Process

A tight and detailed design process will give you the finished results you want and ensure that you reap the most benefits from our construction methods.

Our aim is that the finished building should look exactly as shown on the original architect’s drawing. Anyone viewing the building, externally or internally, should not be able to tell it is a volumetric construction.

Our team of architects, quantity surveyors, design engineers, and MEP consultants will refine your brief and design all projects to BIM Level 2.

We can work from your own design or start from scratch. With either approach, we will design the optimal solution for your needs.

Good design is cost-effective. We will consider the many ways money can be saved, without compromising aesthetics or structural integrity.

Early certification for statutory approvals is a standard part of our process. So, the earlier you engage with our structural design team, the greater the opportunity to achieve a rapid return on your investment.

Our galvanised, lightweight steel frames are manufactured from sheet steel using conventional cold or hot rolled extrusion methods, to form the structural module profile.

The structural steel frame for each building comprises vertical steel hollow-section columns, welded to horizontal hollow-section members, by ‘coded’ welders. Each weld is independently MPI tested and each module certified, prior to progressing to the next stage of production.

Intermediate floor and ceiling beams are incorporated to prevent distortion across members. L-plates are welded to the members and columns at various points to provide a fixing for floor, wall and roof systems.

Our bespoke design system allows modules to be built to most shapes and sizes, only limited by transportation restrictions.

The frame is tailored to the ideal height and span, as dictated by the design. The structural steel frame section dimensions will vary depending on the structural engineer’s calculations.

For the construction of the modules, a massive 85% of the work is finished in the secure environment of our factory. This lends to reduced manufacturing time while keeping a high precision product.

All that is left for the site works is joining the modules together and completing the fit out.

The fit out of the building elements takes place in a clean, controlled assembly-line environment, manned by skilled operatives who are supported by quality control and technical guidance personnel. This allows easy and accurate assembly combined with reduced manufacturing time.

By assembling volumetric modules in our precision-controlled factory environment, using production line techniques, we increase the speed of delivery and quality of product.

The extent of the internal fit out varies from project to project. In some cases, we simply supply the shell.

Where an internal fit out is required, modules are pre-fitted with electrics, plumbing, heating, doors, windows and internal finishes.

The automated production lines transfer the modules through the manufacturing process where all internal finishes, M&E installations, windows, external insulation and some external finishes are applied. They are commissioned prior to leaving the factory, our quality control ensuring that defects are minimised.

Although module design can be restricted by transportation dimension limits and shipping distances, modules are easily transported to virtually any site conditions.

The modules are “shrink-wrapped”, to prevent damage caused by exposure to the elements. They are loaded onto a flat-bed articulated lorry or trailer (other vehicles are available on request).

Our qualified specialists ensure the buildings are level, locked and safely loaded onto the lorries using cranes and winches. The modules are then transported to the specified building location.

The units are carefully craned into position on prepared foundations. The modules are unloaded by the crane operator’s qualified slinger-signallers, supervised by a dedicated lift supervisor.

Our patented connector system is a vital advantage in our construction method. Cast steel connection plates are used to join modules. The plates feature domed “nodules” which locate into vertical columns of the structural steel frame. They incorporate a hole, in which a high yield steel threaded rod is slotted. Depending on the connection requirements, connector plates are manufactured, with either one, two, three or four nodules, the number reflecting the amount of modules to be joined on a given level. Each nodule element is able to withstand a design shear load of 230kN.

Modules are connected both horizontally and vertically by the connector system. The modules are tied down and laterally restrained, to form a composite building mass. The modules are usually then installed from the inside of the building using a scissor lift or cherry picker platform.

The skilled install teams work to exacting tolerances and quality control procedures (all connection details are inspected and recorded), as required for modular multi-storey buildings. The building acts as a post-tensioned building. The connector system provides holding down, lateral restraint, moment connections and progressive collapse capabilities.
Finally, the building has external cladding and roofing treatments attached, which can be easily changed in the future.