BENEFITS OF MODULAR CONSTRUCTION

METHODS TO THE SOUTH AFRICAN

CONSTRUCTION INDUSTRY

BY

ALISTER KAHN HUMAN

201305679

A MINI-DISSERTATION SUBMITTED TO PARTIALLY COMPLY (IN THE MODULE

MCID 6808) WITH THE CONDITIONS OF THE DEGREE

B.SC (HONS) CONSTRUCTION MANAGEMENT

DEPARTMENT OF QUANTITY SURVEYING AND CONSTRUCTION

MANAGEMENT

FACULTY OF THE NATURAL AND AGRICULTURAL SCIENCES

UNIVERSITY OF THE FREE STATE
BLOEMFONTEIN

2016

STUDY LEADER: MRS T BREMER

BENEFITS OF MODULAR CONSTRUCTION METHODSTO THE SOUTH
AFRICAN CONSTRUCTION INDUSTRY

ABSTRACT

PURPOSE OF THE STUDY: The purpose of this study is identify the benefits of
modular construction methods and how it can be of benefit to the South African
construction industry by examining the advantages and disadvantages and the
potential applications thereof and how it can be applied in the South African context.

METHODOLOGY: The methodology followed was by reviewing the literature that

determines the current knowledge base on the subject of modular construction,
which was then followed up by empirical research.

FINDINGS: The advantages of modular construction methods can benefit the South
African construction industry as they are suited to help alleviate issues around cost,
quality, time as well as address the construction skills shortages.

CONCLUSION: By using modular construction methods they help resolve many

issues found in South Africa’s construction industry where buildings are constantly
subject to increased cost, schedule over runs and poor quality. Therefore is of
extreme benefit to the South African Industry

KEYWORDS: Modular Construction Methods, Benefits, Standardisation,

1. INTRODUCTION

Modular construction is known for its time saving capabilities and is now being
recognized and marketed for being more resource-efficient which means that it is a
greener construction process. Therefore it can be said that modular construction is
the way forward for most construction projects in the future (Woodworks, 2014:3-7).

But this type of construction has not been readily adopting by countries like South
Africa. In South Africa there is still a heavy reliance on conventional building methods
and due to the fact that there is very little skilled tradesmen (CETA, 2014:99-100)
around, resources such as time, money and materials are wasted.

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So due to the above, the question to be asked is can modular construction benefit
the South African construction industry?

2. ADVANTAGES AND DISADVANTAGES OF MODULAR

CONSTRUCTION METHODS

2.1 ADVANTAGES

Modular construction methods can provide a project with many advantages. The
following common advantages of modular construction can be considered to be
applicable. These are reduced construction costs, improved quality, reduced
construction schedules, improved health and safety, improved labour productivity and
skills development and improved material storage and security

2.1.2 REDUCED CONSTRUCTION COSTS

For the most part, construction costs generally consist of key elements which consist
of labour costs, material costs, time costs (such as equipment rental) and overheads.
Theoretically if you reduce the cost of any of these items, you will have a reduction in
the overall construction costs (Benton & McHenry, 2010:32-34). According to Smith
(2010:81) reduced construction costs can be derived from using modular
construction methods which in some cases can be reduced by up to 10% when
compared to conventional construction while a report by McGraw-Hill (2011:19)
indicates cost savings for modular construction can be as high as 20%.

2.1.2 IMPROVED QUALITY

The quality of buildings relies to a large extent on the site conditions at the time of
production, the availability of properly skilled workers to conduct the works and the
quality of materials used in the construction of the building (Emmitt & Gorse,
2014b:2). According to McGraw-Hill Construction (2011:23), the improved quality of
modular construction over conventional construction is an advantage that is achieved
through a better work environment due to it being more structured; better retention of
skilled labour force and an increased quality control procedure at the manufacturing
facility.

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2.1.3 REDUCED CONSTRUCTION SCHEDULES

An advantage of modular construction is a reduction in the on-site program duration.

This is achieved by the simultaneous occurrence or overlapping of off- and on-site
activities which would normally be done in sequence when using conventional
construction methods. This overlap of activities is largely possible because of longer
coordinated design periods for modular construction where the contractor can get
involved earlier in the project (Gibb, 1999:33-35).

