Frequently Asked Questions

Modular construction is a building method where structures are manufactured as factory-built volumetric modules. Each module is completed 80–95% in the factory — including structure, MEP services, interior finishes, fixtures, and fittings — then transported to site and craned into position. The modules are connected structurally and services are linked between units.

This approach moves approximately 80% of construction activity into a controlled factory environment, dramatically reducing programme duration, weather dependency, and on-site defects. Think of it as building the way cars or aircraft are built — with precision tooling, quality control at every workstation, and assembly-line efficiency.

Modular projects are typically 50–70% faster than traditional construction. A typical schedule breaks down as: design and engineering 8–12 weeks, factory production 12–16 weeks, and site works including foundations, cranage, and commissioning 4–8 weeks.

A typical apartment building of 100+ units completes in 6–8 months from final design approval to handover, compared to 18–24 months for traditional construction. The key driver is parallel working: factory production proceeds at full speed while site foundations and groundworks are prepared. There is no weather downtime in the factory, and module installation on site can proceed at a rate of 6–10 modules per day.

MODURA operates four manufacturing facilities on three continents:

Portland, Oregon USA — 25,000 m² factory serving the Americas. Annual capacity: 1,500 modules.

Rotterdam, Netherlands — 18,000 m² factory serving Europe and the UK. Annual capacity: 1,200 modules.

Kuala Lumpur, Malaysia — 22,000 m² factory serving Asia-Pacific and the Middle East. Annual capacity: 1,300 modules.

Monterrey, Mexico — 10,000 m² factory supporting North American capacity. Annual capacity: 500 modules.

All four factories operate to identical ISO 9001 quality management systems, so a module from Rotterdam is identical in quality and specification to one from Portland.

MODURA's steel frame volumetric system is engineered for buildings of 40+ storeys. The steel frame provides the necessary strength-to-weight ratio for tall modular structures. Our tallest completed project to date is 26 storeys (The Assembly, London).

Height capability depends on the structural frame specification, module stacking configuration, core design, and local wind and seismic loading conditions. We provide full structural analysis including non-linear analysis for tall buildings during the design phase. For buildings above 20 storeys, we typically incorporate a concrete or steel stability core with modules installed around it.

We provide full technical submission packages to support planning applications, including: BIM models to LOD 400, structural calculations, fire strategy report, MEP design, acoustic performance report, and thermal analysis. Our documentation meets the requirements of planning authorities in all our active markets.

The planning application itself is typically handled by the client's appointed planning consultant. Our technical team works directly with the planning consultant to ensure the modular methodology is fully and accurately represented in the submission. We can recommend experienced planning consultants familiar with modular construction in your jurisdiction.

MODURA modular buildings have a 60-year design life, independently accredited by BOPAS (Buildoffsite Property Assurance Scheme). Steel frame modules, when properly maintained, can outlast traditional reinforced concrete construction because the steel is protected within the building envelope and never exposed to weather.

The controlled factory environment means there is no weather exposure during the critical construction phase — eliminating common causes of premature degradation such as water ingress during construction, freeze-thaw damage to wet trades, and UV degradation of exposed materials. We provide a full structural warranty on every project, with extended warranty options available.

All MODURA factories are certified to ISO 9001 (Quality Management), ISO 14001 (Environmental Management), and ISO 45001 (Occupational Health & Safety). Our structural steel fabrication is certified to EN 1090-1/-2 Execution Class EXC3 — the highest classification, required for high-rise and safety-critical structures.

All modules carry CE/UKCA marking as appropriate for their destination market. Quality is verified through a 147-point inspection on every single module, covering structural integrity, MEP installation and testing, fire protection, weathertightness, and finish quality. Each inspection point is digitally recorded and traceable to the individual module serial number.

Yes. MODURA modules are designed to EN 1998 (Eurocode 8) for seismic resistance. The steel frame system incorporates ductile connections between modules that dissipate seismic energy through controlled plastic deformation, preventing catastrophic failure.

We perform site-specific seismic analysis for every project, including response spectrum analysis as a minimum. For high-seismic zones such as New Zealand, Japan, and California, we provide non-linear time history analysis to verify structural performance under Maximum Considered Earthquake (MCE) conditions. Our Pacific Heights project in California (seismic zone 4) demonstrates our capability in the most demanding seismic environments.

MODURA modules achieve up to 120 minutes fire resistance, tested and certified to BS EN 13501. Each module forms a fire-rated enclosure on all six faces — four walls, floor, and ceiling — maintaining compartmentation independently of adjacent modules. This means fire cannot spread from one module to another through the structural cavity.

