Project Journey

How It Works, Your Project Journey with MODURA

From initial enquiry to completed building. A typical modular project delivers in 50–70% less time than traditional construction. Here is how we do it, seven defined steps, each with clear deliverables, so you know exactly what to expect at every stage.

Start Your Journey
Step 1 · Week 1–2

Enquiry & Feasibility

What we do: Review your project brief, building type, approximate m², location, timeline, budget. Our technical team assesses modular suitability, identifies any feasibility constraints, and provides a free high-level feasibility assessment within 48 hours. We evaluate site access, cranage requirements, local regulatory frameworks, and transport routes at this stage.

What you do: Share your project brief, site information, planning status, and budget parameters. The more detail you provide at this stage, the more accurate our initial assessment will be. We handle all information under NDA if required.

Deliverable: Feasibility letter plus indicative budget range (±15%).

Key decision: Proceed to detailed design? The feasibility assessment is free and without obligation.

Discuss Your Project
MODURA project consultation and feasibility assessment meeting with client reviewing initial project brief
MODURA structural engineers working on BIM model with detailed architectural and MEP coordination drawings
Step 2 · Week 3–12

Design & Engineering

What we do: Full architectural design development, structural engineering to EN 1990–1999 Eurocodes, MEP coordination, fire strategy per BS EN 13501, acoustic design per BS EN ISO 16283, and thermal analysis. The BIM model is developed to LOD 400 with full clash detection across all disciplines. Every module, every connection, and every service route is resolved digitally before a single piece of steel is ordered.

What you do: Approve the design at RIBA Stage 3/4 equivalent. Confirm finishes, fixtures, and MEP specification. Submit your planning application with the MODURA technical submission package we provide.

Deliverable: BIM LOD 400 model plus complete technical design package plus planning submission support documents.

Key decision: Planning consent received? Confirmed design moves to factory production.

Discuss Your Project
Step 3 · Week 13–28

Factory Production

What we do: Steel frame fabrication (Stations 1–3), enclosure and insulation (4–5), MEP first fix (6–7), plasterboard and finishes (8–9), joinery and second fix (10–11), MEP testing (12–13), and the multipoint Factory Acceptance Test (14). Every module progresses through all 14 production stations with digital inspection records captured at each stage. The factory operates 24/5 with two-shift capability for accelerated programmes.

What you do: Visit the factory for a progress inspection (recommended at Station 9, before finishes are locked in). Approve the sample room or module. Any design changes after Station 9 incur significant cost and programme impact.

Deliverable: Completed modules ready for dispatch, FAT certificates, and full photographic record of every module interior and exterior.

Key metric: 14 production stations, ±2mm tolerance, 99.7% first-pass yield at FAT.

Discuss Your Project
MODURA factory production line showing modules progressing through assembly stations with precision tooling
Construction site foundation preparation with laser survey equipment verifying tolerance before modular installation
Step 4 · Week 20–30

Site Preparation (Parallel with Factory)

What we do: While not directly responsible for groundworks, we provide foundation interface drawings, service connection point specifications, cranage layout plans, and site logistics coordination. Our site manager reviews and signs off the prepared foundations before any module is dispatched.

What you do: Complete groundworks and foundations to ±5mm tolerance. Install service connections to the module interface points specified in our drawings. Prepare crane hardstanding (minimum 15m × 15m with adequate ground bearing capacity). Ensure site access for abnormal load vehicles.

Deliverable: Site Ready Certificate. Signed off by the MODURA site manager before the first module leaves the factory.

Critical: Foundations must be within tolerance. Every foundation is laser-scanned and verified against the BIM model before modules arrive. Out-of-tolerance foundations are the number one cause of programme delay on modular projects.

Discuss Your Project
Step 5 · Week 29–32

Transport & Delivery

What we do: Module weatherproof wrapping, GPS tracker activation, export documentation preparation, transport coordination, customs clearance (export and import), and cranage scheduling. Modules are dispatched in the correct installation sequence. The first module needed on site is the last one loaded onto the truck. We manage all abnormal load permits, escort vehicles, and route surveys.

What you do: Ensure site access is maintained throughout the delivery window. Coordinate with local authorities for abnormal load movements if your local jurisdiction requires direct applicant notification. Keep the crane hardstanding clear.

Deliverable: Modules arrive on site in the correct installation order. Real-time GPS tracking link provided to the client team. Weekly consolidated logistics report covering all modules in transit.

Key metric: 8–12 modules delivered and installed per day. Just-in-time delivery eliminates on-site storage requirements.

Discuss Your Project
MODURA modules on flatbed trailers being transported to construction site with escort vehicles
Crane lifting MODURA modules into position on multi-story building with site assembly team connecting modules
Step 6 · Week 30–34

Site Assembly

What we do: Crane modules into position following the sequenced lift plan (8–12 modules per day). Connect module-to-module structural bolts to the engineered torque specification. Seal weatherproof joints between modules using the specified gasket and sealant system. Connect MEP services between modules and to the site risers. Commission all building systems and conduct the integrated fire alarm test.

