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Frequently asked questions

What are the benefits of modular construction compared to stick building on site?

Improved quality – Integrated design reduces re-work. The factory is climate-controlled and quality control checks are more frequent. Modules are strengthened to withstand transport and craning.
Increased schedule certainty – Weather delays are virtually eliminated. Modules are mass produced allowing for high accuracy, and integrated design reduces change orders.
Improved cost predictability – Economies of scale reduce variability, increasing schedule certainty and quality. Quicker build times means lower land holding costs and exposure to inflation.
Reduced waste generated by construction – Optimized material usage means 50% less waste and up to 50% lower CO2 emissions. Optimal storage increases material performance.
Improved safety performance – Permanent safety systems at the factory are superior to temporary on-site systems. Streamlined process reduces injury risk. Up to 80% lower reported accidents.
Increased customer satisfaction – Cost savings, schedule and budget certainty, improved quality, quicker build times, and less disruption to the surrounding community.

How much time does modular construction save?

Site work and module construction can take place simultaneously, shortening the construction schedule by up to 50%. Assembly line production is much more efficient than traditional on site production.

How does the cost per square foot of a modular building compare to a traditional building?

Overall, the completed costs are similar, but there are many other benefits of a modular building that can affect your bottom line, including:

Fixed time and price (no change orders, less variations in costs).
Indoor building improves quality, leading to fewer future warranty costs.
Development projects are completed in roughly half the time, so there are substantial savings in construction financing.
Residents will move in sooner, so you can meet your members’ needs much faster. Project revenue is also collected much quicker.

How do market fluctuations impact building materials on modular projects?

Because we’re dealing with a large manufacturing facility, a lot of time and effort is put into the most efficient design and procurement of materials many months in advance of the actual build. There is a lot of planning that has to happen to keep the facility running at an optimal and efficient pace. Material shortages and delays can have an impact on a project, similar to all construction, however, planning that far in advance means the impacts are minimal to negligible. There are few emergency situations and no short term impacts. Read about how value engineering protected our clients during the lumber price boom.

How does building like this impact the neighboring community?

Modular builds minimize disruptions throughout the construction process. Because much of the work is done in a factory off-site, construction materials and supply deliveries are reduced by up to 70% and overall build time is reduced by up to 50% compared to traditional stick building methods. Craning day can cause a disruption to the neighbourhood, with no parking on the street and having to temporarily block the street while the modules arrive, but Big Block makes sure the nearby residents are well-informed and aware of the process. (Read more about craning day.) Thankfully, these disruptions are only for a number of hours for each building instead of a continuous disruption throughout a longer duration of the project found with most traditional methods of construction. Once the modules are in place, the site construction is completed in a much shorter timeframe which neighboring residents are very grateful for.

Can you do Net Zero with modular construction?

Yes, and in fact, it’s more beneficial to use modular construction when designing to achieve Net Zero because it’s more cost-effective, and there are built-in inspections and testing required in the factory setting that make it easier to implement the more stringent Net Zero requirements.

Can all designs be built using modular construction techniques?

Yes. Anything can be built using a superior building method like modular construction, however it’s important to collaborate with designers and owners very early on to ensure modular is the right choice. Just because you can build everything modular doesn’t mean you should. You need expert advice to determine when it makes sense to stick with a traditional method of construction, and when modular construction is the better choice.

How large are these units?

A typical module ranges between about 800-1,500 square feet. Because the modules are being shipped, smaller modules are not as efficient, so when designing a modular building, we work with our partners to determine the minimum number of the maximum size of modules needed for the design. The maximum size is determined by a number of factors including the shipping restrictions in the province or municipality where the project is being built. We can transport a module up to 72 feet long, and the width can vary depending on the location of the final destination — on the prairies, the modules can easily be 18-22 feet wide, while in the mountains, they can generally only be 14-16 feet wide. Height requirements are also based on transport restrictions, however overall height can generally be 11-13 feet tall.

Is it possible to do pitched or vaulted roofs with modular construction?

Yes, you only need to be mindful of height restrictions when shipping. As long as you can meet those criteria, any unique ceiling features can be designed and incorporated in the build.

How long does it take to build these units in the factory from start to finish?

It typically takes anywhere from six to eight weeks to complete one module from start to finish. The size of the factory determines how many modules are being built at any one time, however typical factories may have 20-30 modules in production at various stages. The modules are built at stations (for example, a framing station, a plumbing and electrical station, drywall station, etc.) and moved from one station to the next similar to a vehicle assembly line. Each module spends between 10 to 15 hours at each station before being moved to the next. The time at each station depends on the number of staff, automation and complexity of the production at that given station.

What is the soundproofing performance?

The module units are all built with four walls, one floor and one ceiling. When two modules are side by side, there are two completed walls separating them. These two walls include framing, insulation and drywall. When two modules are located top to bottom, there is a full ceiling joist and a full floor joist system separating them. These two systems include framing, insulation, drywall and flooring. The double wall construction creates an opportunity for superior sound deadening. Similar to other national building code requirements, it's very important to collaborate with professionals to determine both the sound ratings and fire ratings for all wall assemblies. Whether the building is constructed using a modular built method or stick build method, the sound rating will be determined based on the specifications needed from the customer as long as they meet or exceed building code requirements. Due to the nature of a double wall, the ability to increase the sound performance with modular construction is much easier and more cost effective than stick construction.

How many different trades are needed after you crane to complete the building?

It depends on the amount of stick built construction used in the project. Once the modules are in place, if there are still parts that are completely built using traditional stick frame methods, you may require all the typical trades. When the construction is built using the modular method, typically 75% of the trades are not required on site and those that are required have a much smaller workload.

How is the top of each module protected against water damage?

We have developed a waterproofing technique using an EPDM rubber membrane to ensure there is no water penetration at any point, from the time it leaves the factory to the time the module is in place.

What’s the timeline from when you crane to completion?

Because the interiors of the modules are completely finished with painted walls, flooring and appliances by the time they arrive on-site, construction can be completed within a few weeks after craning. Read more about craning day.

How long do the module units sit on site before they get craned in place?

Units are delivered to a staging site over the course of a few weeks and then moved to the building location the day of the craning. Depending on the amount of modules and transport vehicles, all modules could also be directly shipped to site and craned that same day. Read more about craning day.

Are there any restrictions on road access?

We work closely with shippers to understand the regulations. Every city is slightly different. We take a collaborative approach to design, and take all aspects of the project into account from the beginning. We also consider timing — you typically will not transport modules during times of increased traffic.

A benefit of modular builds is that there are much fewer disruptions in the community; instead of hundreds and hundreds of trucks coming to the site during a longer construction period, there are only a few dozen trucks coming to site over a few days of disruption as the modules are brought to the site.

A misconception about modules is that they move slowly down the highway; that’s not true! The loads are moved at highway speeds, with pilot trucks ahead and behind to warn people of the oversized load.

How do the boxes fit together?

The boxes fit together using structural connections. We secure every box to it’s adjoining boxes and the foundation to ensure the entire building is structurally secured. We work closely with professional architects and engineers to ensure that all structural connections meet and exceed the local building code requirements.

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