Building Knowledge:

Research Highlights

Modular and Prefabricated Housing

Ideas, Innovations, and Considerations to Improve Affordability, Efficiency,
and Quality
Background can be ambiguous whether site labour or the plant is
responsible for making the repairs; and
Modular and prefabricated units are built on an assembly
line in a plant and transported to the construction site. „„ Modular units using standard designs may not work
Prefab or modular building systems can have advantages in all climates and mistakes in the design can be
over traditional on-site construction: repeated on the fast moving assembly line.

„„ Site work can happen at the same time as units

are being built in the plant;

„„ Units can be built when weather does not allow

outdoor construction;

„„ Efficiencies and manufacturing principles

realized on the assembly line can result in savings;
and

„„ Because units are built indoors and closely

supervised they can be of higher quality.

However, there are also a variety of potential challenges

The Real Estate Institute of BC, the Manufactured Housing
with modular and prefabricated construction:
Association of BC and BC Housing with funding from the
„„ Modular units and prefabricated systems may Real Estate Foundation of BC wished to identify ideas,
have to travel long distances to the site, which can practices, and innovations to overcome these challenges
be costly or lead to damage; and help maximize the potential benefits of modular
and prefabricated construction for housing. This report
„„ Modular and prefabricated units are typically lifted examines eight research questions:
off the truck and on to the foundation with a crane,
which can be expensive; 1. Unit design and construction: What are practices
in the modular and prefabricated design and
„„ On-site integration of units, systems or pods can be a construction process to improve the time efficiencies
challenge, and there can be scope gaps; and cost effectiveness?
„„ If units or systems get damaged on route or 2. Materials: What are the materials that can improve
deficiencies are noticed once the unit is on-site, it affordability, sustainability and performance?

3. Transportation: What are options for transporting

modular and prefabricated housing units to
development sites to ensure the process is as time
efficient and cost effective as possible? Page 1
4. Housing Form: What types of modular and Unit Design and Construction
prefabricated buildings are proving affordable,
efficient and durable? What innovations are being „„ Project integration techniques such as use of BIM
made? and inclusion of the on-site construction team in
pre-planning stages can help prevent mistakes or
5. On-site: What are the options for on-site integration integration issues;
of modular and prefabricated housing units at
development sites to ensure the process is as time „„ Efficiencies may be realized on the assembly line
efficient and cost effective as possible? through practices such as automation, twinning
production lines, running 24 hour shifts, building
6. Emergency Lodging: What are lessons learned modules from the inside out, and automating parts of
around using modular and prefabricated construction the assembly line; and
for temporary housing for those displaced during a
natural disaster? „„ Tools that increased the chances of success on a
modular or manufactured project – particularly
7. BC Climatic Appropriateness: Are the best practices larger, more complex projects, include: Modular
identified through this study appropriate for BC’s Test Fit (MTF), Building Information Modeling (BIM),
climate and landscape? Computer Aided Design and Manufacturing (CAD-
CAM), and Computer Numerical Control (CNC) in
8. Sustainability: What are best practices to maximize
manufacturing. These are part of the integrated
the environmental sustainability of modular and
design and project delivery processes (IDP, IPD).
prefabricated housing units during the construction
phase and in terms of energy consumption once the Materials
units are occupied?
„„ Composite wood materials (engineered and
This report provides an overview of what was identified manufactured wood-based products such as
in the literature. The report is only meant to provide a engineered joists, beams, and wall and floor system)
summary of the literature. It is important to note that can offer increased strength, as well as faster building
each project is unique and options covered in this report times and lower carbon emissions;
will not work in all situations.
„„ Despite being combustible, heavy timber and
This information may be helpful to the residential panelized wood products can be designed to have
modular and prefab construction industry as it provides good fire performance, due to the char layer that
a scan of emerging ideas and some best practices. This forms to protect remaining wood from fire;
report can also be used by housing organizations who are
„„ Panelized building systems can lead to faster
considering the use of modular and prefab construction
construction time, increased thermal and structural
as background reading to inform discussions with
performance and lowered labour costs; however,
designers, site construction workers, and modular or
some panels may have challenges around increased
prefabrication plants.
capital costs, sound performance, off-gassing, the
Examples of ideas and practices to maximize the need for specialized trades, and special procedures to
potential benefits of modular construction and prefab, as ensure joints are sealed appropriately;
well as address some of the challenges include:

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„„ Using the structural properties of mass timber „„ Space saving structures such as prefab panels,
systems can provide reliable, affordable, high stackable or folding modules, can be more efficient to
performance buildings on an accelerated schedule transport by truck.
and have potential for mid- and high-rise;
Housing Form
„„ Laminated veneer lumber (LVL) can be used in wood
„„ Modular units can be combined side-by-side or
curtain wall instead of the conventional mullions,
top and bottom to create larger or more units or to
reducing the environmental footprint of the building
extend existing buildings;
and supporting local economies;
„„ In taller, steel-framed modular projects, after roughly
„„ Steel framed modules can provide increased
ten floors of modular, there is a need for a concrete
durability and have been used in recent projects with
or steel core to act as structural support against
non-standard modules (i.e. all modules were not
wind, seismic and other loads. In taller mass timber
identical);
projects, structural support cores (housing utilities,
„„ Agricultural and landscaping materials, such as elevator and stairs) can be created with hybrid
modular green roofs and green wall panels, are being systems including wood, steel and concrete, or
used to offer lower greenhouse gas emissions and concrete and steel; and
improved indoor air quality;
„„ Modular and prefabricated construction has been
„„ Recycled-content and reused materials are being used for six-storey and high rise multi-unit buildings,
used in modular and prefab products to increase its dormitories or work camps, micro units, and flex
sustainability; challenges include off-gassing and housing.
ensuring materials are non-toxic;
On-site Assembly
„„ New materials are emerging that meet rigorous
„„ 3D designs and pilot modules can help ensure
health, sustainability and durability standards such as
alignment of mechanical, plumbing, electrical
BuiltGreen, LEED and the Living Building Challenge;
connections between modules; and
and
„„ Documenting covered connections through digital
„„ Shipping containers have been used as student
pictures or bar code scans can help inspectors find
residences, offices, hotels, malls, affordable housing,
hidden elements and on-site labour do connections
shelters, and emergency lodging.
without damage to the unit.
Transportation
„„ Air bag lift systems can be used where CSA Z-240.10.1
foundations are approved in the place of expensive
cranes;

„„ Barges can be used to transport multiple units at a

time to coastal areas, to save time and money; and

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Emergency Lodging „„ Temporary shelter is ideally built of durable materials
and built to meet code requirements so that it can
„„ Lightweight yet sturdy materials mean cranes may offer an option for permanent housing.
not be necessary;
BC Climatic Appropriateness
„„ Foldable, stackable, or panelized units can be stored
for immediate use after disaster and can be reused „„ Multiple new innovative materials and systems such
(following other disasters) if properly stored; as panelized wall and floor systems, heat recovery
systems, in-floor heating, and high performing
„„ Hinged walls and simple locking systems allow for windows and doors for all climates provide a wide
fast assembly without skilled labour; variety of choices of high performance modular and
„„ Units should have hook ups that are compatible with prefab buildings for all BC climates.
transportable electrical/mechanical units;
Sustainability: Not Just Efficiency
„„ If units are not in storage, pre-existing agreements
with private manufactures to prioritize emergency „„ Sustainable modular and prefabricated buildings
lodging units can speed delivery after disaster; can include solar ready, Passive House designs,
built-in renewable energy, socially and ecologically
„„ Built in solar hot water or solar electrical panels can
sustainable materials, water harvesting and water
offer affordable, on-site services;
reuse such as embedded rainwater harvesting,
„„ Walls should be built with thermal materials to greywater and water reuse systems as well as built-in
protect residents from extreme weather, as there will composting toilets, innovative energy systems and
likely be little opportunity to install insulation once super insulated envelopes.
on-site;
On the next page is a summary of some ideas, practices,
„„ Moveable partitions as walls allow floor plans and innovations referenced in this report, which
to be repurposed depending on the household potentially address challenges and maximize benefits of
composition of displaced residents or other space modular construction. Beside each idea, practice, and
needs at the site; innovation is an icon or icons to suggest how the idea,
practice, or innovation might help optimize modular
„„ Using some modular units to create common indoor construction (e.g. improve affordability, timelines or
space (e.g. for day care, classrooms, or recreational efficiency, sustainability, or quality). The legend in the
areas) in transitional housing can help create a sense centre of the graphic below defines each icon. This
of community; graphic is not a comprehensive overview, but rather just
„„ Pre-testing unit designs before a disaster strikes can suggestions about how the idea, practice, or innovation
help ensure units are comfortable; might contribute to optimizing modular construction.

„„ If permanent housing construction takes longer than The full report, which includes literature review and environmental scan
anticipated, units can be adjustable so that they can sources, can be found at:
be connected through exterior openings to create
BC Housing
larger units; and Manufactured Housing Association of B.C.
Real Estate Institute of B.C.

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LLL Transportation
Materials
Construction

HH H HH
structures

BIM H Barges

H HH
HH containers H
H Durability
H HHH

Housing On-site
L
LL Assembly

HHHH Affordability H

H Efficiency Barcodes

HH Sustainability H
Buildings

H Quality H

LL L
Appropriateness Sustainability Lodging

H HH
H H

HH3 Solar-ready H
H agreements

HH H HH3H
systems harvesting HH

HH
H design H

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This report is intended to provide readers with general information only. Issues
and opportunities related to modular, prefabricated, and manufactured housing
and construction are complex. Readers are urged not to rely simply on this report
and to consult with appropriate reputable professionals and specialists where
appropriate before taking any specific action. The authors, contributors, funders,
and publishers assume no liability for the accuracy of the statements made or for
any damage, loss, injury or expense that may be incurred or suffered as a result
of the use of or reliance on the contents of this report. The views expressed do
not necessarily represent those of individual contributors, BC Housing, BC Real
Estate Institute, Manufactured Housing Association of BC, and the Real Estate
Foundation of BC.

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