modular building case study

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Modular Building Case Study

Each case study starts with an introduction, designed to help introduce the concept of the

case study and encourage students to start to explore more about the project.

There then follows a Topic Lesson Plan. Each Topic Lesson Plan introduces the topic

within the concept of the case study and includes 3 or 4 activities that are designed to

support the teaching the learning of the topic to your students.

The Modular Building case study covers the following topics from the Core Component:

Construction Maths and Science

Design

Law

CBE Industry Relationship Management / Commercial Business

Project Management

Additional topics from the Core Component are embedded within the Topic Lesson Plan.

These embedded topics are:

Health and Safety

Sustainability

Measurement

Information and Data

Building Technology

Digital Technology

The case study and associated Topic Lesson Plans should be used in conjunction with the

following documents:

Modular Building Introduction PowerPoint

Modular Building Industry Links

Links to Assessment

Modular Building: Case Study

Introduce the Case Study

The UK National Housing Federation statistics suggest that today 8.4 million people are

living in unaffordable, insecure or unsuitable homes. In the UK there is a clear demand

for affordable, quality home to serve various sectors of society.

When we think of homes, we typically think of a brick built semi-detached houses, with

a slate roof, and front and rear garden.

But what if things were different?

What if you could order your new home like a car? Such as choosing the layout of the

interior to suit your needs, and ordering fixtures and fittings ahead of time so all your

requirements are in place and everything is ready for you to open your front door and

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move straight in.

Well…with a modular home, this might just be a reality.

In this case study you will learn all about modular homes. You will have the

opportunity to plan a modular housing development and to design the layout of your

own modular home.

You will learn how to brand and market your home using social media and consider

how to protect your intellectual property embodied in the design. So you will be

marketing you own modular home product. You will acquire knowledge of materials to

finish the external façade of your home to create a stunning exterior.

You will then discover the pre-fabrication process to manufacture your home in a

factory, before determining what type of crane should be used to install it upon a

prepared foundation.

To achieve this, it is intended that you will work sequentially through a series of topics

and activities with your tutor. Each topic will broaden your knowledge and

understanding and is designed to build upon what you have previously learned.

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Modular Building: Topic Lesson Plan

Topic: Design

Designing a modular house

Aim and

objective The aim of this topic is for students to learn about designing a

modular home.

The objective of this topic is for students to sketch and prepare

2D/3D drawings depicting modular housing concepts, to meet the

functional requirements of different sectors of their local community.

Students will consider the buildability of the scheme; particularly the

influence modularisation has on the provision of accommodation

within a housing unit and the benefits/disbenefits of adopting a

modularised construction approach on the life cycle assessment of a

unit.

Tutors should allocate their students with a familiar local site, upon

which they can plan for the placement of modular housing scheme

for the local community. Students will consider the planning factors

influencing the placement of the modular housing scheme on their

given site and explore the planning legislation and regulations

governing obtaining permission

How long will

this Topic take

to deliver?

The total time that it might take to deliver this topic is 15 hours.

What

knowledge and

understanding

will students

develop?

This topic has been designed to deliver the following knowledge and

understanding from the Core Component content:

8.2.2 – Students will acquire a knowledge of building with

modular systems considering for instance the integration of

services and shortened construction timescales.

8.3.1 – Students will gain an understanding of the functional

factors influencing the design of modular buildings such as

spatial requirements, aesthetics and selection of materials.

8.3.3 and 14.2.3 – Students will consider the planning factors

influencing the construction of modular housing schemes for

a given site and will be introduced to planning legislation and

regulations.

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8.4.1 – Students will learn about the benefits and disbenefits

that modularisation brings to the life cycle assessment of

housing.

8.5.1 – Students will be encouraged to prepare manual

concept sketches for modular buildings and to formalise these

into 2D and 3D CAD drawings following industry accepted

drawing conventions.

Self-study

activities

Students could use chapters 21 to 23 on the ergonomics of housing

in the ‘Metric Handbook Planning and Design Data’ 6th Edition

edited by Pamela Buxton, to determine the key living requirements

for different demographics of homeowner.

Students could also design their own modular home using the

online tool available at:

https://www.housebyurbansplash.co.uk/configurator/

Activity 1

Title Design the layout of a modular home

How long will

this activity

take to deliver?

It is anticipated that this activity will take 8 hours.

Instructions Tutor Instructions

In this activity your students will prepare hand concept sketches

for modular buildings, and then formalise them into 2D and 3D

CAD drawings, following industry accepted drawing conventions.

First your students should research the demographics of an area

where a module housing scheme is to be constructed. Students can

review the UK Office for National Statistics Data – Towns and Cities

Analysis to assess the target market sector for modular housing in

their area.