2.1.4 IMPROVED HEALTH AND SAFETY

According to McGraw-Hill Construction, (2011:20), there is a notion of improved

health and safety on construction sites that adopts modular construction methods
versus conventional construction is due to the Reduced need for workers on
scaffolding or ladders, avoiding the need to work in tight spaces and working in a
controlled environment such as a factory. By transferring the majority of onsite work
into manufacturing facilities, it subsequently reduces the number of onsite workers
required and therefore reduces the risk of exposing workers to the safety hazards
associated with construction. Work environments in factories are regulated with in
terms of noise levels, air quality and working hours, etc (Smith, 2010:86).

2.1.5 IMPROVED LABOUR PRODUCTIVITY AND SKILLS DEVELOPMENT

Emmitt & Gorse, (2014a:505) states that by transferring the majority of onsite work
into manufacturing facilities, worker skills, whether skilled or unskilled, are applied in
a factory and not on a construction site, which provides the opportunity for the
development of skills specific to a function in the production of the prefabricated item.
Therefore it can be said that the development of worker skills may be easier in a
factory setting as it provides an environment conducive for that activity through
repetition.

2.1.6 IMPROVED MATERIAL AND EQUIPMENT STORAGE AND SECURITY

Large conventional construction sites will usually have a storage or staging area
where materials are delivered before use (Baldwin & Bordoli, 2014:87). These areas
on a construction site are usually open to the natural elements and can therefore be
exposed to unnecessary weather damage. Due to the high cost of replacing

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materials or components, these damaged materials regularly gets installed
regardless. Using materials that is weather damaged is detrimental to the aesthetic
quality of the building (Smith, 2010:183).

2.2 DISADVANTAGES

Modular construction can have disadvantages as well. Common disadvantages of

modular construction as found in literature are: the need for additional material, the
need for additional design and construction coordination, reduced flexibility to design
changes and design constraints and increased capital costs.

2.2.1 NEED FOR ADDITIONAL MATERIAL

According to Emmitt & Gorse (2014a:506), the need for additional material is a
disadvantage of modular construction that comes from the structural requirements of
the modules. Since prefabricated modules usually have to stand on its own, the
additional material can come from the use of extra or larger structural members,
additional bracing for transportation and the additional materials used for the joint
connections on site.

2.2.2 NEED FOR ADDITIONAL DESIGN AND CONSTRUCTION COORDINATION

Smith (2010:83) states the need for additional coordination is a disadvantage of

modular construction. This disadvantage includes an increased effort in the planning
and scheduling for the use of prefabricated modules, the design coordination with
construction and fabrications and the transportation and erection of modules.
Garrison Architects (2008:18) states that a greater level of planning and scheduling is
necessary for modular construction than a conventional construction because of the
close relationship required between design, manufacturing, transportation and
erection requirements of the modules. Thus the need for the design of the modules
needs to be taken into account in the early stages of project planning.

2.2.3 REDUCED FLEXIBILITY TO DESIGN CHANGES AND DESIGN

CONSTRAINTS

The reduced flexibility to design changes is another disadvantage of modular

construction. Modular construction increases the need for coordination of all the

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activities (design, transport, etc) and therefore any late changes to the design can
disrupt the subsequent activities in the construction process. Therefore it is of the
utmost importance that once the design has been approved the design must not
change as modular construction is not adaptable to late design changes (Smith
(2010:96).

