Modular Construction, or Prefabricated Prefinished Volumetric Construction (PPVC) describes a construction method whereby free-standing self contained volumetric modules complete with finishes for walls, floors and ceilings are manufactured in a suitable off-site manufacturing facility and then installed on site in a pre-determined pattern (often stacked to multiple levels) to form the completed structure.
To raise construction productivity, reduce the overall need for labour, reduce cost and improve timelines the industry is encouraged to embrace the concept of Design for Manufacturing and Assembly (DfMA). The design and construction process is revised such that as much work as possible on repeated sub-assemblies may be done off-site in a controlled manufacturing environment.
PPVC is one of the game changing technologies that support the DfMA concept to significantly speed up construction. It can potentially achieve a productivity improvement of up to 50% in terms of manpower and time savings, depending on the complexity of the projects. Furthermore, dust and noise pollution can be minimised as more activities are done off-site. With the bulk of the installation activities and manpower moved off-site to a factory controlled environment, site safety will also improve.
Modular Systems provide solutions to a number of construction sectors and have the capability to achieve up to 23 stories. The system can accommodate most schemes including; hotel, student, care home and residential projects. End benefits include factory quality internal finishing, speed of erection, cost and programme certainty.
The lightweight structure allows savings through reduced foundation requirements and often negates the need for in-situ floor slabs.
Windows, doors, mechanical and electrical, decoration, carpets, fixed furniture, and en-suite toilet fit-out are all completed within the factory. Modular rooms have total flexibility for external façade treatment and can also accommodate all forms of roof construction. The systems standard wall and ceiling build-ups should offer a minimum 90 minute fire resistance with U-values and acoustic performance assistance and also achieve a 120 minute fire rating when required.
A fully integrated PPVC sub-contractor should also be capable of providing stair cores, linen rooms, plant rooms, floor and ceiling corridor cassettes.