Table of Contents

Foreword 4
Kullman History 5
Introduction 7

Part 1 Overview 9

Concepts 10
Advantages 12
Procurement 13
Design process 18
Lean fabrication 20
Craft 21
Time savings 23
Cost 24
Building performance 26
Sustainability 27

Part 2 Modular Design 33

Massing 34
Kullman Frame System (KFS) 36
Fire protection 38
Architectural design of modules 39
Bathroom pods 52
Codes and regulations 53

Part 3 Construction process 55

Factory 56
Setting 60
Finishing 70

Part 4 Examples in detail 75

Appendix:
Glossary 95
Acronyms and abbreviations 97
Bibliography 98

3
Foreword
Industrialization of the building process has
remained the great unfulfilled promise of
our time. The waves of efficiency increases
that have transformed the production
of nearly every other product of the last
century have had no corollary in the design
and construction industry. In fact, a study
comparing productivity (measured in
contract dollars per work hours) found that
since 1964 non-construction productivity
has more than doubled whereas the
construction industry has experienced a
productivity decrease of more than 20%
(Khemlani, p4).
We now face a crisis of affordability in the
construction industry. As a culture we have
largely failed to deliver high-performance
and durable buildings at an affordable
cost. This has vast societal consequences
from homelessness to compromised
living standards and the inefficient use of
resources.
To walk onto a construction site today is to
be surrounded by disorder. To manage a
contemporary construction project is to be
overwhelmed by weather, uncooperative
or overly-scheduled subcontractors, lack
of accountability, and poor craftsmanship.
Even the most experienced client
understands that schedule and cost
projections are likely to be in continuous
flux. To a very real extent we build the same
way today that we did thousands of years
ago: by assembling materials and men at a
site and figuring things out as we proceed.
Over the course of the twentieth century
there have been many attempts to bring
industrialized building systems to market.
Nearly all, with the exception of the
mobile home, have failed. Le Corbusier’s
“Machine for Living” has not captured our
4
imagination. This may be due to our own
inherent conservatism, nostalgia, or the
need for individual expression. But why
should our buildings be the only place
where these sentiments prevail? One could
argue that for the most part we express our
identities in our homes and buildings just
as we do in the purchase of products – we
want choice, we appreciate options, and
we certainly want value, performance, and
reliability.
Compared to a well-run in-situ construction
effort, industrialized building offers two
primary advantages: predictability and
time savings. These are so dramatic that
they immediately translate into significant
cost advantages. In an industrialized
building project there are two construction
sites: the field and the factory, operating
simultaneously. An industrialized building
can be constructed in half the time of a
conventional building.
Multiple advantages flow from this time
savings; construction financing costs
and general conditions are halved,
and quality control is much easier to
maintain. Compared to a poorly-run in-
situ construction effort, the advantages of
industrialized building are compounded.
Modular buildings are conventionally
understood as an assembly of boxes.
There is an inherent logic in this as large
modular components allow the greatest
degree of completion in the controlled
factory environment. The module itself is,
however, infinitely variable. It can be formed
and combined into endless configurations.
Modules can be joined, bridged, stacked,
and cantilevered. It can be a component of
a hybridized system, used in combination
with in-situ construction. For this reason
industrialized construction can be seen as
a process, that is, a particular way to build
rather than a predetermined product or set
of components. It is open to architectural
expression in the same way any other
building system is, and like other systems it
has its own logic and potential.
The emergence of the fully industrialized
building at this moment is being
increasingly facilitated by computer-
aided design. Like the contemporary
automobile, created and engineered as
a virtual object before it is produced,
industrialized buildings profit tremendously
from integrated computerized design. The
factory setting allows the optimization of
this technique as fabrication and assembly
are rationalized through time motion
studies. There is no doubt that the use
of CNC fabrication and robotic assembly
will create ever greater advantages as
industrialized buildings continue to evolve
with the application of mass customization
techniques by architects.
This book is a manual, describing the
procurement, processes, constraints,
and possibilities of industrialized modular
building. The book defines processes,
details, structural concepts and case
studies with enough specificity to act
as a planning guide. This manual can
also be seen as a point of departure for
any number of as-of-yet unimagined
applications and techniques. This book
was prepared at the request of the Kullman
Building Corporation, whose dedication to
both the potential of industrialized building
and the advancement of architecture is
exemplary.
James Garrison
New York City, 2007
History of the Kullman Building Corporation
In the same year Charles Lindbergh would
make his solo crossing of the Atlantic and
Hollywood would introduce the “talking pic-
ture,” a quiet but determined Sam Kullman
started his own company building diners.
Sam struck out on his own, leaving behind
a good job with an industry leader and now
a major competitor. With the Great Depres-
sion looming, perhaps it wasn’t the best
time for start-ups, yet Sam’s business acu-
men and attention to quality and customer
loyalty allowed him to thrive. Six years later,
his former employer faced bankruptcy
while Sam’s new company began a legacy
of quality and innovation that now stretches
75 years - and counting.
The diner industry provided turn-key, porta-
ble restaurants that served a market seek-
ing fast, low-cost, home-cooked meals.
Kullman Diners during this period earned
a reputation within its industry for innova-
tion and quality, placing it as a leader by
the onset of World War II. The company
consistently strove to introduce the latest
materials into its product line, which then
featured the earliest uses of stylized, fabri-
cated stainless steel and Formica surface
laminates - elements that still make the
diner so immediately recognizable today.
Returning from service in World War II,
Sam’s son Harold Kullman joined the com-
pany after having earned his own degrees
in finance and engineering. In a time when
the industry produced larger and more or-
nate diners, Kullman advanced the design
and construction standards of the industry.
Sam’s direction would see Kullman build
some of the roadside’s most streamlined
and soaring restaurant designs.
Trends would prove fickle, however. By the
mid-1960s, the spread of the “family res-
taurant” concept would induce Kullman’s
designers to reverse course. Suddenly, the
diner experience would reflect a cozier set-
ting drawing from colonial America - then
all the rage in home decorating.
Still, the decade would not bode well for
the industry. With the rise of the fast-
food industry encroaching on America’s
roadsides, the demand for large, multi-sec-
tioned diners had seriously contracted. The
spreading popularity of homey chains such
as Howard Johnson’s and their meticu-
lous attention to operational consistency
threatened the family-owned diner as never
before.
Clearly, the company would need a new
direction or face its own demise. “We were
friendly with presidents of different banks,”
Harold recalls, “because we provided
financing for some of their diner projects.”
At the time, banks looked to expand their
business by building more suburban
branches. Kullman developed some plans
up for branch banks, exploiting the advan-
tages of prefabricated construction.
The result was America’s first bank con-
structed in the modular process installed
in Marlboro, New Jersey and still in use.
This milestone coincided with the entry into
the business of the Kullman family’s third
generation, Robert Kullman. Seeing a new
direction for the family business, Robert set
out to prove to the world of the benefits of
modular construction.
Strip a diner of its stainless steel, its
restaurant equipment, furnishings and
ornamentation, and what remains is a
highly durable steel and concrete build-
ing module, that interconnects with other
such modules to form a variety of building
types. Kullman, with Robert’s urging, ag-
gressively pursued this new potential in the
5
corrections, educational, institutional, and
broader food service markets.
The company coined the term “Acceler-
ated Construction” to describe a building
process free from the uncertainties of
weather, site conditions, and contractor
relations. Accelerated or factory construc-
tion utilizes the same building materials
and labor found on any project site, but
with an extra measure of quality control
and predictability.
With the explosive growth of wireless
communications, equipment shelters
have also become a core part of the
company’s business. Kullman’s design-
build capabilities and tight control over
the manufacturing environment made it
a logical candidate for mass-producing
diminutive but vital structures to protect
sensitive communications equipment
against extreme weather and vandalism.
often plague on-site construction by local
labor in foreign countries.
With all those old stainless steel diners
disappearing off the landscape, the smart
money betted on the diner’s extinction. Yet,
some individuals took notice and worked to
elevate this unique architectural form into a
new level of appreciation. In 1988, Jeffrey
Gildenhorn’s new restaurant in Washing-
ton, D.C. drew its inspiration from the style
of a classic 1950s vintage Kullman diner.
Gildenhorn asked the company to build
the American City, a retro-styled diner that
complied with all modern building codes.
Kullman has since furthered this trend
with new retro-styled diner construction
and renovations across the northeast and
overseas.
In 1995, Kullman moved to its new facility
in Lebanon, New Jersey, greatly expand-
ing the company’s capacity to produce an
increasing variety of building types. In the
past decade, Kullman constructed hospi-
tals and a college campus, while its food
service division has branched out to build
double drive-thru hamburger restaurants
and stylish drive-up businesses for coffee
vendors. In 2003, the company expanded
its presence in the correctional facility
market by acquiring the key assets of Mark
Solutions, Inc., the leading manufacturer of
galvannealed steel jail and prison cells.
“The next time you talk on a cell phone,
leave your child at school, call a police
dispatch for emergency services or wonder
how Americans are being protected in
overseas embassies, think Kullman.”