Once the students have determined the different type of users

likely to purchase from the scheme, they can progress to consider

their needs. Students should be encouraged to explore the spatial

requirements for each user, and to think about how these might be

dealt with flexibly in a modular system. Students will need to

determine a suitable set volume of space for a modular unit and

how that volume of space can be easily changed to suit different

users. Students should be encouraged to research different existing

modular schemes to gain ideas. Students should produce a mood

https://www.housebyurbansplash.co.uk/configurator/

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board of images and hand-sketches (or use Sketchit) to capture

these ideas and to develop the concepts for their modular housing

units.

Once concepts for the module housing have been developed,

students should produce elevations, plans, sections and isometric

drawings of a housing unit following standard construction drawing

conventions; this could be done in AutoCAD.

Student Instructions

You have been asked to develop a design for a new modular

housing unit to be installed on the site located at [XXX insert site

location XXX]. You are to:

(a) Research the demographics of the surrounding neighbourhood

to the site, to establish who is likely to want to purchase or rent

a modular home. You should present your conclusion in a

demand statement clearly identifying a final target market

sector for the scheme.

(b) For the established target market sector prepare a matrix of

the accommodation needs of a typical modular home resident.

(c) For the identified target market sector prepare a mood board

of concept design ideas (images and hand sketches) for a

modular housing unit to accommodate the needs of the typical

resident. You should consider:

(i) the overall size of the modular unit or units,

(ii) the internal layout and finishes,

(iii) how separate units might be arranged to form the final

home

(iv) the external aesthetics

(v) choice of materials

(d) Consider your mood board and prepare a statement justifying a

final design selection for a modular home for your typical

resident.

(e) Prepare elevations, plan, sections and an isometric drawing of

your final modular design using a computer-aided design

package. Your drawings should be prepared to a scale and be

complete with a drawing title frame.

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Worksheets /

templates

2D and 3D drawing frame template

Demand Statement Template

English, maths

and digital

skills

There will be an opportunity for students to practice:

M5 Processing data

D1 Use digital technology and media effectively.

Industry Links To support this activity the following Industry Resources Links

could be used:

Town and Cities Analysis

Metric Handbook

Choose how much space you need

Drawing convention

SketchUP

AutoCAD

Construction and Design Manual – Container and Modular

Buildings

Activity 2

Title Building for whole life cycle of a home

How long will

this activity

take to deliver?



Your students will consider the buildability of a modularised home

system. They will also be introduced to the concept of a building’s

life cycle and determine the benefits/disbenefits of adopting a

modularised construction approach for the life cycle assessment of

a unit.

Your students should watch the documentary ‘Modular construction

in building’. You should encourage them to research different

types of modular construction e.g. volumetric modules, panel

systems, pods or hybrid systems. Students should review the

website of different manufacturers of modular systems. The article

‘Construction Methods: Modular’ contains a list of volumetric

manufacturers which you may find useful.

You will then brief students on building life cycle assessment. For

the different stages of a building life cycle students will then

consider the benefits/disbenefits of adopting a modularised

construction approach.

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You have been asked to prepare a construct report to explain the

implications of building using a modular system. Within the report

you are to:

(a) Research and explain three different types of modular

construction, explaining how these are manufactured and

installed on site. For each type of modular system, you should

comment on what site preparation work is required and how

essentials services are integrated e.g. plumbing for bathrooms.

(b) Prepare a flow chart illustrating the different stages of a

building’s life cycle. Annotate each stage of the life cycle flow

chart to explain the benefits/disbenefits of adopting a

modularised housing system.

Worksheets /

templates

Construction Report Template

English, maths

and digital

skills


E3 Create texts for different purposes and audiences

D2 Design, create and edit documents and digital media


could be used:


Buildings

Modular constructing in building

Life cycle assessment

Activity 3

Title Planning a modular housing development scheme.

How long will

this activity

take to deliver?



You should identify a local, site familiar to the students, to

accommodate a proposed new modular housing scheme. The site

selected should have sufficient scope to present the students with

at least four planning constraints such as:

a. access to natural light and/or light pollution

b. highway access

c. flood risk

d. contaminated land

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e. mature trees

f. conservation area

g. area of outstanding natural beauty

h. listed building

i. flora and fauna

The students should be given a scale plan of the site and

photographs of the surrounding area. If possible, the students

should visit the site to get a richer appreciation of the potential

planning issues that might arise.

