor living space, this home is ideal for narrow waterfront lots.

The Craftsman Cottage is perfect for a budget-conscious new family and is designed with expansion in mind. As the homeowner needs to expand, so can this home. Pre-designed additions can be added when the home is set or with minimal rework at a later point.

SPECIFICATIONS:

SQ FOOTAGE: 945 sq. ft. (base model)
# BEDROOMS: 2
# BATHROOMS: 1
SPECIAL FEATURES: A reverse two-story plan with pre-designed additions; designed to be simple, green and flexible, weather-tight set service included in standard cost
MISC: Great narrow lot design. Home is shipped ENERGY STAR and green ready.

Like it? Don’t like it? Think something should be changed or added?
Please feel free to comment on this design by leaving a comment below.