If you don’t use a cell phone, you don’t

eat at diners, you or your child may have
attended one of the many school facili-
ties Kullman has constructed. Kullman
calculates over 60,000 students presently
attend the over 2,500 classrooms built by
the company in just the last 20 years.

In 1994, Kullman made history yet again

by building a United States embassy
building at its plant in Avenel, New Jersey
and shipping it to Bissau, Guinea-Bis-
sau. This development marked the first
construction of an American embassy in
America, and its success led to projects
for Ashgabat, Turkmenistan and Bishkek,
Kyrgyzstan. Built, shipped, and assem-
bled by American personnel with security
clearances, Kullman helped the State
Department avoid the security risks that

6
Introduction
Structure of the book
This book is intended to be a process
and product desk reference manual for
architects and engineers considering or
engaged in modular construction with
Kullman Buildings Corporation. This book
compares and contrasts the Kullman
method of modular construction with any
of the various forms of in-situ construction
and provides the technical information
necessary for the architect to design a
building which can be constructed by
Kullman.
Part 1 - Overview
This section introduces the topics,
concepts, and advantages of modular
building. It examines both generalized
advantages and the Kullman method of
construction.
Part 2 - Modular design
This section provides technical design
information, including discussions on
engineering, space planing, fire protection,
architectural details, and codes and
regulations.
Part 3 - Construction process
This section is a sequential examination of
the building process. It follows the process
of modular construction from the factory to
the final application of finishes on site.
Part 4 - Examples in detail
This section gives examples of Kullman’s
work. It includes built work, competitions,
and prototypes.
Deciding to go modular
An increasing number of architects
and engineers today are discovering
the numerous benefits of modular
construction. The decision to build using
modular construction should be made after
careful consideration by both the architect
and the client. Modular construction is
not right for every project. Architects
must understand the specific implications
and benefits of modular construction for
each individual project. By describing
the process of modular design and
construction, this book can work as a
guide for deciding if modular is appropriate
for a given project.
7
Pierson College, Yale University, New Haven, CT

8
Part 1-Overview

Concepts 10

Advantages 12

Procurement 13

Design process 18

Lean fabrication 20

Craft 21

Time savings 23

Cost 24

Building performance 26

Sustainability 27

9
Overview

Concepts

Definitions of “modular” the manufactured housing industry uses

All uses of the term modular refer in some
way to a self-contained component of a
system which has a well-defined interface
in relation to the other components. This
term, however, has been co-opted by
many disciplines, each giving it their own
shade of meaning. Modular has discreet
meanings in the disciplines of computer
programming, music, philosophy,
medicine, mathematics, and design.
Further complicating matters, even within
the design discipline the terms modularity,
Le Modular, modular design, modular
home, modular constructivism, modular
construction, and just plain modular
each have their own discreet meanings.
Finally, even when the term “modular
construction” is understood to have the
correct definition, it carries with it a wide
variety of connotations. Modular may be
ugly homogeny to some and contemporary
refinement to others. Modular buildings,
simply stated, are volumetric components
of a building which are manufactured in
a factory, and transported to the site on a
flatbed trailer and erected into a finished
building.
the term “module” to describe individual
manufactured housing units.
Modular and architecture
Modular buildings designed by an architect
often blur the distinction between product
and a custom designed object. This is the
case because modular buildings generally
have their own systems and methods of
construction. When working with Kullman,
the system of construction relates only
to the structural frame allowing finishes,
configuration, etc., to be determined by
the architect similar to any other custom
designed building.
The continuum of prefabrication
The vast majority of buildings constructed
today use some prefabrication. Modular
construction lies at one end of a continuum
of various types of prefabrication (see
Figure 1.1.1 across). Modular construction
expands prefabrication as a viable and
beneficial option for an increasing number
of building project types.

Modular building v. manufactured housing

Kullman produces modular buildings

not manufactured housing. This is an
important distinction. A “modular building”
is composed of factory-built volumetric
units which are transported to a site on
a flatbed trailer. These modules must be
lifted into their final location. Conversely,
a “manufactured home” has an integrated
permanent chassis to which axles are
directly attached for transportation. These
buildings are typically of lower quality than
modular buildings. Much of the confusion
Figure 1.1.1: Continuum of prefabrication
between these two terms arises because

10

Open v. cellular plan
In the past, only buildings which employed
a repetitive cellular plan were built using
modular construction. However, this
boundary has been pushed by advances in
the techniques of building and assembling
modules. Modules can come together in
a number of ways to create an incredible
variety of spatial forms including large span
spaces. As well, open-sided modules
can be combined to create buildings of
near-infinite length. These capacities
expand the design possibilities for modular
construction.
Overview
Repetition v. customization Building projects particularly well-suited
to modular construction
Although almost any building can now be
divided into modules, certain project types Almost any type of building can be built
will receive the greatest economic benefit. either entirely or in part using modular
Today economies of scale can be achieved construction. Below is a list of project
through mass customization. The term types which are commonly built using
mass customization describes the ability of modular construction and which have
certain products with pre-designed facets shown significant advantages using this
to be customized. Until the very end of type of construction.
the last century, exact repetition was the
only way to achieve economies of scale. Building types
Modular construction, as compared to in-
situ construction, can more readily utilize Single-family residences
this type of economy. As a result, exact Multi-family residences
repetition dominated the modular industry Hotels
during this period, leading to buildings Dormitories
which were, in many cases, banal. Classroom buildings
Digital design, computer numeric control Correctional facilities
(CNC) fabrication technologies, and High-security government facilities
various systems approaches allow mass Hospital patient towers
customization to replace exact repetition Clinics
as a means of achieving economies of Offices
scale. Kullman is at the forefront of such Gas stations
advances and has invested in advanced
modeling software, and numerous CNC
fabrication technologies, in addition to Building types or building components
developing the Kullman Frame System
(KFS). Architects working with the Kullman Food service
system can now create custom designs Equipment enclosures
in which each module is different while Building additions
achieving an industrialized economy of Rooftop penthouses
scale. Physical plants
Building components
Bathrooms
Elevator shafts
Mechanical plenums
Elevator shafts
Staircases
11
Overview
Advantages
The advantages of modular construction
are diverse. From a client’s perspective
the greatest benefits are reduced costs,
consistent high quality, and a savings in
time. The advantages enumerated here
should be understood as interrelated and
overlapping topics rather than discrete or
autonomous issues.
12
Procurement
Increases the ability for collaboration and
single point of responsibility.
Design process
Wide-ranging benefits of increased
collaboration and flexibility.
Construction schedule
Reduces construction time up to 50%.
Financial - cost control
Lowers hard costs, soft costs, financing
costs, out-of-service costs, and provides a
faster return on investment.
Craft - quality
The factory setting allows for the
improvement of building craft.
Factory efficiency
Methods of production reduce task time.
Sustainability and energy efficiency
Improves project sustainability and viability
of LEED® rating.
Disturbance
Minimizes disruptions to adjacent buildings
and occupants and increases cleanliness.
Technology
Greater ability to manufacture components
with a high degree of technical complexity.
Site
Eliminates various site constraints such as
staging, weather, transportation, etc.
Security
Reduces the possibility of job-site
vandalism or theft.
Safety
The factory environment improves
conditions for construction workers
Risk
Increases in the predictability of quality,
cost, and time reduces the risk assumed
by the client.
Relocatability
Creates the possibility of moving the
structure to a new location.
Oversight
The client and architect can oversee and
preview parts of the structure in the factory.
This enables conflicts to be identified and
resolved early, subverting the large costs
associated with discovery of such conflicts
in the field.
 Overview

Procurement

At the beginning of a project, architects

and clients must consider approaches to
procurement. The procurement process
for ready-made products is different
from that for custom-designed objects.
As modular construction is both ready-
made and custom-designed, some
slight adjustments must be made to the
typical process of building procurement
to account for these differences. There
are four standard types of construction
procurement which are relevant to modular
construction: design-bid-build, negotiated
bid, design-build, and strategic partnering.