What you do: Provide site power and water connections. Coordinate follow-on trades (external cladding, landscaping, external works). These can begin as soon as the building is watertight and powered.

Deliverable: Watertight, powered, and commissioned building with all MEP systems live and tested.

Key metric: Building enclosed and services live in 2–4 weeks, compared to 6–12 months for traditional construction of equivalent size.

Discuss Your Project
Step 7 · Week 34–36

Handover & Aftercare

What we do: Final commissioning of all building systems. Client familiarization walkthrough covering every system, every room, and every maintenance access point. Delivery of the O&M manual (digital plus printed copies). BIM asset data model handover in COBie format if required. The 12-month defects liability period begins on the date of practical completion.

What you do: Final sign-off and acceptance. Take possession of the building. Begin fit-out of any non-modular areas such as ground-floor commercial space or external works. Register warranty documentation with your insurer.

Deliverable: Practical Completion certificate, full documentation pack, BIM model, and preventive maintenance schedule.

Aftercare: 24/7 defect reporting hotline with 48-hour response guarantee during the defects liability period. Extended warranties available on structure (up to 60 years), weatherproofing (up to 25 years), and MEP systems (up to 10 years). Annual building health check included for the first 3 years.

Discuss Your Project
MODURA quality inspector conducting final building commissioning and client handover walkthrough
Benchmark

Total Programme Comparison

Real-world programme durations for typical projects. MODURA modular construction consistently delivers in half the time of traditional methods, with better quality, lower cost, and greater certainty.

Project Type Traditional Build MODURA Modular Time Saving
100-unit apartment building24–30 months10–14 months50–60%
150-key hotel20–26 months9–12 months55–65%
5,000m² office16–22 months8–10 months50–55%
School (20 classrooms)14–18 months6–8 months55–60%
Healthcare facility30–36 months14–18 months50–55%
Decision Gates

What Has to Be True Before Each Phase Starts

Most modular projects that run late were never behind in production. They were behind at a gate nobody noticed they had passed. These are the four gates and the evidence each one requires before the next phase is authorised.

GateEvidence required to proceedWho signs it offWhat it costs to proceed without it
Gate 1 — Feasibility to DesignSite survey, geotechnical report, transport route assessment, and a written module-size strategyClient + MODURA engineeringThe building gets designed to a module that cannot legally travel the last mile. Redesign at this point runs 3–6 weeks.
Gate 2 — Design to FabricationStamped drawings, destination-code compliance matrix, first article approval, and frozen scopeClient + authority having jurisdictionFrame steel is cut to a superseded revision. Change orders after steel release run $4,000–$22,000 per affected module type.
Gate 3 — Fabrication to TransportFAT documentation, lashing plan, export document set, and confirmed booking windowMODURA quality + client representativeModules sit finished in the yard or at port. Storage and demurrage run $95–$340 per container per day.
Gate 4 — Delivery to Site AssemblySigned site-readiness confirmation, foundation survey, crane plan, and site access verificationClient’s principal contractorCrane and crew mobilise to a site that cannot receive modules. One day of standing time is $3,200–$7,400 and it is not recoverable.

The pattern in the third and fourth columns is the same each time: the cost of skipping a gate is always paid later, at a higher price, by whoever is standing on site when the problem surfaces — which is never the party who skipped it. Gate 3 and Gate 4 are the two that most often get compressed under programme pressure, and they are the two with the highest recovery cost. Our factory gates are documented the same way, and the freight consequences of missing Gate 3 are set out line by line on our shipping page. For the full pre-construction sequence, see modular construction scheduling and permitting and zoning.

Scope of Work

Who Does What — and at Which Phase

The single most common source of disagreement in an off-site project is a scope boundary that was assumed rather than written down. This is the division of responsibility we contract to, phase by phase.

Work itemMODURA & partner factoriesClient / principal contractorDecision point
Site investigation & geotechnical reportReview and structural interpretationCommission and provide the reportBefore Gate 1
Foundation design and constructionProvide module point-load schedule and tolerance envelopeDesign and build foundations to that scheduleGate 1 — schedule issued on approval
Building design and stamped drawingsFull architectural, structural and MEP design for off-site productionApprove; arrange local code review where requiredGate 2
Module fabrication and fit-outComplete — structure, envelope, MEP first and second fix, finishesFirst article approval and periodic inspectionGate 2 → Gate 3
Factory acceptance testingExecute, document, and share the full recordAttend or appoint a representative to witnessGate 3 — this is the last factory exit point
Export documentation & customsPrepare and pre-lodge the complete export packageAct as importer of record; pay duty and tariffGate 3, completed pre-loading
Main carriage and trackingBook, monitor, and report weekly; sensors travel with the cargoNominate receiving contact at destinationDuring carriage
Site access, hardstanding and craneProvide lift plan, module weights, and sequenceProvide access road, hardstanding, and lifting contractorGate 4
Inter-module connectionsSupply connection kits and supervise first connectionsExecute remaining connections per drawingSite assembly
Final commissioning & handoverCommission MEP systems, hand over records and certificationAccept handover; assume builder’s risk coverPost-assembly

