Have you ever wondered how modular units come together to become a quality built home? In the next series of blogs, we will be pulling back the curtain, so to speak. We will also educate you on what specifically happens behind the scenes in the building of a modular home. In these posts, we will be taking you through our factory one production stage at a time to discuss the specifics of how a modular home is built.

A modular home is built via what is called a Building System. A “Building System” is simply a systematic approach to constructing homes. Experienced craftsmen build homes inside a modular home production facility. These components are called units, sections or modules. These units later come together at the jobsite to complete a fully functional and beautiful new home. Modular units generally range between 14 and 16 feet in width and can command over 60 feet in length. Please note that widths may vary according to the modular home manufacturer.

We will begin with floors. Floors are built simultaneously with walls and roof systems. Those stages will be discussed in upcoming posts.

Stage Two: Floor

Every stage of the production process is important, but floors are among the first elements constructed in the building of a modular home. Floors are built on what are called jigs or floor tables. Jigs are a stationary piece of equipment that act as a template so that the wood segments conform to the standard floor widths. This ensures that the floor widths are exact and are constructed within measurement tolerances.

Westchester Modular Homes’ floor systems are double banded at the perimeter for extra strength and are constructed with 2 x 10 Floor Joists spaced and fastened 16” on center. Floor decking is comprised of sturdy ¾” tongue and groove plywood glued and fastened to the floor joists. Your manufacturer may have an option for an engineered open joist system that provides superior strength as well as having the ability to install mechanical ducts, pipes and wires without drilling. When the floor is complete, it is swept free of any dust or debris. Then it is readied for the next stage which is wall installation.

Have you ever wondered how modular units all come together to become a quality built home? In the next series of posts, we will pull back the curtain so to speak, and educate you on what specifically happens behind the scenes in the building of a modular home.

Last week we began with floors. This week roof and ceiling systems will be the topic. As mentioned in our previous blogs, roof systems are built simultaneously at the same time as walls and floors.

Unlike conventional site-built construction, roof trusses are usually not used in the building of a modular home. In site construction, roof trusses are built separately and are installed via a crane at the job site after the framing is complete. Instead, the roof and ceiling systems in a modular home are built into the actual structure of the home. Engineered with a fold-up self-supporting rafter system, the modular roof system might be one of the more complicated stages of the modular home construction process.

Stage Three: Roof/Ceiling Systems

For easy installation, roofs are usually built adjacent to the floor and wall stations. Roofs and ceilings begin with the laying out of the drywall and the construction of framing. The 2”x6” or 2”x8” wood members used in the construction are spaced 16” on center. If prescribed by the engineered drawings, a Microlamb beam may be installed in areas of large spans to accommodate heavy weight loads.

Drywall is then adhered to the ceiling framing with a special foam seal spray application. According to the style of home you are building, 12″-16″ front and rear overhangs are then installed. The roof and ceiling structure is then lifted and carried via crane and is set fastened and strapped to the perimeter top plate of the unit as well as lagged into its interior walls.

Stage Two: Walls

Wall fabrication transpires usually in an area close in vicinity to the floors. Also, walls are usually constructed on what is called a floor table. For exterior walls 2” x 6” studs are used and 2” x 4” studs for interior walls. All stud members are laid out in increments of 16” on center as a standard and then nailed in place. In addition, to reinforce the areas where a future kitchen will be installed, wood blocking is put in place for kitchen cabinets. Then drywall is adhered to the studs by a special foam seal adhesive. As a result, this technique allows for a smooth, flawless finish to the drywall with no nail pops.

Walls are then lifted by crane over to the floor section where they are carefully set into place. Exterior partition and marriage walls are usually put into position and nailed first. It is important to note that walls are fastened direct to the floor system in a perpendicular manner as prescribed by a nailing a schedule. This ensures a very sturdy, tightly built structure. Interior walls are then lifted and carried over to the floor system, placed into position and then again fastened to the floor structure. On LEED and Energy-Star homes, exterior walls are caulked to the base of the walls to the deck for maximum energy efficiency.

The first thing you should know is that no modular manufacturer is the same. Selecting a modular home manufacturer is similar to most any buying decision you make; there is the good, the bad and the ugly. Manufacturers come in a range of sizes from small to medium to large. Some build literally over a thousand homes per year and others less than a few dozen. Some manufactures specialize in dealing with a very custom product and others may be limited in their options and amenities. Most manufacturers are limited in the geographic area they market to and are generally limited to a 300-mile radius that they can ship due to cost considerations. Also, manufacturers typically have different series of homes that focus on various design applications, such as vacation homes, custom homes and even multi-family homes.

When choosing the right manufacturer for you, be sure to take an “apples to apples” approach when comparing the materials used in the building of your new home. All manufacturers build to a different standard specification. Some start with a bare bones specification in order to provide the lowest cost possible, however, you can purchase options a la carte to obtain a better spec. Others begin with a much higher standard but may have a higher base cost up front. For example, some manufacturers use all plywood construction and others use OSB; some use 2×4 exterior walls while others use 2×6; and some use high insulation values exceeding code requirements and others provide just enough to meet the code. The list can go on and on…

Once you have a comfort level with the “Nuts and Bolts” of the construction of your home, consider these tips in choosing the right manufacturer.

1. First Impression

Does the manufacturer’s website answer your questions? Are you able to access the floor plans, photographs and options that satisfy your needs? Are they transparent? Do they engage in social media? Are you getting the information that you need to come to a decision? If you ask them a question, how quickly do they respond to you?