Design-bid-build:

Design-bid-build is the conventional

method in which a project is designed by
an architect and bid among competing
builders. In this method, an architect
produces bid documents which are then
bid by a qualified general contractor who
will select a subcontractor to provide the
modular components. The owner can
bid the site and modular components
separately. If this route is chosen,
construction management services are
recommended, and extra care must be
taken in definition of the separate scopes.

Figure 1.3.1: Flow chart of procurement process for design-bid-build

13
Overview

Although many architecture projects
are procured by design-bid-build, this
method has some distinct disadvantages
in modular construction. Design-bid-build
does not take complete advantage of the
potential collaboration benefits of modular
construction including time savings.
Because most modular manufacturers
have their own systems for the design
and construction of modular frames, the
production of bid documents will require
one of the following approaches:
Design using a manufacturer’s standard
system:
• Limits the competitive options for
bidding.
• Expedites the design process.
Design using a performance-based or
prototypical system:
• Less architectural control of final
product.
• Additional design work will be required
after the manufacturer is selected.
• Less certainty of cost early in the design
process.
Kullman (as well as most other modular
manufacturers) only provides bids on a
lump sum basis. The alternatives to lump
sum bids all require a type of accounting
which is difficult in the context of modular
construction. Also, contractor overhead
comprises a higher percentage of the total
cost. This is difficult to account for on a
project specific basis.
AIA contract documents:
A141™, B141™, B151™

Design and engineer a custom

modular system:

• Severely limits the number of

manufacturers interested in bidding.
• Additional burden on the design
process.
• Maximum design flexibility.
• Increased cost.

14
 Overview

Negotiated bid:

With negotiated bid procurement, the

architect and client select either a modular
manufacturer or a general contractor who
is teamed with a modular manufacturer
at the beginning of the design process.
If only the modular manufacturer is
preselected, there are two arrangements
which can be made for providing general
contracting services:

• The modular manufacturer can provide

general contracting directly or through a
general contractor hired by the modular
manufacturer This provides single-point
procurement.

• A general contractor can be selected

through design bid-build procurement.
The modular manufacturer or
manufacturers are specified as a pre-
condition of the contract. Specifying
the modular manufacturer is similar
to specifying a group of qualified
manufacturers for any other typical
Figure 1.3.2: Flow chart of the procurement process for negotiated bid building product.

Negotiated bid procurement allows for

the maximum collaboration between
the architect, client, and modular
manufacturer. Manufacturers’ capabilities
and standard systems can efficiently be
incorporated in design. (See “Benefits of
Collaboration” in the “Design Process”
section)

AIA contract documents:

A101™, A111™, 143™

15
Overview

Design-build:

In design-build procurement, the client

enters into a single contract with Kullman
to provide partial or full design services
in addition to construction services. The
design-build contract can be signed at
various points in the process. There are
two permutations of design-build.

Traditional design-build

Kullman provides in-house design services

or retains an architect’s services directly.
Kullman has developed relationships with
various architects or can work with any firm
of a client’s choosing. The Architectural
& Engineering Services Department at
Kullman can provide final construction
documents.

Design-build with bridging documents

In design-build with bridging documents,

the architect produces bridging documents
which Kullman completes in-house. The
architectural drawing set can be used as
bridging documents when the drawing Figure 1.3.3: Flow chart of procurement process for traditional design build
set has reached a stage of completion
between final design development and
50% construction documents. This type
of procurement takes advantage of the
collaboration benefits described in the
following design process section.

This method provides all of the potential

benefits of the pre-selection process.
Also, this system is a single point of
procurement and responsibility for the
client.

AIA document: A141™, A142™, A143™

16
 Overview

Strategic partnering

The client employs the modular

manufacturer for an extended period
of time for multiple projects. This is the
method of procurement used by clients
to acquire communication shelters from
Kullman. This method requires a high
volume of repetitive work and is therefore
not typically used for architectural projects

Figure 1.3.4: Flow chart of procurement process for design build for bridging documents

Figure 1.3.5: Flow chart of procurement process for strategic partnering

17
Overview
Design process
The potential for expanded involvement of
Kullman in the design phase of the project
is of great benefit for architects, although
the method of procurement will affect this
collaboration. These benefits include:
Pricing
Kullman can provide up-front pricing
guidance on an individual project basis;
generate estimates early in the design
process; collaborate on value-engineering;
and for negotiated bid procurement, can
provide an accurate pricing guidance at
an earlier stage of design than in typical
bidding.
Logistics
Modular solutions depend upon well
coordinated logistics. Kullman is solely
responsible for means and methods of
construction; however, architects must
also consider these issues in the design
process. When working with Kullman,
architects are able to understand with
greater transparency what the means
and methods of construction will be. This
transparency improves design efficiency
because the design team can anticipate
and/or consult with Kullman on the
manufacturing implications of design
decisions. This gives the architect a greater
ability to predict and monitor work quality.
Resources & consultants
It is important for consultants to be familiar
with modular construction. Structural and
MEP engineering for modular construction
requires specialized knowledge. Although
architects can work with any consultant
of their choosing, Kullman’s Architectural
& Engineering Services Department
can recommend consultants who are
familiar with modular construction. The
department can answer project specific
18
questions, provide additional resources
or updates to the content of this book,
and recommend contacts for outside
consultant services.
Prototyping / mock-ups
Prototypes or mock-ups allow the client,
architect, and contractor to predict
the outcome of the project with a high
degree of certainty. The ability to create
prototypes can be a significant benefit for
projects such as hotels, plant rooms, etc.
Prototypes can be produced at a much
lower cost for modular construction than
for in-situ construction. These prototypes
or mock-ups can usually be completed
in about a month. Modular prototypes
are built using the proposed methods of
construction, whereas prototypes of in-situ
construction cannot exactly replicate the
process of construction.
Construction documents
Collaboration on construction documents
is one of the most significant benefits
of working with Kullman. The benefits
include:
• The seamless integration of the Kullman
Framing System into the design.
• Streamlined specification process.
• Kullman has the ability to produce
appropriate systems drawings, thereby
eliminating some drawing redundancy.
• Construction documents are combined
with shop drawings, thereby eliminating
the need to produce the latter as a
separate process.
• BIM (Building Information Modeling)
and other advanced software programs
have multiple benefits discussed in the
following section.
There are three basic arrangements
which can be made for the preparation of
construction documents:
• The architect can produce 100%
construction documents. Kullman will
produce shop drawings.
• The architect can collaborate
with Kullman on the production of
construction documents. Kullman is
ideally involved in a “review and advise”
capacity throughout the process and will
typically begin to provide drawings at a
point between final design development
documents and 50% construction
documents.
• The architect can produce bridging
documents which Kullman completes
in house. This is only applicable when
using a design-build method of
procurement.
Use of advanced digital analysis
Kullman collaborates with architects using
a wide range of advanced architectural
software.
Revit / BIM
For many projects, Kullman uses the
software program Revit for Building
Information Modeling (BIM). This program
expedites the drafting process, decreases
document errors, delivers more information
to team members, and improves the
speed and accuracy of estimating. These
benefits result in reduced project duration
and cost. Perhaps the greatest advantage
of this software program is the way in
which it facilitates collaboration between
disciplines (including between the architect
and Kullman). Collaboration is facilitated
through the method of generating
the model, the setup of the software

