Articles
Building
Ideas Winter 1998
Making the Move to Modular Construction |
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A modular home costs less and takes less time to build,
as these homeowners discovered.
The neighbors were amazed when Wayne and Sherri Neale's new vacation
home rolled up on two flatbed trucks in Rehoboth Beach, Delaware.
The house was prefabricated in a factory in two sections—including
the porch, most of the plumbing, wiring, cabinets, and even the
carpet.
What the Neales bought was a modular home, a realistic option
for many homeowners. "They rolled the two sections of the
house off the truck and put them together in one day," Wayne,
an Alexandria, Virginia, architect says. "The roof comes
on the truck, too, complete with hinges. They flip the roof over
and snap it in place. By sunrise, the house was all there."
The builder and his crew spent six more days hooking up the plumbing
and electricity from the outside and finishing the prefabricated
house. "It's a very synchronized process," Sherri adds.
In the factory, a modular home begins with a complete set of detailed
drawings. Sections move down an assembly line where the floors,
walls, ceiling joists, and rafters are attached. Then the roof
is built. The factory workers also apply finishes to the house,
including paint, cabinets, counters, carpet, and surface flooring
materials, such as wood, tile, or linoleum. The module is then
ready to be shipped. Modules can be built as large as can fit
on a flatbed truck, and any number can be joined together on-site.
Once it's trucked to the site, the home can be completed in a
week to 90 days. When compared to the building time for a site-built
house— from four months to a year or more—you can
see why this method is popular. |


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Modular construction
is less dependent on weather than on-site building methods. If you
want to move in the spring, most of the home's construction can
be done during the winter in the factory and assembled
quickly on-site. In areas of the country fraught with labor shortages
or where the building season is short, choosing a modular home makes
construction less frustrating and time-consuming. "We can
build a high-quality 900-square-foot ranch or a 3,000-square-foot,
two-story home in a short time—that's why these homes are
popular. And we deliver it to the site up to 90 percent complete,"
says John Trant, executive vice president and chief operating officer
of All American Homes, a modular home building company.
Modular homes are built to withstand shipping and are more precise
than site-built homes because they're constructed in factories under
controlled conditions. Because building costs can vary regionally
across the country, modular homes either cost less or are comparable
to similar site-built houses in the area.
Charles Bevier, editor of the industry publication Building
Systems magazine, notes that most modular homes meet or exceed
local and state building codes. In fact, most modular homes routinely
outshine site-built homes in terms of sturdiness and durability.
For example, in contrast to some site-built methods, drywall in
a modular home often is both glued and screwed to the studs; double
and triple headers frame stairways and doors. "In a site-built
home, the roof decking can be as thin as 5/16 of an inch, but in
a modular home, it's at least 3/4-inch," says Don Carlson,
editor and publisher of Automated Builder magazine. "And
it's glue-nailed on, not just nailed on as in site-built homes.
The strongest home we build in the United States is the modular
home." "A
homeowner knows the quality he or she is getting with a modular
home," says Barbara Martin, executive director of the Modular
Building Systems Council of the National Association of Home Builders.
"There are no price overruns because it's all built to specification
in a factory. Once you're quoted a price, that's it."
One drawback to modular homes is the wait—from three to eight
months—until the factory can fit your home into the assembly-line
schedule or while the factory workers get materials for your home.
Yet, Ron Evans, president and chief executive of Nationwide
Homes, another large modular home company, says the wait is
over. In fact, his factories added so much capacity this year that
he guarantees customers a 45-day turnaround from order to delivery
of their home.
Another persistent problem with modulars was their cookie-cutter
look. If you wanted a contemporary-style home, you were out of luck.
Most companies offered traditional looks— ranches, colonials,
and two-stories—but today many offer cutting-edge contemporary
or custom designs. "Most companies have architects on staff
who use computer-aided drafting to quickly assemble a number of
predrawn features, such as doors and cabinets, and help you personalize
your home," Bevier says. Most companies work with local builders
who act as the company's dealer, much like a car firm has local
dealers. A few companies will work directly with a homeowner or
an architect, such as Wayne Neale, who wanted to see his own design
built.
The Neales couldn't be happier with their factory-built home. "Things
are joined properly, and the carpentry is far better than any I've
seen built on-site," Wayne says. "Even the door casings
are joined almost like furniture, extremely tight in the miters."
He adds, "By building a modular home, we got a house where
the quality level of the construction is extremely high. It was
the right choice for us." |
| How
to Pick a Modular Home Company
Trying to find the right modular home company
to build your new house can be confusing. We asked modular home
experts how to choose a good company - one that will provide the
house you want. Here are their suggestions:
- Make sure the company is registered with the Modular Building
Systems Council of the National Association of Home Builders.
Their phone number is (800) 368-5242.
- Contact at least three registered companies that ship to your
area. Look through their brochures. Ask to speak to their local
dealers or builders.
- Meet with the local dealer in person. Make sure the company
can build the type of home you want. Look at the standard plans
offered and ask about making any changes you may require. If
you have a custom design in mind, make sure your plan is suitable
for modular construction.
- Find a builder with experience in building modular homes.
Ask how many modular homes he or she has built. Request references.
Call those homeowners and ask about the experience. For example,
if problems arose, how were they handled? Were the homeowners
satisfied with the overall result?
- Ask if the company has a web site. Visit the site to find
out more about the company and its products.
- Be wary of last-minute changes on a modular home, they can
be extremely expensive.
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