Volumetric modular · Factory-built to ±3 mm
Modulon Structures builds fully finished volumetric units on a controlled production line — structure, envelope, services and fit-out complete before a single unit reaches your site. Foundations run in parallel. Install takes days, not seasons.
Who we are
Site-built construction repeats every decision on every project, outdoors, in the weather, with a different crew. We moved 84% of that work into a 41,000 m² plant with jigs, torque control and dimensional QA on every unit. The result is a building that behaves the same in Anchorage as it does in Austin — and a programme your lender can actually underwrite.
Production range
Each unit is a certified, repeatable product with a fixed shipping envelope, a published U-value and a known crane weight. Specials start from these, never from a blank sheet.
The workhorse of the range: a single-span studio unit that ships on a standard trailer and lands as a finished room.
A wider office unit with a CLT floor cassette, tuned for open-plan desking at 8 m² per person.
A short unit for meeting rooms, quiet rooms and welfare, designed to infill the ends of a run.
A single teaching space sized to a 30-pupil standard classroom, delivered with furniture in place.
The widest teaching unit we make: a pair of classrooms either side of a demountable acoustic wall.
A serviced teaching laboratory with fume extract, gas isolation and chemical-resistant surfaces.
Tool 01
Pick a unit, a quantity and an arrangement. Gross floor area, footprint, trailer movements and the crane window recalculate from the real production dimensions of the unit you selected.
Select a catalogue unit, a quantity and an arrangement. The plan, gross floor area, transport movements and install duration recalculate from the unit's real production dimensions.
Basis: One unit per trailer, 12 crane lifts at 8 lifts per shift, 1.8 m double-loaded corridor. Foundations, risers and roof completion are outside this window.
How it runs
Groundworks and manufacture run at the same time. That single overlap is where the programme saving comes from — everything else is discipline.
We resolve the brief into a unit schedule against the standard range, then test it for transport, crane reach and site access before anything is drawn.
Production drawings, structural certification and MEP coordination complete to a single freeze date. After freeze the plant owns the geometry.
Fourteen units a week down the line: frame, envelope, first fix, second fix, fit-out, snag, weatherproof, wrap. Foundations proceed on site in parallel.
Permitted route, escorted movement, crane study signed off. A typical eight-lift shift sets a floor plate a day with the building weathertight behind it.
Inter-module connections, riser tie-ins, roof and façade completion, then integrated commissioning and a single handover file.
Tool 02
The traditional bar chart is a staircase — every trade waits. Ours is two columns running side by side, and the site only becomes critical when the first unit arrives.
The same building, priced two ways. On the traditional track each trade waits for the one before it; on the modular track the plant and the site run at the same time.
Inside the plant
Torque-controlled fixings, welded frames released only after dimensional QA, and a moisture record for every timber cassette that ships. A wet Tuesday in February changes nothing about the building you receive.
Tools 03 & 04
Can it legally reach the site, and can it carry the stack you want on top of it? Both are answered before we quote, not after.
Every unit leaves the plant on a public road. This is the shipping cross-section of the selected unit set against a standard trailer deck, a 40 ft high-cube container and the legal highway envelope.
Note: Limits shown are the common North American / Northern European baseline. Modulon files the route survey, permits and escort booking as part of every delivery package.
Volumetric units carry load through four corner posts. Add storeys and watch the accumulated axial load — including the second-order amplification we apply for stability — approach the capacity of the standard post.
Basis: 1.35G + 1.5Q with 1.2 kN/m² superimposed dead and 2.0 kN/m² imposed, load shared equally over four corner posts, 200 kPa allowable bearing. Wind, seismic and disproportionate collapse checks are carried out per project.
Tool 05
Sort by whatever governs your project — floor area, clear height, crane weight, envelope performance or lead time.