interface, and functions allowing real-time
collaboration with architects on the design
of a building through an internet capable
server.
Shop drawing
The conventional shop drawing method
uses the architectural drawings as basis for
reinterpretation by tradespeople into their
own drawings which must be resubmitted
to the architect. Kullman has developed
specialized functions within Revit to
facilitate the production of shop drawings.
This process automatically generates
shop drawing packages from the overall
BIM. These packages include the details
for each part being produced and a bill of
materials.
Figure 1.4.1: Shop drawing created by IntelliWall
IntelliWall
For projects which are not designed using
Revit, Kullman uses the software program
IntelliWall to produce the shop drawings of
light-gauge steel framing. This program
automatically generates the most efficient
layout of the steel studs. As well, it
automatically generates a bill of materials,
and includes this bill with the dimensioned
drawings all on one sheet.
SolidWorks
For projects involving custom metal
fabrication Kullman uses the software
program SolidWorks to provide parametric
design capabilities and seamless
integration with CNC (Computer Numeric
Control) milling.
Figure 1.4.2: Revit model Muhlenberg dormitory
Overview
Catia or NavisWorks
For more complex logistics simulations,
Kullman uses Catia or NavisWorks, 4D
modeling programs, to simulate the on-site
building process. These programs allow
for the animation of a building model to
demonstrate the setting process including
the movements of the crane and the
delivery of the modules. This dynamic
modeling tool identifies any potential
conflicts in the setting process.
Figure 1.4.3: Screen shot of Catia 4D model
19
Overview
Lean fabrication
Kullman has adopted lean fabrication
practices. This refers to a method
of conceptualizing and performing
industrial processes in a more efficient
way. The lean paradigm began in auto-
manufacturing by the Toyota Production
System (TPS) and has metamorphosed
into the construction industry. “Lean
construction” and “lean manufacturing”
are separate terms with overlapping
meanings and both are influential in the
transformation of Kullman’s operation.
The focus of “lean” is to reduce all of the
various types of waste and to improve
overall value for the customer. Kullman has
implemented lean production practices in
four areas:
Integration of BIM
See “Use of advanced digital analysis”
under the previous section on “Design
process.”
20
Input material flow Integrated subcontractors
Contractor-generated takeoffs have been In the Kullman factory, outside
the standard means of estimating and subcontractors are hired on a project-
organizing material flow for a specific job. specific basis. These subcontractors
With this conventional approach most of perform tasks which require very
the materials are purchased at one time specialized skills and are not common to
and stockpiled on site, which risks damage all of the modules produced at the Kullman
and misuse. In lean production practice, factory. The subcontractors work in the
the bill of materials generated by the BIM factory alongside Kullman constructors.
replaces the much more time-consuming, Typically fire protection, masonry, and
inaccurate, and often wasteful method of the installation of some highly technical
performing takeoffs. Material is ordered specialized components are performed by
using the Kanban Method which results subcontractors.
in the elimination of inefficiencies related
to material stockpiling. The material for
each workstation is delivered directly to
the station by the supplier. The material
is scheduled to arrive only at the moment
that it is needed and it is delivered directly
to strategically located points to maximize
worker efficiency. This practice reduces
unnecessary human motion and material
movement.
“One-Piece Flow Manufacturing Method”
This method makes use of a production
line with multiple stations where the work
is performed. Each one of these stations
performs specific tasks so that when the
module has passed through all stations it
is complete and ready to ship.

Craft
Craft is defined as the construction of a
building with skill and with careful attention
to detail. The high level of craft in modular
building is the result of:
• Increased skill level and cooperation of
constructors.
• Repetition of work.
• Improved physical access to the work.
• Improved working environment.
• Access to technology in the factory
environment.
• Monitoring and quality control.
• Tolerances.
Increased skill level and cooperation of
constructors
Union
Kullman is a union workplace. The union
ensures that the workers are dedicated
craftsmen and fosters a sense of
collaboration between the workers.
A highly skilled, specialized workforce
A consistent flow of work is necessary to
attract highly skilled production workers
to an area. This is the case for both the
Kullman factory and urban areas. In the
latter, skilled workers are available some
of the time but not on a consistent basis.
In remote locations, generalization often
replaces specialization.
Continual training
Kullman organizes continual training
for its workforce. On a weekly basis
Kullman hosts either a “Tool Box Talk”
for construction products and services,
or a “Lunch and Learn” to learn about
architectural products.
Increased stability of the workforce
The majority of Kullman’s workforce is
comprised of long-term employees. They
are dedicated craftsmen and have many
years of experience working together. With
in-situ construction, a subcontractor’s
workforce may or may not be comprised
of long-term employees. On the project
site the various subcontractor work
forces often have little or no experience
working together, and when working under
separate contracts, have minimal incentive
for cooperation.
Repetition
Optimize
The organization and layout of work on an
in-situ construction site is temporary and
therefore not worth the time investment
required in order to optimize as a work
environment. The Kullman factory
has invested in time-motion studies of
individual work stations to find ways of
optimizing workflow.
Intuit
For workers on an in-situ construction site
each job and each day yields a new work
environment. Conversely, a factory worker
knows exactly where the needed tool will
be, and with experience this knowledge
becomes intuitive. Consistency allows
for uninterrupted concentration on the
task at hand and provides time savings.
Although it may seem like a minute point,
studies and experience indicate that this
has significant cumulative effects.
Jig
The modular building construction process
provides increased opportunities for
jigging. A jig is any type of apparatus for
Overview
holding work and for guiding a machine
tool to the work. The increased use of
jigs is the result of the repetition of factory
work, even on customized projects. As
well, the increased ability for storage and
easy access of items in a factory relative to
job site setting improves the viability using
jigs.
Improved physical access to the work
Increased proximity of the location of the
work to the requisite tools and materials.
Improved exposure of the work
In-situ construction is characterized by
the process of concealing previous works
or assemblies such as framing with
successive layers of material. Conversely,
modules expose more surfaces and
spaces throughout the construction
process. This exposure allows better
access to a greater number of building
components after the finishes have been
applied. Thus, work can be performed or
inspected from two sides of an assembly.
Improved ergonomics
The placement of the work and the
arrangement of workstations allow
the Kullman assembly to work without
impediment or strain.
Fewer confinements, interferences, or
disruptions
Confinement is a difficulty for many
construction activities. In modular
construction, the work is surrounded by
open factory space and not subject to
many interior space constraints.
21
Overview
Improved working environment
Indoor work environment
The factory environment eliminates outdoor
conditions such as uncomfortably high or
low temperatures, precipitation, wind, and
sun exposure allowing for a predictable
workflow and consistent quality of product.
Increased control of pollutants and hazards.
The Kullman factory is monitored and
controlled for air quality and ventilation. As
well, hazardous or noxious construction
activities have their own zones equipped
with specialized mitigation and safety
equipment, such as spray booths, welding
shields, vent hoods, etc.
Improved auxiliary services
The Kullman factory has improved auxiliary
services such as bathrooms, a locker-
room, and break-room with lunch facilities.
Access to technology
Stationary technologies
Mobile on-site technologies are generally
less efficient and accurate than stationary
shop technologies. Although many
components of in-situ construction are
fabricated in remote shops, these items
must be dimensionally coordinated, timed
for delivery, packaged, shipped, delivered
to the site, and unpacked. This laborious
process has the effect of increasing
cost and encourages the fabrication of
components on-site. At the Kullman
factory the use of stationary technology
and shop methods is maximized
throughout construction.
22
Increased security
A secure environment and the elimination
of job-site theft allows for greater
investment in equipment and tools.
Additional security measures such as
optical scan access doors are installed at
the Kullman factory for use with specific
project types such as embassies and
military facilities.
Investment in technology
The high volume of buildings produced
by Kullman provides a greater economic
incentive to invest in technology. This
allows high first costs to be offset by lower
life-cycle costs.
Monitoring and quality control
Accessibility and visibility of work
The improved physical access to the work
allows for the inspection of any component
at any time during the construction
process. This is a benefit for owners,
architects, building inspectors, quality
control staff, and Kullman.
Quality control
For in-situ construction, day-to-day
quality control is typically a function of
the superintendent or general contractor
who is concerned with many aspects
of the construction process. Modular
construction allows for the ability to
more closely monitor work and improve
quality. This is the case because in
modular construction, quality control is a
very methodical and consistent process
performed at each assembly station,
eliminating error and reducing the time
needed to perform the quality checks.
Proximity between the office and the work
For in-situ construction the tasks of
estimating, drafting, ordering, and
management are performed in an office
which is disconnected and often distant
from the job site. Conversely, all of
Kullman’s staff is located directly adjacent
to the factory floor. This allows for quick
resolution of any issue that may arise.
More importantly, it creates a feedback
loop between the planning of work and the
realities of the work being performed.
Tolerances
The primary factors in determining
tolerances are the inherent characteristics
of the material or assembly and
craft. Because factory methods improve
the craft of construction, tighter tolerance
can typically be achieved in modular
relative to in-situ construction.
In modular construction, tolerances fall into
two categories: inner-module tolerances
and assembly tolerances. Inner-module
tolerance refers to the tolerance of the
walls and finishes within a modular frame.
Assembly tolerance refers to the tolerance
of the module frame itself and the process
of placing modules on site.
 Overview

Time savings

Construction scheduling
The ability to perform site work and
building construction simultaneously
is the greatest time benefit of modular
construction. For in-situ construction, most
work must proceed sequentially where
each construction task is a point along
the critical path. In modular construction
the modules are fabricated within the time
required to complete site work, which
means that only the setting and finishing of
modules affect the critical path.
Factory time efficiency
Factory time efficiency refers to the
decreased time required to perform a
given task in factory relative to in-situ
construction environments.
The “Craft” and “Lean fabrication” sections
of this book describe many of the factors
which contribute to factory time efficiency.
Kullman has worked diligently to find and
capitalize on the diverse opportunities for
efficiency. By investing in time-motion
studies of their factory work stations,
Kullman has been able to analyze each
action of individual constructors and to find
numerous ways of maximizing the flow of
work. Kullman estimates a 70% reduction
in task time for work performed in their
factory compared with the same tasks
performed in the field.
The production of equipment enclosures at
Kullman exemplifies the potential of factory
time efficiency. Equipment enclosures
are manufactured by Kullman in 4.5
days, whereas a similar structure using
in-situ methods might require 60 days.
(See “Equipment enclosures” in “Part 4
Examples in Detail”)