Instruct the students to consider the planning factors influencing

the placement of the modular housing scheme on the site, and to

explore the planning legislation and regulations governing

obtaining permission. In order to do this, you should encourage

your students to review the planning authority’s local plan for site

and to review the planning portal to determine the planning

process.


You have been asked to assess the suitability of the site located at

[XXX insert site location XXX] to be used for a modular housing

scheme. You are to:

(a) Research the existing planning zoning for the site as set out in

the local plan and explain what implications this will have on

obtaining planning for the new scheme.

(b) Prepare a matrix of the site-specific planning factors which are

likely to impaction upon obtaining permission.

(c) Produce a flow chart of the key stages in the planning process

required for the scheme.

You should present your findings in a short feasibility report.

Worksheets /

templates

Planning feasibility report template.

English, maths

and digital

skills


E1: Convey technical information to different audience

E5: Synthesise information

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D1: Use digital technology and media effectively


could be used:

Local Plan

Planning Application Process

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Topic: Construction Maths and Science

Installing a modular home

Aim and

objective

In this topic students will be introduced to the maths and science

embedded within the context of constructing a modular home.

Students will learn about the properties of materials that can be

used to clad the modular building and protect it from

environmental conditions.

Student will then focus on how to install a volumetric modular

home into position onto a concrete base. Students will calculate the

total load generated by the modular home and then select an

appropriate crane to lift the home into position. To select a crane

the learners will need to use trigonometric techniques.

How long will

this Topic take

to deliver

The total time that it might take to deliver this topic section is 10

hours.

What

knowledge,

understanding

and skills will

students

develop?

This topic has been designed to deliver the following knowledge

and understanding from the Core Component content:

2.1.1 – Students will gain an understanding of the materials

that can be used for the cladding or skin of a modular

building and how these can be protected from the effects of


2.3.1 – Students will acquire an understanding of the

structural science of how loads and forces act on buildings.

7.1.3 – Students will use trigonometric techniques correctly

to solve construction problems.

Self-study

activities

Students could watch the vlog, entitled ‘Moving Houses with a

Crane’ and record the key stages of the lift, along with any issues

presented in the video.

Activity 1:

Title Protecting a modular home from the environment

How long will

this activity

take to deliver?



In this activity you will support students to gain an understanding

of the material that can be used for the cladding of a modular

building and how these serve to protect the building from

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It is intended that students will learn firstly about the

environmental conditions that are likely to affect the outer skin of a

modular home. You might approach this by providing metrological

conditions for a given site, such as rainfall and temperature and

ask the students to consider what this will mean for the outer

fabric of the building. Through this process students will be made

aware of processes like moisture movement, freeze-thaw and

thermal ageing.

Once familiar with these processes you should work with students

to understand the properties of different cladding materials. These

materials might include, timber, slate, concrete or composite metal

profile cladding. Material properties should embrace the content of

the syllabus, and include mass, workability, resistance to

moisture/vapour penetration etc.

Once familiar with the material properties and potential

environmental effects students’ will justify a selection for the

cladding of their modular building.

Student Instruction

You have been asked to propose a cladding material for your new

modular housing unit to be installed on the site located at [XXX

insert site location XXX]. You are to prepare a material

specification for the cladding which:

Defines the likely environmental conditions your modular

home will experience on the site located at [XXX insert site

location XXX]

Make a recommendation for a suitable cladding material

justifying your selection by considering the benefits and

disbenefits of the materials in comparison with other

available options

Worksheets /

templates

Material specification template

English, maths

and digital

skills


E3 Create texts for different purposes and audiences

E4 Summarising information/ideas

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could be used:

Materials for Architects and Builders

Activity 2:

Title Installing a modular home

How long will

this activity

take to deliver?



In this activity your students will calculate the weight of a modular

housing unit and then select a suitable crane to lift the unit onto its

foundations.

To start this exercise, you will need to provide the students with a

list of densities for standard materials used in modular construction

such as timber and plasterboard. Students will use these densities

in conjunction with the drawings of their modular home (developed

previously for Activity 2 of the Design Topic) to calculate the

weight of the modular unit. Weight in newtons is density,

multiplied by both volume and gravity.

Once the weight of the unit is established the students, should

revisit the site plan for the proposed scheme issued previously for

the Design Topic. On the site plan you should indicate a proposed

position for the crane, and this should require the students to lift

the modular building over the top of an existing structure. Lifting

capacities for cranes vary with distance, angle and how far the

crane’s outriggers are extended.

You should support your students to determine the space for

outriggers, the distance from the centre pin of the crane to the

centre of the load, and to then use trigonometry to find the angle

of lift. Your students should then use the crane lifting capacity

tables to determine a suitable crane to make the lift.