The full production range on one line each. Sort any column, or filter to the application you are procuring for. All figures are as-built production values, not marketing rounding.
| Fire | Acoustic | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| MS-S24 Studio Unit MS-S24 · Workspace | 41.5 | 12.20 × 3.40 m | 2.70 m | 14.8 t | 0.16 W/m²K | REI 60 | 52 dB Rw | 4 storeys | 9 wks |
| MS-O32 Office Pod MS-O32 · Workspace | 55.4 | 13.20 × 4.20 m | 2.80 m | 18.6 t | 0.15 W/m²K | REI 60 | 54 dB Rw | 5 storeys | 10 wks |
| MS-M18 Meeting Cell MS-M18 · Workspace | 30.6 | 9.00 × 3.40 m | 2.70 m | 11.2 t | 0.17 W/m²K | REI 60 | 55 dB Rw | 4 storeys | 8 wks |
| MS-E28 Classroom Module MS-E28 · Education | 51.2 | 12.20 × 4.20 m | 2.95 m | 17.4 t | 0.14 W/m²K | REI 60 | 55 dB Rw | 3 storeys | 10 wks |
| MS-E40 Double Classroom MS-E40 · Education | 61.2 | 13.60 × 4.50 m | 2.95 m | 20.1 t | 0.14 W/m²K | REI 90 | 56 dB Rw | 3 storeys | 11 wks |
| MS-L22 Laboratory Unit MS-L22 · Education | 46.4 | 12.20 × 3.80 m | 3.00 m | 19.8 t | 0.15 W/m²K | REI 90 | 52 dB Rw | 3 storeys | 12 wks |
| MS-H26 Consulting Suite MS-H26 · Healthcare | 51.2 | 12.20 × 4.20 m | 2.90 m | 19.2 t | 0.14 W/m²K | REI 90 | 58 dB Rw | 4 storeys | 12 wks |
| MS-H34 Diagnostic Unit MS-H34 · Healthcare | 61.2 | 13.60 × 4.50 m | 3.10 m | 24.6 t | 0.13 W/m²K | REI 90 | 60 dB Rw | 2 storeys | 14 wks |
| MS-R30 Apartment Unit MS-R30 · Residential | 48.7 | 11.60 × 4.20 m | 2.60 m | 21.4 t | 0.12 W/m²K | REI 90 | 58 dB Rw | 8 storeys | 9 wks |
| MS-R18 Studio Apartment MS-R18 · Residential | 28.6 | 8.40 × 3.40 m | 2.60 m | 14.9 t | 0.12 W/m²K | REI 90 | 57 dB Rw | 8 storeys | 8 wks |
| MS-C16 Camp Cabin MS-C16 · Site & Camp | 18.4 | 7.20 × 2.55 m | 2.40 m | 7.9 t | 0.20 W/m²K | REI 30 | 45 dB Rw | 3 storeys | 5 wks |
| MS-K20 Kitchen & Mess Unit MS-K20 · Site & Camp | 41.5 | 12.20 × 3.40 m | 2.70 m | 16.8 t | 0.18 W/m²K | REI 60 | 48 dB Rw | 2 storeys | 7 wks |
Note: U-values are whole-envelope averages measured on the production sample. Fire ratings are the certified assembly rating; acoustic figures are laboratory Rw for the party wall build-up. Lead time is from released production drawings to units complete on the yard.
Delivered
Education, healthcare, workplace and residential — the same twelve units, arranged differently.
Twenty-four teaching spaces added on a live school site, with every lift booked outside term time.
Eight storeys of stacked volumetric homes over a transfer podium, handed over 31 weeks from groundbreak.
Imaging and consulting suites set overnight beside an operating hospital, with no daytime road closures.
Forty studio units for a creative tenancy, fitted out in the plant down to the door furniture.
Performance
Every figure below is measured on delivered projects, audited annually, and written into the contract where a client asks for it.
Journal
Volumetric uses more steel than panelised construction, because every unit has to survive being lifted. Here is where we win…
Read →Modular does not make any single activity faster. It moves activities off the critical path — and that distinction is…
Read →Site construction absorbs error with packers and sealant. A production line has to design the error out, because the twelfth…
Read →Next step
Tell us the use, headcount, site constraints and target handover date. Within five working days you receive an indicative unit schedule, a transport plan, a crane study and a fixed-price band.
Tell us the use, headcount, site and target handover date. You will get an indicative unit schedule, a transport plan and a price band within five working days.
Tell us how many units, the site address and your target handover date. Our estimators reply within five working days.