Small in-situ construction project

Weeks 0 5 10 15 20 25 Modular construction
Start-up Weeks
Substructure
Superstructure
Interior work
Services
Finishes
Commissioning
Project Hand Over
In-situ construction
Small modular construction project Weeks
Weeks 0 5 10 15 20 25
Production planning
Manufacture modules
Siteworks
Module setting
Site finishing
Commissioning
Project Hand Over

TRADITIONAL IN-SITU CONSTRUCTION

MODULAR CONSTRUCTION

50%-70% EXPECTED REDUCTION

Figure 1.7.1: Gantt chart comparison between Figure 1.7.2: Gantt chart comparison of construction
construction schedules for modular and in-situ schedules for modular and in-situ communication
construction shelters.

23
Overview
Cost
“Time is money.”
This saying is the key to understanding
how many of the previously discussed
advantages create cost savings in modular
construction.
A concept which is useful in considering
cost is the value-to-volume ratio. This ratio
compares the total value of the finishes,
equipment, etc. to the volume of the
module. In general, modules which have
a high value-to-volume ratio will ensure
that there are sufficient opportunities for
manufacturing cost savings to offset the
relatively fixed cost of transportation and
setting.
Hard cost
The definition of hard cost will differ
depending on the role or point of view
of an individual in the project. This
discussion is framed from the client’s point
of view, which means that hard cost refers
to all construction costs which are paid to
the contractor.
Hard cost savings include:
• Factory time efficiency.
• Lower labor rate.
• Decreased general conditions.
• Fewer incidents of component damage
or errors.
• Fewer building risk claims.
• Transportation.
Hard cost expenses include:
• Redundancy and robustness.
• Factory overhead.
24
Factory time efficiency
Efficiency helps to lower labor and
other costs. For most types of in-situ
construction, the direct labor cost accounts
for about 50% of the total hard cost. The
labor savings for modular construction will
be proportional to the reduction of total
man-hours required for construction.
Lower labor rate
The rate for labor in urban areas is
generally higher than at the Kullman
factory. Kullman workers are paid well and
yet the cost of their employment is lower
than workers performing similar work in
many dense urban areas such as Boston
or New York City.
Decreased general conditions
General conditions are typically 10 - 12%
of total hard cost. Modular construction
allows for fewer components, shorter
use, and even the elimination of many
components of the general conditions.
These items include: security service,
craning, parking, dumpsters including
carting and tipping, and temporary
installations such as portable restrooms,
site-fence, unloading dock, contractor
office/trailer, finished assembly protections,
and materials storage.
Fewer incidences of component damage,
error, or theft
This refers to the costs accrued when any
building component cannot be installed
as planned. This problem can occur
if building components are defective,
incorrectly ordered, damaged during
storage, installation, or in the course of
subsequent construction activities, or
stolen from the job site by workers or
intruders.
Many contractors make some budget
allotment for these issues. Although
problems may occur in any construction
practice, the controlled environment of the
Kullman factory makes these problems
much less common.
Transportation
Modular construction generally has a lower
overall transportation demand.
Two studies which demonstrate this
principle are discussed in greater detail
in the “Sustainability” section. For the
purpose of this discussion; however, it is
sufficient to state that modular construction
generally has about a 5% reduction in
overall transportation demand.
Redundancy and robustness
Redundancy and robustness requirements
lead to additional use of materials.
Modular construction often requires up
to 5% more overall structural material
than similar in-situ construction. While
constituting a mild increase in material use,
redundancy and robustness have several
advantages (see the “Robustness” and
“Redundancy” sections).

Soft cost
Soft cost refers to other expenditures or
lost revenue associated with construction.
This would include design fees and
financing among other expenditures. The
soft cost savings of modular construction
would be difficult to quantify in a
construction value-engineering format
because these savings restructure the
entire project delivery and assumptions.
The soft cost savings include:
• Reduced construction loan costs.
• Less out-of-service time.
• Faster return on initial investment.
• Reduced design costs.
Financing
For some projects, lenders may be more
willing to authorize a construction loan for
a project if it utilizes modular rather than
in-situ construction. This is the case for
speculative developments because the
risk in forecasting future market conditions
increases with time. As well, for modular
construction there is a lower risk of
contractor cost overruns or delays and
an increase in the reliability and quality of
project outcomes. Some lenders have
recognized these benefits. For lenders
which have not recognized the effect of
modular construction on risk, Kullman has
found it beneficial to bring the lenders to
the factory to see firsthand the methods
$
Draw cycle (2 or 4 weeks)
Figure 1.8.1: In-situ construction: graph of construction
loan draws
$
Draw cycle (2 or 4 weeks)
Figure 1.8.2: Modular construction: graph of
construction loan draws
Note: For clarity, the diagrams show the same total
construction cost.
and advantages of modular construction.
Reduced construction loan costs
Modular buildings can be built in less time
than in-situ construction. This reduces
the period of the loan and therefore the
interest cost. Interest accrual is not,
however, based on the duration of the
overall project, but on the duration of each
individual draw. For estimating purposes,
a 50% reduction in construction duration
can be assumed. For many projects the
greatest dollar amount savings will come
from reduced construction loan costs.
Overview
Less out-of-service time
For certain types of projects such
as building additions or building
replacements, reducing out-of-service
time results in a very significant cost
savings. Out-of-service time also includes
alternative facilities costs. This is the case
for many college dormitory projects where
alternative housing will have to be found
if the project cannot be completed in a
relatively short window of time.
Faster return on initial investment
For almost all income-producing projects a
faster return on investment is a significant
financial benefit. This advantage of
modular construction must be considered
within the context of the personal or
institutional goals of the client.
Design process
There are many opportunities for savings
related to the design process. The
components of the process which may
have a reduced cost are:
• Construction cost estimating.
• Engineering fees.
• Construction documents.
• Construction administration.
The exact savings is determined by various
factors including the nature of the project
and the method of procurement.
25
Overview

Building performance

Acoustical Thermal and moisture Robustness

Multi-unit modular construction is inherently
insulating to sound. Module mate-lines
typically occur in between walls and floors.
Because each module has its own framing,
there can be no direct sound transfer
through the light gauge steel framing into
adjacent surfaces. Additional acoustic
barriers such as acoustical quilts can be
easily and efficiently integrated between
modules.
Attaching the insulation and vapor barrier
in the factory is preferred because a
much higher quality installation can be
achieved in the factory environment.
All of the advantages discussed in the
“Craft” section play a part in this; however,
“Improved Access to the Work” is of
particular benefit in regard to insulation
installation. Ideally, cladding is attached in
the factory for various reasons, including
as a means of protecting the insulation
from damage during transport and placing.
The term robustness refers to the
additional structural capacities of modular
buildings in order to withstand road
vibration, vehicle braking, and the craning
forces. Modular buildings are built to
be stronger structurally than a similar in-
situ building. The benefits of robustness
include increased strength and durability,
seismic resistance, and future additional
loading capacity.

Air infiltration is a greater component

of thermal performance than is often
recognized. Modular construction generally
achieves a lower rate of air infiltration,
which is the result of many of the issues
discussed in the “Craft” section.