Student Instruction

You have been asked by a member of the project team to complete

some calculations to determine the required capacity of a crane to

position your modular home onto its foundations. The position of

the crane and the location of the modular home’s foundation plinth

are shown on the plan provided by your tutor. You have also been

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given a list of material densities and some crane lifting capacity

tables. For your modular home design, you are to:

(a) Calculate the total weight of your home.

(b) Determine the height and angle of crane lift required.

(c) Justify a suitable crane to complete the lift.

Worksheets /

templates

List of material densities

Site plan showing location of crane and the foundation plinth for

the modular home.

English, maths

and digital

skills


M2 Estimating, calculating and error spotting

M5 Processing data

M6 Understanding data and risk

M7 Interpreting and representing with mathematical

diagrams


could be used:

Crane lifting capacities tables

How to read a crane load chart

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Topic: Law

Legal compliance

Aim and

objective

The aim of this topic is to introduce students to important legal

compliance issues governing the design and marketing of their

modular home.

Students will learn about the key contents of Building Regulations

2010, and the process of obtaining Building Regulation approval.

Students will understand that it is a requirement to obtain a

completion certificate confirming that their modular home complies

with Building Regulations before any sales can be processed.

They will also consider how they can protect the intellectual

property they have invested in the design of their modular home.

How long will

this Topic take

to deliver


hours.

What

knowledge,

understanding

and skills will

students

develop?



14.6 – Students will gain and understanding of the

implication of the building regulations, and of breaches or

failure to comply with building regulations for the

construction project and key stakeholders.

14.7 – Students will acquire an understanding of the

importance, implications and ways of protecting intellectual

property rights.

Self-study

activities

Students could review the ‘Building Regulations Planning Portal’ to

determine what happens if you fail to comply with Building

Regulations.

Activity 1

Title Managing Legal Compliance

How long will

this activity

take to deliver?



You will introduce students to the key contents of Building

Regulations 2010, covering the main areas that the regulations

seek to control including structural stability, fire, sound insulation,

materials, toxic substances, ventilation, sanitation, and drainage.

You will support the students to understand the process of

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obtaining Building Regulation approval, particularly the

requirement to obtain a completion certificate for a modular home

prior to sale. You will then introduce the students to the concept of

intellectual property and how they can use intellectual property

laws to protect the design of their modular home. As part of this

you will introduce the student to the concepts of trademarks and

patents.

Student Instruction

You have been asked to provide a guidance document to be used

by the project team on achieving legal compliance for your modular

home. You are to:

(a) Provide a guide to the key areas controlled by the Building

Regulations 2020.

(b) Prepare an annotate flow chart detailing the principle stages in

the process of obtaining Building Regulation Approval.

(c) Explain if your modular home is considered a ‘product’ and how

might intellectual property laws be applied?

Worksheets /

templates

Not required for this activity.

English, maths

and digital

skills


E1 – Convey technical information to different audiences

D1 – Design, create and edit documents and digital media.


could be used:

Building Regulations Planning Portal

Building Regulations 2010

The Building Regulations: Explained and Illustrated

Building Regulations Pocket Book

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Topic: CBE Industry, Relationship Management, Commercial Business

Procurement routes for modular housing and selling the end product.

Aim / objective The aim of this topic is to introduce students to the unique

procurement routes for modular homes within construction.

The objective is that students will focus upon the supply chain to

gain an understanding of how factory-based manufacturing and

prefabrication techniques used in modular housing influence logistic

activities.

You should introduce students to BIM to enable them to acquire an

appreciation of how integrating computer systems into the supply

chain is leading to potential efficiencies in terms of time, cost and

quality.

Students will be encouraged to consider how a finished modular

home can be sold using social media and advertisement.

Students will be asked to consider the unique selling point and

vision for their modular scheme.

How long will

this Topic take

to deliver?


hours.

What

knowledge,

understanding

and skills will

students

develop?



9.3.1 - Students will gain an understanding of the logistical

activities in the construction supply change and the process

of monitoring and controlling inventory.

9.3.2 – Student will acquire an appreciation of how

integrating computer systems into the construction supply

chain is changing procurement methods and leading to

potential efficiencies.

11.12.1 – Students will consider how products and services

can be promoted through social media and advertisements.

12.5.1 – Students will learn how to exploit a product or

service and the importance of having a vision.

Self-study

activities

Activity 1

Title Procurement routes for a modular home

How long will

this activity


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take to deliver?


Using the Industry Resource Links provided you will support

students to acquire an understanding of the different stages of

production of a volumetric modular home within a controlled

factory environment. Students will consider how materials are

handled and stored, and how the final modular home is

transported.

