How Modular Architecture is Shaping the Future of Design

For any discussion about the future of design – modular architecture is now part of that conversation.

Trends in the field point to it as well. Back in 2015, the Modular Building Institute notes that modular construction constituted 2.9% of all construction while expecting it to grow to 5% in 2020.

As it turns out, modular buildings now make up more than 6% of new construction in the United States. With a market now expected to grow from $89.18 billion in 2022 to $95.59 billion in 2023, modular construction is in demand because it’s become more cost effective, efficient, and flexible in design.

Modular design’s history can be traced back thousands of years to the ancient Romans who created prefabricated sections of their forts that could be assembled on-site for quick defense. And modular configurations have been commercially available since the early 20th century.

The difference in today’s approach to modularity is advances in technology. From enhanced building materials and greater precision in manufacturing, to the logistics behind transporting building components, the entire process is now done with greater quality and efficiency. The result is a modern architecture approach that’s often more innovative in design and efficient in completion than today’s traditional methods.

In this piece, we’re taking a closer look at the practice of modular design and exploring its details and advantages, as well as implications for the future of the built environment. Feel free to read on or skip ahead:

• What is Modular Architecture?
• Benefits (and Challenges) of Modular Architecture
• What Makes a Project a Good Fit?
• A Modular Approach to Residential Homes
• Modular Architecture for Commercial Buildings
• Modular Architecture for Healthcare Facilities
• A Creative Architecture Approach

What is Modular Architecture?

Modular architecture’s definition is rooted in the term ‘module’: where prefabricated units of a structure are assembled in configurations designed to meet different sizes, complexities, or functions.

Modular Versus Prefabricated

The relationship between modular construction and other types of prefabricated approaches like panelized construction is similar to the relationship between 3D and 2D design. While modules are three-dimensional units comprised of several prefabricated pieces, panels are individual flat pieces assembled on-site. So, one could think of modular construction as a specific application of prefabrication where floors, walls, and roofs are integrated into larger units, often comprising one or more rooms.

Simply put, prefab deals with the manufacturing of the individual units (walls, floors, and other elements) with assembly of entire spaces happening later at the construction site.

Benefits (and Challenges) of Modular Architecture

With a number of factors driving added attention to modular architecture – the rapidly growing need for adequate, affordable housing significantly among them – there are numerous benefits being found by both designers, builders, and the community who eventually uses the final product.

Of course, with the benefits of any approach also come challenges. Below we’ll take a closer look at both in some key areas.

Quality Control
A modular approach to design and building allows for greater control of the overall quality of a structure. With units prefabricated in a factory setting as opposed to being subject to field conditions (i.e., short building windows in colder, wetter seasons, etc.), there’s less degradation of materials.

Also, because modular construction is simplified to an assembly process, reliance on different skill levels or unfamiliarity from on-site labor – and quality issues that can arise as a result – are dramatically reduced.

However, since units are prefabricated, often with proprietary materials and methods, if quality issues do arise, they aren’t able to be addressed on-site as easily as with conventional construction.

Constructability
A huge benefit of a modular approach is time. Construction time on a modular structure takes a fraction of the time it takes to build from the ground up. The process is also safer for workers as fewer people are needed for less complicated tasks on a shorter schedule, minimizing site risks.

This benefit can be even greater when used at scale while applying templated configurations across multiple sites, as opposed to a one-off approach for each building.
It’s estimated that modular approaches can reliably save at least 20% in construction costs, including the potential for an estimated $22B in savings annually across U.S. and European markets. This savings makes sense when you consider the reduced construction time that leads to a reduction in overall emissions from heavy equipment.

While site accessibility is a challenge with any project, because modular design involves the use of larger units, this can be a limiting factor for difficult to reach locations.

Repeatability
As mentioned, modular design lends itself to repeatability and scalability. The consistencies gained in minimizing onsite construction issues like weather or access, improve the quality of overall construction while being more insulated from the elements. Using a system of repeated building blocks leaves less room for variation in quality and creates a process that can then be repeated across multiple sites.

Sustainability
Modular design is also better for the planet. The approach bakes in an emphasis on minimizing waste in the construction process because the process is primarily carried out in the controlled environment of a manufacturing facility. The units themselves are also often made using recycled materials. Almost every client values sustainable methods that lessens onsite waste and materials, because less waste not only lowers a project’s overall carbon footprint, it also lower costs associated with disposing and transporting that waste.