Two rows in this table cause more delay than the other eight combined: foundations and crane provision. Both sit on the client side, both are on the critical path into a gate, and both are frequently treated as site work that can be arranged late. They cannot. Foundation tolerances for a volumetric module are tighter than for a site-built frame, because a module arrives square and rigid and will not accommodate a slab poured to generous tolerance. See what the finished product requires in our apartment and hotel programmes, and what is checked before dispatch on the factory page. Procurement and tender structure is covered in the RFP and procurement guide, and the commercial model in our turnkey construction guide.

Programme

Milestones: Factory-Built vs Site-Built, Month by Month

A 120-key hotel, 8,000 km export route, 44 modules. Both columns assume a clear site and an approved design at month zero — the comparison is the delivery method, not the project.

MonthVolumetric modular programmeSite-built programmeCumulative modular advantage
Month 1Site survey, transport route assessment, module-size strategy frozenSite establishment, temporary works, accessFoundations designed in parallel from month 2
Month 2Design development; foundations designed and poured on siteExcavation and foundation works beginDesign and site work overlap — impossible on a site-built frame
Month 3Drawings stamped; steel released to fabrication; module shells startFoundation complete; steel frame erection beginsTwo workforces, two sites, no shared critical path
Month 4Envelope, insulation and MEP first fix inside controlled hallsFrame erection continues; weather-dependentWeather removed as a programme variable
Month 5Finishes, joinery, MEP second fix; IPQC at each stationRoof, envelope, then internal works beginInterior fit-out already substantially complete
Month 6Factory acceptance testing; export documentation pre-lodgedServices rough-in; inspection roundsQuality verified before the building moves
Month 7First modules loaded and shipped — main carriage beginsInternal finishes beginBuilding is complete on land, not on site
Month 8Main carriage in transit; destination clearance preparedFinishes and services continue—
Month 9Arrival, clearance, haulage, crane offload; assembly beginsFinishes continue; external works beginEquivalent to roughly month 14 of site-built progress
Month 10Assembly complete; connections and commissioningCommissioning of completed areas begins—
Month 11Handover, first revenueSnagging and practical completion3–4 months earlier
Month 14–15(Operational)Handover, first revenueModular has been earning for 3–4 months

The compression is not in any single phase — the modules still take months to build. It comes from running the factory programme and the site programme simultaneously instead of sequentially, which is only possible because the building is finished somewhere other than where it lands. On a project carrying debt service or pre-let commitments, three to four months of earlier revenue is usually the largest single number in the business case, and it is the reason schedule certainty rather than construction cost tends to decide these projects. For the freight and risk structure across month 7 to month 9, see logistics and risk transfer; for what the ex-factory price includes, see how we quote. Programme finance and draw timing are set out in payment draw schedules, and site delivery sequencing in transportation logistics.

Before You Sign

Process Questions We Are Asked Before Every Contract

The five questions that recur in nearly every programme review, answered in the terms a project director actually needs.

How firm is the eleven-month programme?

The factory leg is firm because it is indoors, sequenced and measured — production variance on our lines runs under two weeks across a 44-module programme. The site leg is firm only if Gates 3 and 4 are honoured. Any programme that assumes foundations can be poured late is a schedule, not a plan.

What happens if we change the design after steel release?

Changes before Gate 2 are absorbed into design. After steel release, each affected module type carries a change cost and a schedule impact that varies with how far the module has progressed. This is why first article approval exists: approving one complete module before the run protects every module after it.

Can we visit while the modules are being built?

Yes, and we would rather you did. Factory access is arranged at defined points in the production sequence — normally at frame completion, at envelope closure, and at FAT. A client representative at FAT has more influence over the finished building than a client representative on site ever does.

Who is responsible if our local authority rejects the design?

We design to the destination code and provide the compliance matrix, but approval sits with the authority having jurisdiction in your market. The practical rule: engage them at Gate 1, not at Gate 2. Jurisdictions that have not previously approved volumetric construction ask questions about foundations and connections, and those are cheapest to answer before steel is released.

What is the single biggest risk to the programme?

Not production and not shipping — site readiness. In our projects, delays attributable to the factory leg are rare; delays attributable to foundations, access and crane availability are routine across the whole off-site industry. A principal contractor who takes those three items seriously is worth more to your programme than a lower building price.

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Start Your Project Journey

Share your project brief with us. We will provide a free feasibility assessment within 48 hours and a detailed programme for your specific building type, size, and location.

Start Your Journey