You will introduce students to the concept of ‘just-in-time supply’

and ‘Kanban systems’ in prefabrication. Once the students have

acquired an understanding of the fabrication process for modular

homes you will discuss with them how computer systems can be

integrated into the process to increase efficiency.

The students should acquire as a minimum, an understanding of

BIM and the use of common data and communication standards

such as COBIE.

Student Instruction

You have been asked to provide a presentation to new members of

the project team to explain the off-site factory manufacturing

process for your new modular home. Within the presentation you

are to:

(a) Prepare a flow chart illustrating the key stages of off-site

production.

(b) Explain the principles of ‘Just-in-time supply’ and the Kanban

systems in prefabrication.

(c) Outline how computer systems can integrated into the

manufacturing process. You should comment particularly on the

impact of BIM and COBIE in the modular home construction

process.

Worksheets /

templates

PowerPoint slides template.

English, maths

and digital

skills


E2 Present information and ideas.

D1 Use digital technology and media effectively.

D3 Communicate and collaborate.

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could be used:


Buildings

Modular Home Factory Tour

Kanban Production

Kanban Production System Basis

What is BIM?

What is COBIE?

Activity 2

Title Marketing modular homes

How long will

this activity

take to deliver?



This activity builds upon work undertaken in the Design Topic.

There is no need to go into great depth in this topic (and tutors

may decide to leave Marketing and Branding out all together), but

it is a useful way to illustrate some of the commercial

considerations and decisions that housebuilders encounter.

You will support your students to develop a marketing strategy for

their modular home solution using social media, for the target

market sector identified previously.

You will teach your students how to undertake a SWOT analysis to

define the unique selling points for their modular home concept,

and to identify how they might reach the market for the new

modular homes using different types of social media e.g. Facebook,

Instagram, Twitter, YouTube, Pinterest etc.

You will then introduce them to the concept of brand, the purpose

of vision statements in a marketing strategy, and also the key

constituents of an advertisement.


You have been asked to contribute to a plan to market the modular

housing scheme you previously designed. You are to:

(a) Complete a SWOT (Strength, Weakness, Opportunities,

Threats) analysis of your modular home concept to identify the

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unique selling points. As part of this SWOT analysis you will

consider the marketing opportunities presented by different

social media routes and any threats to successful marketing.

(b) Prepare an advertisement suitable for use on Facebook for your

modular home concept. Students may wish to create a brand

logo for their concept.

Worksheets /

templates

SWOT Analysis Template

English, maths

and digital

skills


E1 – Present information and ideas

E3 – Create texts for different purposes and audiences

E5 – Synthesise information

D2 – Design, create and edit documents and digital media


could be used:

Ted-Talks on Marketing

Seth Godin’s Blog

Creating a Social Media Marketing Strategy in 8 Easy Steps

Designing Brand Identity

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Topic: Project Management

Meeting the Project Team

Aim / objective The aim of this topic is to introduce the students to some basic

principles of project management.

Students will gain an understanding of the organisational structure

of a construction project team delivering modular homes.

Students will learn about the roles fulfilled by different team

members, before going on to prepare a project programme to plan

the delivery of a modular home scheme.

How long will

this Topic take

to deliver


hours.

What

knowledge,

understanding

and skills will

students

develop?



13.1.1 – Students will gain an understanding of the

common roles and responsibilities of stakeholders, project

teams and the project manager.

13.3.2 – Students will acquire the ability to interpret and

produce project management tool and documents.

Self-study

activities

Students could undertake an online introductory course in project

management (refer to Industry Resource Links).

Activity 1:

Title Planning the project

How long will

this activity

take to deliver?



You should introduce the students to the key roles and

responsibilities within a construction project team.

You will then support them to understand the key steps in

preparing a project programme for a modular home scheme. This

will involve the students preparing a Gantt chart, breaking the

work into different task and allocating resources.

You will need to give the students a list of resources and the

duration of activities.


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You have been asked to support the project management of the

production of the modular home, by preparing key planning

documents. You are to:

(a) Prepare an organisational organigram defining the key

members of the project team. You should annotate with

each project team member’s responsibilities.

(b) Using the resource and construction time data provided by

your tutor, you should prepare in the format of a Gantt

chart a programme for the production and installation of

your modular home.

Worksheets /

templates

Gantt chart template

Project team organigram template.

Construction activity timing and resource data to support

preparation of Gantt Chart.

English, maths

and digital

skills


E5 – Synthesise information

M10 – Optimising work processes

D3 – Communicate and collaborate.


could be used:

Introduction to Construction Project Management

modular building case study

Documents