2.2.4 INCREASED COSTS

While the use of modular construction methods can lead to reduced construction
costs, there are elements of this method that can lead to increased costs. Gibb
(1999:39) provides a list of items not really thought of when considering modular
construction method which could potentially add increase the cost to a project. These
are the true costs of having items made in a manufacturing facility, the additional
costs of transportation for the prefabricated modules and the additional costs from
the need of bigger cranes needed to erect modules

3 METHODS FOR IMPLEMENTING MODULAR CONSTRUCTION

3.1 INTRODUCTION

As with most factory-made items, to make the product financially feasible, large
volumes of the product needs to be made and sold. This is known as the ‘economy of
scale’ principle. But for this principle to produce its inherent benefits, the components
need to function and look the same. This can therefore be defined as standardisation
(Garrison Architects, 2008:11)

3.2 STANDARDISATION

As with factory made items, modular construction components are made through
manufacturing processes in factories or enclosed environments (Emmitt & Gorse,
2014a:488). This means that the manufacture of modular construction components
lends itself to the ‘economy of scales’ principle and that it would become cost-
effective as more components are manufactured.
Standardisation and modular construction are perceived to be the identical but they
are not quite. CIRIA (1997:1-8) established that even though they can be used
independently, it is when they are used together that the greatest benefit can be

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sought. Therefore, as the components are built in factories, the principles of mass
production and mass customisation can apply.

3.3 MASS CUSTOMISATION

Fewings (2005:310) states that mass customisation is a change from staunch mass
production methods towards more flexible methods that allows for a broad range of
products to be produced, in varied quantities while allowing for more numerous
design changes. Therefore it can be said that in mass customisation the principle of
‘economies of scale’ is replaced by ‘economies of scope’ as it allows for the benefits
of mass production to be productively combined with automated systems and in
doing so, offer products with more design options to chose from which can suite
multiple project specific needs.

3.4 STANDARDISED DESIGN

Standard designs can be in many forms in construction. It is accepted that in

standardised products, the components have the same dimensions and look.
Examples of these standard components in construction are in the form of precast
concrete panels, cladding systems and roof trusses (Gibb, 1999:54). These systems
can be designed in such a way that they can be tailored to any building design all the
while improving the efficiency of the construction process while providing the project
the inherent benefits of using modular construction methods (Garrison Architects,
2008:35).

4 POTENTIAL APPLICATIONS OF MODULAR CONSTRUCTION

METHODS

4.1 POTENTIAL AREAS FOR APPLICATION

According to Garrison Architects (2008:11), modular construction methods are

particularly well suited to be implemented for certain buildings types. The following
common building types suitable for modular construction are residential housing,
healthcare facilities such as clinics and hospitals, educational facilities such as
schools and university buildings, hotels, office buildings, prisons, petrol stations

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Two of the named building types are relevant to the broader South African society as
a whole which namely are schools and residential housing

4.1.1 MASS RESIDENTIAL HOUSING

The South Africa population has grown by over 50% since 1994 and therefore need
an additional 5.6million homes to house this population. In October 2014, the
Department of Human Settlements has developed a brief in which the aim is to
deliver more than 1.5 million houses to the population by 2030 (Republic of South
Africa. Human Settlements, 2014:10). A standard design and modular system
(precast concrete, panelised systems, etc) for these types of houses can be
developed and accepted for use, the advantages of reduced schedule, reduced cost
and better quality will come to the fore.

4.1.2 SCHOOL AND EDUCATIONAL FACILITIES

Certain modular systems can be installed at one site and when no longer needed,
disassembled, relocated and assembled at another site ready for use. A design that,
for example, allows the schools’ footprint to be extended or reduced such as when a
certain schools has lost learners due to migration or when another school needs
more classroom space, the modules of underutilised schools could be relocated to
schools where it is needed.

5 RESEARCH METHODOLOGY

5.1 RESEACH DESIGN

A survey in the form of a questionnaire was conducted amongst selected

construction industry professionals. The questions revolved around the various
advantages and disadvantages of modular construction methods and whether or not
in their opinion it would be of benefit to the construction industry.

5.2 STRUCTURE OF THE QUESTIONNAIRE

The questionnaire used a combination of multiple choice answers, personal opinion

and a 3 or 5-point Likert scale. The questionnaire was divided into two sections as

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 follows: Section 1 - Respondent information and Section 2 - Knowledge and opinion
on the subject matter of the study.

5.3 POPULATION SIZE AND RESPONSE RATE

A total of 30 questionnaires were sent to industry professionals, who work for

companies with a national footprint, in the following professions: Quantity Surveyors–
6; Project Managers– 6; Architects– 7; Contractors– 6 and Services Engineers– 5.
Of the 30 questionnaires circulated, 22 were returned. This presents a response rate
of 73.33%.