Fire suppression systems (sprinkler or water mist) are pre-installed, pressure-tested, and commissioned in the factory. Detection systems are integrated and tested before modules leave the factory. The compartmentation strategy ensures that fire integrity is maintained between modules, protecting means of escape. All materials meet Class A1 or A2 fire rating as standard.

Modular construction typically delivers 10–20% lower total project cost when all factors are accounted for. Direct build costs (materials and labour) are broadly comparable to traditional construction. The savings come from four main sources:

Reduced preliminaries — a shorter programme means fewer weeks of site overheads, scaffolding, security, and welfare facilities. Lower finance costs — earlier completion means reduced interest during construction and earlier revenue. Fewer defects — factory quality control dramatically reduces snagging and rework costs. Earlier revenue generation — for commercial projects, opening months earlier translates directly to additional income. The business case is strongest when programme compression has genuine financial value.

For road transport, the maximum module size is typically 4.5 metres wide × 16 metres long × 3.6 metres high, subject to local highway regulations, escort vehicle requirements, and route surveys. These dimensions accommodate most residential and hotel room types.

Larger modules — up to 5.5 metres wide and 20 metres long — can be transported by sea or river barge where water access is available. During the design phase, we optimize module count and dimensions to balance factory efficiency with transport logistics. Where necessary, larger spaces (such as open-plan offices or restaurant areas) can be split across two or more modules with a site-made connection that is structurally and visually seamless.

Yes. We provide containerised shipping from all four factory locations. Standard MODURA modules are designed to fit within ISO container dimensions for efficient ocean freight, flat-packed where possible for volume optimization.

We have delivered to 15+ countries across Europe, North America, the Middle East, and Asia-Pacific. Our logistics team handles the full chain: factory load-out, port handling, ocean freight, customs clearance, destination port handling, road permits and escort arrangements, cranage, and on-site installation. We typically ship 4–8 modules per vessel, with multiple vessels running concurrently for larger projects.

There is no strict minimum order size, but volumetric modular construction is most cost-effective at 20+ modules due to the fixed costs of factory setup, transport logistics, and cranage mobilization. We regularly handle projects from 5 to 1,000+ modules.

For smaller projects (under 10 modules), we can advise on whether a panelized or hybrid modular approach might deliver better value. Every enquiry receives an honest, transparent assessment of the best construction methodology for the specific project — we would rather recommend the right solution than sell a modular project that is not commercially optimal.

Submit your project brief via our contact form or email [email protected]. To give you an accurate budget estimate, please include: building type and use, approximate gross internal area (m²) or number of units, project location, and target completion timeline.

We respond within 48 hours with an indicative budget estimate based on comparable completed projects. For detailed pricing, we provide a full commercial proposal following an initial design workshop (typically 2–3 weeks), during which we develop a preliminary module layout, structural concept, and MEP strategy specific to your project.

Yes. Every MODURA project is designed to the client's specification — we do not sell standard, off-the-shelf modules. Custom elements include: facade materials and architectural expression, interior finishes and fixtures, MEP specification (heating, cooling, and ventilation strategy), room layouts and apartment configurations, and module dimensions within transport limits.

What remains standardized is the structural frame system, quality assurance processes, MEP connection details between modules, and the factory production methodology. This is where the reliability, quality, and speed come from. The result is a building that is architecturally and functionally unique, built on a proven, tested engineering platform.

All MODURA projects include a 12-month defects liability period as standard, with extended warranty options available up to 10 years for structure and 5 years for MEP systems. Ongoing maintenance requirements are comparable to traditional buildings: periodic MEP servicing, facade cleaning, and component replacement on their normal lifecycles.

We provide a comprehensive Operation & Maintenance (O&M) manual and a BIM asset data model that enables facilities management teams to access every component specification, warranty information, maintenance schedule, and replacement part number digitally. Click on any component in the BIM model and see its full lifecycle data. This is a significant advantage over traditional buildings, where O&M information is often incomplete or lost.

Yes. In the UK, MODURA's BOPAS accreditation ensures mortgageability with all major lenders including Lloyds Banking Group, Nationwide, Barclays, NatWest, and Santander. BOPAS certifies the 60-year design life and structural durability of the modular system, satisfying lender requirements for long-term asset value and security.

Similar accreditation and warranty schemes exist in other markets — including ICC-ES in the United States and DIBt in Germany. We can advise on the appropriate certification pathway for your jurisdiction and the specific requirements of your lending institution. In all cases, the key lender concern is long-term asset durability, and our independently certified 60-year design life directly addresses this.