In-situ construction Modular construction

Figure 1.9.1: Sound transfer through structures

26

Sustainability
Modular construction provides inherent
qualities and opportunities which can
increase the sustainability of a building
project.
There are many ways to gauge the
environmental impact of a building. The
most comprehensive method is the life
cycle assessment. There are, however,
other metrics and tools used to gauge
performance which are more prescriptive
and broadly instrumentalized as a mandate
or incentive. Some of the various metrics
which are particularly applicable to
modular construction are:
• LEED® (Leadership in Energy and
Environmental Design).
• CHPS (Collaborative for High
Performance Schools).
• EnergyStar.
• Healthy Homes.
The list of clients requiring LEED® in some
form has been growing exponentially. For
this reason the discussion of sustainability
in this guide is organized around LEED-
NC. There are, however, various aspects
of sustainability particularly relevant
to modular construction which are not
recognized by the LEED® system.
LEED
This section refers to the LEED-NC®
Green Building Rating System for New
Construction and Major Renovation,
Version 2.2, unless otherwise noted. In the
following section, the title of each credit is
underlined and italicized. The two-letter
acronym at the beginning of each title
indicates the category under which that
credit is classified. The acronyms and
categories used in the following section
are:
• SS (Sustainable Sites)
• EA (Energy & Atmosphere)
• MR (Materials & Resources)
• EQ (Indoor Environmental Quality),
(Disclaimer: the USGBC does not endorse
Kullman and does not ensure compliance
with any of the credits discussed.)
Modular construction in general facilitates
achieving many LEED® credits. Kullman in
particular has gone further to incorporate
sustainability into its practices and will help
with the documentation of LEED® credits.
Technological investment
Many LEED® credits directly and/or
indirectly encourage a greater level
of technological investment in the
building. Modular construction facilitates
technological investment in various ways.
Compared with in-situ construction,
modular construction can integrate
technological components into a building
more economically. Thus technologically
complex buildings are among the best
suited for modular construction.
Construction pollution
SS Prerequisite 1: Construction Activity
Pollution Prevention
This credit requires the creation of an
“Erosion and Sedimentation Control Plan”
(ESCP) in compliance with the 2003 EPA
General Construction General Permit.
Modular construction may help buildings to
achieve this credit in two ways:
Overview
• The ESCP requires consideration of all
construction activity which produces
significant particulate matter, pollutants,
and run-off, as well as the storage of all
materials on site. Modular construction
eliminates the vast majority of on-site
building activities considered in the
ESCP.
• Foundation work is a primary concern of
the ESCP. For small modular projects,
precast foundations may be an option
which reduces foundation work.
Urban development
SS Credit 2: Development Density and
Community Connectivity
This credit requires development in dense,
typically urban areas.
Site selection is typically considered
separately from construction type;
however, modular construction may
increase the viability of building in urban
areas. Some benefits include increased
economic value due to inflated labor cost
in urban areas, decreased disruption to
adjacent sites and to the public, and less
roadway congestion.
Site disturbance
SS Credit 5.1: Site Development: Protect or
Restore Habitat
This credit requires that “greenfields:
… [must] limit all site disturbance to 40’
beyond the building perimeter.... [or for]
previously developed or graded sites,
restore or protect a minimum of 50% of the
site area (excluding the building footprint)
with native or adapted vegetation.”
27
Overview
For greenfield development, modular
construction will significantly limit site
disturbance. Typically the crane can be
located on a roadway or parking lot which
makes this credit easy to achieve. For
previously graded sites, replanting will
require less effort if the soil has not been
compacted by construction activity or
covered with construction debris.
Building configuration
SS Credit 5.2: Site Development: Maximize
Open Space
This credit has various options for
compliance; however, building vertically is,
in many cases, the best way to achieve this
credit.
Modular construction has an increased
potential for savings in vertical
applications, because a higher percentage
of the overall construction is composed of
factory produced elements.
Energy performance
EA: Prerequisite 2: Minimum Energy
Performance
EA: Credit 1: Optimize Energy Performance
This credit requires specific benchmarks of
energy performance.
Air infiltration and the installation quality of
the insulation are the two main benefits of
modular construction in terms of improving
energy performance. (See “Building
Performance”)
28
Job-site recycling
MR: Credit 2.1: Construction Waste
Management: Divert 50% from Disposal
MR: Credit 2.2: Construction Waste
Management: Divert 75% from Disposal
This credit requires recycling of
construction materials.
Kullman meets the requirements of this
credit on every building regardless of the
pursuit of LEED® certification. At Kullman
all metal, paper, and plastic is recycled.
These materials are stored until the full
container capacity is reached ensuring
transportation efficiency. At Kullman
recycling is a means of saving money. For
in-situ construction, even when this credit
is achieved it typically comes at a cost
to the building project. This is the case
for various reasons: subcontractors are
not trained to separate recyclable items;
multiple types of material are swept up
together; there is little room to separate
and store various materials; and finally
carting companies are less willing to pick-
up and transport relatively small quantities
of materials.
Recycled content
MR: Credit 4.1: Recycled Content: 10%
(post-consumer + ½ pre-consumer)
MR: Credit 4.2: Recycled Content: 20%
(post-consumer + ½ pre-consumer)
The easiest way to achieve and
document this credit is in cases where
primary structural material meets the
recycled content benchmark. Although
the information shown below is based
on general 2006 data it demonstrates
the extent to which steel exceeds the
requirements of this credit.
Steel stud framing:
(24.6% post-consumer + ½ 6.6% pre-
consumer) = 27.9% which is greater than
10% or 20%.
Wide flange structural steel framing:
(56.6% post-consumer + ½ 32.7% pre-
consumer) = 72.95% which is greater than
10% or 20%.

Regional material sources
MR: Credit 5.1: Regional Materials: 10%
Extracted, Processed, and Manufactured
Regionally
MR: Credit 5.2: Regional Materials: 20%
Extracted, Processed, and Manufactured
Regionally
This credit defines “Regionally” as within a
500 mile radius.
Kullman sources the majority of its
materials regionally. If the project site
is located within the map shown (Figure
1.9.1) it will likely qualify for this credit.
Often design teams do not seek to earn
this credit because of the extensive
documentation requirements. Kullman will
provide the necessary documentation.
Figure 1.10.1: 500 mile radius from Kullman factory
(the map will have to be re-centered to a project’s
specific location)
Forestry practices
MR: Credit 7: Certified Wood
This credit requires the sourcing of wood
which is Forest Stewardship Council ®
(FSC) certified.
Kullman works with suppliers who stock
FSC-certified wood and can easily obtain it
for any project seeking this credit.
Indoor air quality (IAQ)
EQ: Credit 3.1: Construction IAQ
Management Plan: During Construction
EQ: Credit 3.2: Construction IAQ
Management Plan: Before Occupancy
This credit requires that an Indoor Air
Quality (IAQ) management plan be created
and followed for the safety of construction
workers.
The Kullman factory is a very safe and well-
ventilated place. All noxious construction
activities take place in the spray room or
using a vent hood. The Kullman factory
can easily comply with even the most
stringent IAQ management plan. Only
activities occurring on the job site would
have to be considered for LEED® reporting
purposes. This means that factory
construction is exempt from consideration
of this requirement. Rather than a possible
loop-hole allowing the intent of the credit to
be undermined, this should be understood
by the design team as a means of
simplifying the submission requirements.
Overview
Toxicity
“EQ: Credit 4.1: Low-emitting Materials:
Adhesives and Sealants”
“EQ: Credit 4.2: Low-emitting Materials:
Paints and Coatings”
EQ: Credit 4.4: Low Emitting Materials:
Composite Wood & Agrifiber Products
These credits have various requirements
for materials which are “applied on site”
Kullman avoids the use of highly emitting
materials wherever possible and can
comply with the requirements prescribed
for achieving both of these credits.
Technically, only job site applications are
considered by LEED®. If no portion of a
material is applied on-site, the credits are
not available. However, if any portion of
the material is applied on site, the entire
application of the material (including the
portion applied in the factory) must be
evaluated.
Acoustics
EQ: Prerequisite 3: Minimal Acoustical
Performance (LEED for Schools Only)
EQ: Credit 9: Enhanced Acoustical
Performance (LEED for Schools Only)
Mold prevention
EQ: Credit 10: Mold Prevention (LEED for
Schools Only)
These credits only apply to LEED for
Schools, but it is important to remember
that typical modular construction strategies
and materials lend themselves to increased
acoustical performance and resistance to
mold, independent of building typology.
29
Overview
Innovation & design
The nature of modular construction leaves
plenty of room to gain LEED points for
Innovation & Design. Up to four points can
be earned by far exceeding required goals
on established points in earlier sections
or by proposing, accomplishing, and
documenting something truly innovative.
Principles not considered by
LEED
Factory time efficiency
The consumption of resources for day-
to-day living comes at an environmental
cost. In this way, labor is an environmental
resource which can be used in terms of
efficiency. The factory time efficiency of
modular construction means that this
most precious resource can be used with
the greatest possible efficiency. Kullman
estimates that the man-hours required to
construct a modular building may be as
low as half those needed to construct an
in-situ building.
Longevity
Longevity is an important and often
overlooked component of sustainability.
One way of considering the environmental
impact of a building is by amortizing the
inputs of its construction by the length
of the building’s useful life. In this way,
longevity is a primary determinate of the
sustainability of a building. Structures
built by Kullman are durable and of high
quality. Although the ultimate longevity of
a building is rarely predeterminable, quality
and durability are two of the primary factors
influencing longevity.
30
Design for end of life
This is a key concept of sustainability. In
order to design for end of life, a building
must contain recyclable materials as well
as have the ability for these materials to
be easily recovered. Steel construction
is inherently the most recyclable type of
construction; however, it is often difficult
to recover steel from in-situ construction.
Modular buildings can be more easily
deconstructed, removed from a site, and
recycled as raw material stock. Modular
buildings also have the unique advantage
of being easily relocated and/or factory
refurbished.
Waste
Although job-site recycling is considered
by LEED®, Kullman exceeds the
prescriptive requirements and, in fact,
reduces initial waste in various ways. Both
the lean method of construction and the
reduction of disposable items which are
part of the general conditions contribute to
initial waste reduction.
Disruption
Modular construction decreases
disruptions to adjacent or undisturbed
sites. LEED® does recognize impact to
greenfields; however, modular construction
exceeds the prescriptive requirements.
Furthermore, modular construction reduces
the quantity and duration of disruption to
any type of site.
Transportation
Modular construction generally reduces the
overall amount of transportation of people
and materials required for construction.
The amount of transportation required
is variable for every project. As well,
variability exists in the identification of
correlative in-situ construction projects and
the measurement of transportation.
Studies performed by the Steel
Construction Institute in the UK found
a 40% reduction in transportation
demand. As well, Michele Kaufman
Designs reported finding a decrease in
transportation demand in the construction
of modular homes compared with
construction of the same home using in-
situ methods.
Overview
Part 2 - Modular design