6 EMPIRICAL STUDY FINDINGS

6.1 SECTION 1: RESPONDENT INFORMATION

Table 6.1 – Years of Experience of Respondents

0–5 6 – 10 11 – 15 16 – 20 21 – 25 26 – 30 >30
years years years years years years years
Quantity Surveyors 1 1 0 0 1 0 1
Project Managers 0 0 0 0 2 2 0
Architects 0 0 0 0 1 2 3
Contractors 0 0 0 0 2 0 3
Services Engineers 0 0 1 0 2 0 0
Total: 1 1 1 0 8 4 7
Percentage: 4.55% 4.55% 4.55% 0% 36.36% 18.18% 31.81%

Table 6.1 – Indicates the years of experience for respondents.

6.2 SECTION 2: KNOWLEDGE AND OPINION ON THE SUBJECT MATTER OF

THE STUDY.

The respondents’ level of knowledge and opinion of the subject matter is identified in
this section of the questionnaire.

Question 1 - Have you been involved in a project using modular construction

methods?
68.18% of respondents indicated that they have been involved in projects that used
modular construction methods.

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Question 2 - Do you consider modular construction methods an appropriate
replacement for conventional construction methods?
54.55% of respondents agree that modular construction methods are an appropriate
alternative form of construction when compared to conventional construction.

Question 3 - Would you suggest using modular construction methods to a

client?
86.86% of respondents confirmed that they will suggest the use of modular
construction methods to a client.

Question 4 - Do you believe modular construction methods offers cost benefits

over conventional construction methods?
63.64% of all respondents agree that modular construction methods offer better cost
benefits than those of conventional construction.

Question 5 - Do you consider the quality of the finished product of modular

construction methods to be equal, worse or better than buildings built by
conventional construction?
77.27% of respondents believe that when modular construction methods are used,
they produce buildings of better quality when compared to conventional methods

Question 6 - Do you believe modular construction methods offers

time/schedule benefits over conventional construction methods?
54.55% of respondents strongly agree while 45.45% of respondents agree that using
modular construction methods offers project schedule benefits when compared to
conventional construction.

Question 7 - Please provide your opinion on the following advantages of

modular construction.

Question 7.1 - Improved health and safety of workers onsite and reduces onsite
risks/accidents
54.55% of respondents agree that by using modular construction methods, health
and safety aspects on site are improved.

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Question 7.2 - Improved working conditions on site for workers
63.66% are of a neutral opinion that working conditions on site are improved when
employing modular construction methods.

Question 7.3 - Increased on-site productivity

There was a tie of opinion with 50% of respondents agreeing that modular
construction methods increase productivity on site while 50% were neutral about it.

Question 7.4 - Addresses the skills shortage as less skilled labour needed
on-site
54.55% agree that modular construction methods address the skill shortage problem
as less skilled labour is needed on site.

Question 7.5 - Develop permanent skilled workforce in factories

45.45% of respondents are neutral about the fact that by using modular construction
methods, a permanent skilled workforce is developed.

Question 7.6 - Fewer disturbances to neighbouring buildings due to

construction activity
72.73% of respondents agree that by using modular construction methods, less
disturbance to neighbouring buildings are experienced.

Question 7.7 - Efficient use of site as less on-site storage needed

50% of respondents agree while 27.73% of respondents strongly agree that less on
site storage is needed when using modular construction methods.

Question 8 - Please provide your opinion on the following disadvantages of

modular construction.

Question 8.1 - Higher initial capital costs compared to conventional

construction
68.18% agree that modular construction methods have a higher initial capital outlay
than conventional construction.

Question 8.2 - The need for additional transportation of modules

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59.09% of respondents agree that there is a need for additional transportation when
using modular construction methods.
Question 8.3 - The need for additional design and construction co-ordination
50% of respondents agree that when using modular construction methods, additional
design and construction co-ordination is required.

Question 8.4 - Reduced flexibility to design changes

68.18% agree that there is a reduction in design flexibility when modular construction
methods are used.

