Offsite construction tends to produce more consistent quality through every stage in the production process. This is because offsite construction utilizes manufacturing techniques, building the same elements out of the same material uniformly.
The manufacturing environment typically employs systematic quality programs. It’s the uniformity of each piece created in a controlled environment that allows offsite construction to have more consistent quality, both throughout multiple stages in one project and across multiple projects.
Due to the consistent crew and the controlled workflow, offsite location projects tend to be completed on a shorter construction schedule. The controlled environment helps eliminate setbacks that put traditional construction projects behind schedule, such as bad weather days. Modular construction results in buildings opening 30% to 50% sooner than onsite construction.
According to the U.S. Labor Department Bureau of Labor Statistics, there are statistically less fatal injuries in manufacturing than in traditional onsite construction.
Although modular construction projects don’t always cost less than traditional construction, they often have a more predictable cost. The manufacturing environment oftentimes leads to less time wasted and less materials wasted, which reduces overall cost.
Since offsite construction removes the bulk of the physical project to a separate location away from the final site, work can be completed at both sites simultaneously. While the modules are being manufactured offsite, site prep can take place, saving a significant amount of time for the overall project.
Using manufacturing techniques such as implementing standardized measurements or elements for multiple projects helps to reduce material waste overall. A significant amount of the construction takes place in a controlled offsite location, therefore the scrap materials of one project can be used for another instead of discarded. Additionally, the final site of the project doesn’t have to be disturbed to the same extent as a traditionally built structure, helping to maintain the surrounding environment.
Stage 1: Pre-Design
Legality, financing, insurance, and project element ownership are established in the pre-design phase.
Stage 1
Stage 2: Design
The design phase includes correspondence between the architect and the modular manufacturer.
Stage 2
Stage 3: Post-Design
The post-design phase includes material procurement, and manufacturing team coordination as the project moves to the building phase. Then the teams work through the fabrication process, delivery, and assembly.
Stage 3
Modular Stadium Construction
An example of a modularly built stadium, made entirely from repurposed shipping containers, was completed by Falcon Structures using 122 container modules. Fortress Obetz located in Obetz, Ohio, is the largest shipping container building in the U.S. to date. Each container was prepared offsite at Falcon’s facility and shipped to its current location to be installed in a total of only 10 working days over a few months.
Commercial Modular Buildings
Many multi-level buildings, like apartments, are being built using modular construction. A current trend uses shipping containers that are modified individually offsite, then stacked together after delivery.
Modular Stadium Construction
An example of a modularly built stadium, made entirely from repurposed shipping containers, was completed by Falcon Structures using 122 container modules. Fortress Obetz located in Obetz, Ohio, is the largest shipping container building in the U.S. to date. Each container was prepared offsite at Falcon’s facility and shipped to its current location to be installed in a total of only 10 working days over a few months.
Modular Office Buildings
Office buildings built following modular construction practices can be either single-unit or multi-unit structures. These single-unit structures can be as small as a 10-foot shipping container or they can be as large as a multi-story building – which can, in fact, remain relocatable. Shipping container modular elements can be pulled apart, loaded onto a truck, and shipped to a new location with less hassle than moving a traditional building.
Government Modular Buildings
An example of a multi-unit living space was built by Falcon Structures for the Department of Homeland Security, which needed mobile workforce housing that could be relocated along the U.S. border. Not only did the structure need to be mobile, but it also needed to be secure, so repurposed shipping containers became the clear choice for this project.
Three 20-foot shipping containers were pieced together to make space for a bunkhouse for six workers and a restroom, kitchen, and living room. A custom chassis was built to hold the containers in anticipation of their frequent relocation.
Military
Falcon Structures has built several military MOUT facilities (military operations in urban terrain) to help soldiers train for urban warfare. One of the MOUT structures included over 700 shipping containers. The use of shipping containers allows frequent reconfiguration of the facility, allowing the soldiers to train in environments that keep them on their toes.
Internally, the shipping containers were built out with moveable walls and doorways, and externally the containers were finished with a realistic façade resembling the cities they would be likely to see in combat.
Storage
Single-unit storage structures are ideal when space is limited or where space does not exist, like in an open field. Shipping container storage units bring storage to a new level of security and accessibility.
The boxes can come in a variety of sizes, 10-foot, 20-foot, or 40-foot and they can be modified with a personnel door for easy access or the cargo doors can remain operable to make storing large items easier.
Need something beyond just a standard shipping container? Modify the unit with insulation, air conditioning, and internal and external lights to create exactly what you’re looking for.
Equipment Enclosures
Repurposed shipping containers make great equipment enclosures for a variety of reasons. Most often, an equipment enclosure houses sensitive and valuable industrial equipment that needs to be kept cool and secure.
Examples of these types of enclosures range between server rooms, prefab uninterruptible power supplies (UPS) enclosures, audio equipment enclosures, remote terminal units (RTUs), and so many more.
These enclosures must be durable, portable, secure, and modifiable, so they can keep equipment safe in harsh climates, against thieves, or with frequent relocation. Additionally, many insulation and air conditioning options are available, which keeps equipment at the desired temperature.