Massing 34

Kullman Frame System (KFS) 36

Fire protection 38

Architectural design of modules 39

Bathroom pods 52

Codes and regulations 53

33
Modular Design

Massing

Types of assembly
Modular construction has evolved to
the point where architects can initially
conceptualize building form irrespective
of the modular unit. Form generation in
this manner may be applicable to certain
project types or architectural ideologies.
Other architects may choose to use
the tectonics of modular building in the
generation of form.

Figure 2.1.1: Module structural massing

34
 Modular Design

Modularization
The KFS system is flexible enough to
accommodate any conceived architectural
form as the perimeter of a module can
have any imaginable relationship to the
structural frame.

With some modification, almost any

architectural form can be modularized;
however, as stated earlier, best results
are achieved when designs are initially
conceived as modular.

Module Width:
13’ Common Maximum
16’ Oversized Maximum

Module Length:
52’ Common Maximum
60’ Oversized Maximum

Figure 2.1.2: Irregular modular floor plan Module Height:

12’ Maximum

Building Height:
12 Stories Maximum
Non-attached Semi-attached Attached *Some states may allow larger module sizes to be
transported overroad (see Transportation section).

The diagram at left shows a number of

possible combinations and orientations
Solo
Field joint Mate Stack of modules. An incredible diversity of
Field Pods within
other framework form can be derived from these very few
elemental types of interfacing modules.

Shift Turn Void Shift Turn

Figure 2.1.3: Elemental module relationships

35
Modular Design

Kullman Frame System (KFS)

Structure Since all loads are transferred exclusively

The Kullman Frame System is the
product of 80 years of experience in
producing modular buildings. Kullman
has developed this frame system through
research and collaboration with architects
and engineers.
This system offers advantages of compact
member sizes, minimal welding, high
rigidity, and the fewest possible column
and connection points. The KFS is based
on a Vierendeel truss which spans to the
module ends so that the corner columns
carry vertical loads to the foundations.
through the end columns, openings
and glazing can be configured without
consideration of shear forces.
Interstitial truss module
A compact version of the KFS can be
used between vertically stacked modules
to provide structural support for larger
clear spans and additional space to run
services.
Non-load-bearing pod
Pods include bathrooms, plant rooms,
or other modules which do not comprise
any part of the building super structure. KFS Building Module

Consequently the ends are the only These types of structures are typically
required connection points. built using light gauge steel (LGS) frames.

Figure 2.2.1: Distribution of forces (load path) in

stacked modules using conventional structure which KFS Interstitial Truss Module
bear directly at each column

Figure 2.2.2: Distribution of forces (load path) in Pod

stacked modules which bear through the four corner
columns Figure 2.2.3: Types of frames

36
 Modular Design

Figure 2.2.4: Exploded axonometric of the

Kullman frame

37
Modular Design

Fire protection

GWB

Fire rating for the KFS is typically achieved

with a UL rated GWB enclosure. For a
two hour fire rating, walls and ceilings are
finished with two layers of GWB creating
a rated separation between the occupied
spaces and the structural steel frame. To
stop flame spread within the mate-line
cavity, mineral wool is packed between
steel members during the setting process.
Where openings are placed or systems
pass through the module wall the two
hour encasement of the structure must be
maintained.

Thin-film intumescent coating

(intumescent paint)

The application of intumescent paint is

particularly useful because it requires Figure 2.3.1: Fire protection - 2 Layer GWB liner
virtually no building volume and can
be more efficiently applied in a factory
setting than in the field. This method
is expensive if it is used to cover large
areas of a structure; however, for selective
applications in modular construction it is
often viable. Bolted or riveted connections
cannot occur over intumescent coated
steel, because this breaks the required
fire protection. This necessitates that fire
rating be applied in the field. Intumescent
coatings are applied in the Kullman
factory and/or on site by a specially
licensed subcontractor. At connection
plate locations either sprayed fire resistant
material or GWB is installed after the
connection plates are installed.

Figure 2.3.2: 2 hr. fire-rated section detail

38
 Modular Design

Architectural design of modules

Interior openings between

modules
Typical: 8’-0”
Possible w/o modification: 9’-6”

Clear span openings are possible but will

Figure 2.4.1 Longitudinal section showing typical opening
require one of the following:

• Increased beam depth

• Incorporate interstitial truss module

• Weld frames across mate lines

Figure 2.4.2 Longitudinal section showing clear span

Figure 2.4.3 Longitudinal section showing clear span

Figure 2.4.4 Cross section showing clear span

39
Modular Design

Wall thickness
Wall thicknesses vary depending on fire
rating and location of the wall within the
module. These dimensions assume the
use of light gauge steel studs and 5/8”
gypsum wall board.

Interior Wall (unrated): 5 1/4”

Interior Wall (2 hr fire rated): 6 1/2”

Interior Wall on Mate-Line: 8 5/16”

Exterior Wall (w/o cladding): 9 3/4”

Exterior Wall (w/ masonry cladding): 1’-3 3/8”

Mate-line Gaps
The term mate-line refers to the gap
between structural members of adjacent
modules.

Plan: 1/2”
Elevation/Section: 3/4”

Figure 2.4.5 Plan section of typical mate line wall condition

40
 Modular Design

Plan detail
(2 Hour Rated As Shown)

For 0 or 1 Hour rating remove one layer of

GWB.

Figure 2.4.6 Typical plan detail

41
Modular Design

Exterior wall section detail

(2 Hr Rated As Shown)

For 0 or 1 Hour rating remove one layer of

GWB.

Figure 2.4.7 Typical section detail

42
 Modular Design

Mate-line section detail

(2 Hr Rated As Shown)

For 0 or 1 Hour rating remove one layer of

GWB.

Figure 2.4.8 Typical Mate-line section detail

43
Modular Design

Roofs
There are several options available for
roofing modular buildings.

1 Separate module: The roof can be

constructed of independent modules which
are set on the building on site.

2 Integrated: The roof can be integrated

into the construction of a module in the
1a 1b
factory (ideal for flat-roof and low-sloping
roofs).

3 Hybrid: This option is a combination

of the separate module and integrated
approach. The overhang and a portion
of the roof are included in the occupiable
module and a separate roof module is set
on site. This method is useful for more
steeply pitched roofs.

4 In-situ: The roof can be constructed

using pre-fabricated trusses which are
3
placed on site. This works well for multi- 2
unit construction.

5 On site off building: The roof can be

constructed conventionally off the building
then lifted into place. This is ideal for multi-
unit construction with available site space.