Question 8.5 - The need for additional material in construction, assembly and
transportation
59.05% of respondents were neutral about the need for additional construction
materials in assembly and the transportation of modular construction components.

Question 8.6 – Has poor integration /interface with conventional construction

methods
50% of respondents indicated they were of neutral opinion when asked if there is
poor integration and interfaces when used in conjunction with conventional
construction methods.

Question 8.7 - Site-specific constraints such as restricted access

54.55% were also neutral about there being a disadvantage of experiencing site
specific constraints when using modular construction methods.

Question 9 - Do you believe that certain buildings/structures should be

standardised by using modular construction methods/components.
63.66% of respondents confirmed that they agree that certain building types needs to
standardised and be built using modular construction methods.

Question 10 - Between modular construction methods and conventional

building methods, which do you feel is better suited to the current South
African Construction Industry?
54.55% of respondents indicated that they believe modular construction methods are
better suited to the South African construction industry.

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Question 11 - Modular construction is the future of the South African
construction industry?
68.18% of respondents believed that modular construction methods are the future
way to build in South Africa.

6.3 QUESTIONAIRE CONCLUSIONS

The conclusion that can be drawn from this survey is that there is a general
agreement among the respondents with the reviewed literature as to the advantages
and disadvantages of modular construction methods. Most of the respondents
agreed with or gave positive responses from Question 4 to Question 11.

7 CONCLUSIONS

Modular construction methods can be used for a variety of building and construction
projects. When used, this concept was found to provide many benefits to the
construction industry. These attributes of modular construction methods are of great
benefit to the South African Industry where buildings are constantly subject to
increased cost, schedule over runs and poor quality.

8 RECOMMENDATIONS

This study looked at the advantages and disadvantages found in using modular
construction methods and evaluating the characteristics of each of them. The
advantages of using modular construction methods are clear and should seriously be
adopted. As South Africa is a developing country with a serious need for buildings
and infrastructure, it would be a good idea for designers and engineers to start
incorporating more modular components in their designs so that the advantages of
modular construction methods can be of benefit to the construction industry.

9 FUTURE RESEARCH

Future areas of research that should be considered to determine if it is feasible for

the South African context are:

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 • An optimised design for mass housing or schools.
• Research can be conducted into common building specifications and
construction details that is widely used in the South African industry so that it
can be determined if they can be standardised or to what degrees they can be
customised.

10 REFERENCES

Benton, W. & Mc Henry, L. F., 2010. Construction Purchasing & Supply Chain
Management. 1st ed. New York: McGraw-Hill Education.

CETA, 2014. Sector Skills Plan Update: 2013/2014, Pretoria: CETA.

CIRIA, 1997. Snapshot - Standardisation and Pre-assembly. London: Construction

Industry Research and Information Association.

Emmitt, S. & Gorse, C. A., 2014a. Barry’s Advanced Construction of Buildings. 3rd
ed. West Sussex: John Wiley & Sons, Ltd.

Emmitt, S. & Gorse, C. A., 2014b. Barry's Introduction to the Construction of

Buildings. 3rd ed. West Sussex: John Wiley & Sons, Ltd.

Fewings, P., 2005. Construction Project Management: An Intergrated Approach. 1st

ed. Oxon: Taylor & Francis.

Garrison Architects, 2008. Modular Architecture Manual. 1st ed. s.l.:Kullman

Buildings Corporation.

Gibb, A. G. F., 1999. Off-site Fabrication - Pre-assembly, Prefabrication &

Modularisation. Caithness: Whittles Publishing.

McGraw-Hill Construction, 2011. Prefabrication and Modularization:Increasing

Productivity in the Construction Industry, Bedford: McGraw-Hill Construction.

Republic of South Africa. Human Settlements, 2014. A Social Contract for the
Development of Sustainable Human Settlements, Pretoria: Government Printer.

Smith, R. E., 2010. Prefab Architecture - A Guide to Modular Design and

Construction. New Jersey: John Wiley & Sons.

Woodworks, 2014. Putting the Pieces Together, s.l.: Woodworks.org.

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