Establishing Design Goals for Clients
The benefits of modular design also extend away from the job site. While of course not exclusive to a modular approach, the use of 3D visuals can be particularly useful in facilitating a discussion that requires an extra degree of predefined design decisions with the client.

A discussion including a modular architecture approach can draw out a client’s true goals for the project, like if they want resilient products that are easy to maintain for a buyer that can be weatherproofed during the short build season. Different components of the structure can be modular in an ‘a la carte’ type approach to meet the design, avoiding the challenges that come with limited variety and allowing for design flexibility.

A Modular Design Approach: What Makes a Project a Good Fit?

It’s one thing to consider a modular design approach, but it’s another to decide which projects are most suitable for it. The reality is it’s a different design process from what traditionally takes place and might not always be the right solution depending on the project details.

For one, designers have to think in a more integrated way because the pieces of the puzzle are bigger. Units also must be designed to thorough specifications to make sure everything fits just right when it comes time to build. Architects need to think about how one gets the most customization in the fewest components, while also considering the need for flexibility. Owners also tend to invest more in early phases of the project so the prefab process can begin, meaning decisions need to be made early so that can be conveyed to financiers.

Consideration of a modular approach is best done early in the design process to truly reap the benefits in identifying projects that are a good fit.

An Answer to the Housing Crisis: Modular Residential Home Design

Modular architecture can be especially useful for residential home design. With the growing housing crisis plaguing the United States, it’s estimated that 3.8 million more homes must be built now to keep up with population growth in the future, and modular design lends itself to the need in a unique way.

Given its repeatability, scalability, and time-saving capabilities, modular construction allows for a number of cost-effective solutions to building houses en masse. Rather than a one-off approach with a traditional stick-built home, modular home design delivers a shortened schedule, material cost savings, and a more sustainable project, ultimately getting people into homes – and developers paid – more quickly.

Modular Housing Common Questions

When considering modular architecture for housing projects, there are a few common questions to consider:

Can modular homes be stacked?

Modular homes can be designed as a single standalone structure or multiple story building by stacking them. Bottom line: there are many structural and design possibilities.

Can modular homes be renovated?

Modular homes can be modified and renovated, though much depends on the initial structural integrity and design which may require specialized knowledge and resources.

Can modular homes be built anywhere?

One of their greatest benefits is that modular homes can be placed just about anywhere. There are some constraints since the larger components need to be able to be accessible to a site.

Modular Architecture for Commercial Buildings

Large-scale projects don’t just include housing. While not currently as common, commercial buildings are increasingly being built using a modular approach.

In cases where there is a need for meeting rigorous quality standards (due to regulation or client specifications) a modular approach can help ensure those standards are met. This is especially common in advanced manufacturing and the automotive industry for example. Efficiency with energy, materials and construction timelines are also goals that lend themselves well to a modular approach to commercial facilities.

Modular Architecture as A Growing Application in Healthcare Facilities

Healthcare is another area where modular design is growing in popularity, and the concept is gaining hold for several reasons.

While the priorities of healthcare have evolved over time to place a greater emphasis on patient-centric model that emphasizes convenience and experience, the physical infrastructure for the industry has comparatively lagged. An effort to catch up has turned many to the benefits of modular design for the development of new healthcare facilities.

Modular architecture is helping bridge that gap with healthcare facilities by simplifying coordination and install of multiple, complex infrastructural components that are often needed.

In addition to being more innovative and scalable in design, the cost-efficient nature of a modular approach is especially fitting an industry where creating the convenience for communities of nearby facilities is a priority. Considering the size of these projects, insulation from factors that often cause delays in construction (weather, labor shortage etc.) and other on-site complications is also an important consideration in getting healthcare facilities operational on schedule. These efficiencies also translate to cost savings and a better return on revenue.

Applying Creative Design Approaches to Architecture

Every project is unique and the options for bringing them to completion are numerous. The ability to deliver creative designs that meet a diverse set of client goals and project types is at the heart of our architecture practice. Modular design is just one approach in a world of possibilities to consider.

Take a closer look at our architecture work and learn more about a design-forward mentality that fits into a unique set of multidisciplinary capabilities.