4 5
Figure 2.4.9: Roof types

44

Foundations
Typically, KFS modules place a point
load rather than a distributed load on a
foundation. Therefore, slab-on-grade
is not a typical solution for modular
construction. Rather, perimeter and piloti
foundation systems are the best solutions
for modular construction.
KFS modules are set onto 3/4” or 1” steel
bearing plates which are embedded in
the concrete foundation. The leveling
tolerance of the steel plates is ±1/16”.
Shims can be used to achieve this level.
The specification of cast-in-place concrete
Figure 2.4.10: Foundation detail
Modular Design
for modular construction will stipulate a
tolerance of ± 1/8” . This allows for a better
application of the finishes and minimizes
the amount of shimming required.
In most cases the major consideration
is providing an accessible crawl space
underneath the bottom module to allow for
service connections. The minimum crawl
space height is typically determined by
building code prohibitions on inaccessible
crawl spaces. An inaccessible crawl space
is typically defined as any space with less
than 18” between ground and bottom of
joist. Ideally, crawl spaces should be no
less than 3’ high if connection of the MEP
services are to be made.
Figure 2.4.11: Piloti foundation
Figure 2.4.12: Perimeter basement foundation
45
Modular Design

Vertical circulation

Elevator shaft and stair modules can be

configured in a number of ways to suite
an individual project. The shaft modules
can be constructed by Kullman to suit any
standard type of elevator.

Figure 2.4.13: Possible elevator configuration

46
 Modular Design

Figure 2.4.14: Possible stair configuration Figure 2.4.15: Typical stair detail
(facing wall removed for clarity) (steel with concrete treads)

47
Modular Design
Mechanical, electrical, and
plumbing systems
Decentralized systems
Factory installation of mechanical,
electrical, and plumbing (MEP) is one of
the most significant cost-time benefits
of modular construction; however, the
configuration of MEP systems requires
some special consideration for modular
construction. Most in-situ construction
utilizes centralized distribution of services
whereas a common strategy in modular
construction is to decentralize systems.
There are various reasons for and benefits
of this approach. The vertical dimensions
of modular building components are
necessarily limited by over-the-road
clearances. A typical module maximum
of 12’ will yield a clear interior dimension
of approximately 10’8”. This is too
little to allow a conventional three-foot-
deep ceiling plenum while maintaining
adequate ceiling heights. Another reason
for decentralizing MEP systems is that
when each modular unit is more or less
self-contained, it allows architects to
adopt more of a plug-and-play approach
to design, construction, and addition.
Furthermore, decentralizing avoids some of
the complexities in the routing of systems
and making field connections. The final
benefit of the decentralization of systems
is improved environmental control. This is
the case because occupants are able to
avoid using mechanical HVAC unless it is
truly needed.
48
Hookups
For most in-situ construction types, MEP
installation occurs before finishes are
applied. Although this is also the case
for modular construction, there is an
additional step of connecting the services
after a module has been placed. This
step requires field access where systems
are connected. Removable floor or wall
panels allow connections to be made
between modules. The design of access
points and chase enclosures can be
integrated with the building’s finishes.
This is a useful feature of any building as Figure 2.4.16: Field connection shafts; remote fixtures
it facilitates any needed maintenance and
future systems replacement. In general,
shafts and chases should be sized for tool
and assembly clearances and may serve
adjacent modules. See figures 2.4.16 and
2.4.17.
Interstitial module
For buildings where high-volume, low-
velocity duct work and other space
intensive systems are required, the
plenum area is typically constructed as an
independent and fully integrated module.
This is ideal for laboratories and hospital
applications. See figure 2.4.19.
Figure 2.4.17: Field connection shafts; adjacent fixtures
Module
Supply line
End use
Duct
Connection
Location
in module
Mate-line
Access panel
Service chase

Figure 2.4.18: Interstitial module between a group
of stacked modules and an in-situ constructed
volume
Figure 2.4.19: Interstitial module between each
occupied module
Modular Design
Heating and cooling systems Electrical
Package wall units Electrical is the simplest service connection
Many modular buildings and especially in modular construction. Typically a
temporary modular buildings such as junction box is located on each module
classrooms use wall-mountTM units. In the which is connected to the main power
past these systems have been noisy and supply.
inefficient, and did not ventilate well. Today
these systems have been completely re- Plumbing
engineered and can provide quiet, highly
efficient HVAC. Assuming adequate access, plumbing
can be easily connected in modular
Terminal construction. See figure 2.4.16 and figure
Another strategy is to use terminal 2.4.17. Pipe “union” or torch sweating are
conditioner units. These systems use a commonly used.
centralized condenser unit which pipes
water to terminal conditioner units. The
general mechanical efficiency of these
units make this alternative a more
environmentally sustainable solution
High-velocity small duct
A third approach is to use high-velocity
small duct systems. These systems have
a centralized conditioner unit and use
small flexible ducts to supply air to the
desired location. The size of the duct
reduces the need for large shaft spaces.
Plenum
A fourth option is to increase the space
between modules to create a ventilation
plenum. This has great practical benefit
and can be utilized as a piping and conduit
chase as well. See figure 2.4.18.
Radiant
Radiant heating and cooling systems
are effective because they use very
little vertical space, are best suited
to installation in a controlled factory
environment and have the additional
benefit of reduced energy use.
49
Modular Design

MEP chases
Vertically aligned chases can service
multiple units; chase size is dependent on
the number of utilities contained within.

Access panel (min. 20 in.) or door allows

connection of utilities between modules
after setting process.

Note: Depending on design, MEP services can

potentially be constructed within a typical 6” wall.

Figure 2.4.20: Plan section of service shaft

50
 Modular Design

Electrical
Hot Water
Cold Water
Waste Water
Toilet Vent
Air Vent
Connection Collars

Figure 2.4.21: MEP connections

51
Modular Design

Bathroom pods

Bathroom pods are designed and

customized to the users’ and architectural
needs. They are manufactured as
individual pods in Kullman’s controlled,
lean manufacturing facility. Depending
on the clients’ selection and application,
the structure is manufactured either out
of GRP (Glass Reinforced Plastic) or light
gauge steel frame with thin composite floor
technology.

The mechanical, electrical and HVAC

systems are pre-installed as well as all
finish materials including sinks, toilets,
tile, showers, tubs, shower curtains, towel
racks, and finished flooring. Once the
unit is manufactured to code, completed
and inspected, the door is locked and
it is packaged for delivery. The pods
are delivered to the site and only four
connections need to be made: hot and
cold water, electrical, wasteline and any
necessary venting.

Figure 2.5.1: Bathroom pod components

52

Codes and regulations
Code and administrative law
All local building codes governing
construction apply to modular buildings.
Because modular buildings are
constructed at a distance from municipal
building inspectors, a third-party inspector
system has been established. The
administrative code of each state makes
provisions for this method of inspection.
In the permit drawing set, modular and in-
situ components should be represented
together as a final whole. However the
drawing should still clearly differentiate
site work components from modular
components. Copies of these sets of
drawings must be sent to the local building
department as would be the case for any
building. An additional set of the same
drawings should be sent to Kullman which
will forward them to TRA, their third party
inspector, for review.
Inspection
At Kullman the independent third-party
inspector is T.R. Arnold and Associates Inc.
(TRA). The Quality Assurance department
within KBC is inspected by TRA regularly.
TRA certifies the Quality Assurance
program which works with a level of
autonomy within the KBC factory. At the
Kullman factory various plates and insignia
are attached to each module. The required
plates are shown in Figures 2.6.1,2,3. The
local building inspector is responsible
for checking all in-situ construction and
verifying that the modules display the
requisite plates and insignia.
Modular Design
Approval
There are two methods of approval for
modular projects: discrete model approval
and systems basis approval. The projects
described in this book use discrete model
approval. This system of approval is
relevant to most architecture projects
whereby construction documents and
specifications are generated for a specific
Figure 2.6.2: Code plate
building and approved on that basis. The
systems basis approval is used for pre-
designed systematized modules where the
approval for each individual building would
become redundant. This system is used
with high volume products such as the
equipment shelters built by Kullman.
Notes:
For modular buildings, an organization called The
Interstate Industrialized Buildings Commission (IBC)
has sought to create modular code uniformity between
states; however, currently only NJ, MN, RI, and ND are
members. For Manufactured Housing, on the other
hand, the U.S. Department of Housing and Urban
Development (HUD) has developed a national code,
(the Manufactured Home Construction and Safety
Standards) which supersedes all local or state codes.
It is important to remember that because residential
modular buildings do not have an integrated chassis,
this code does not apply to their construction.
Figure 2.6.1: TRA insignia Figure 2.6.3: Data plate
53
Part 3 - Construction process

Factory 56

Setting 60

Finishing 70

55
Construction Process

Factory

1 Office
2 Diner
3 Locker room
4 Break room
5 Receiving area
6 Line 1 - Communications
7 Gantry
8 Loading jib crane
9 Track / wheel rail
10 Steel/welding
11 Line 3 - Component assembly
12 Line 2 - High bay
13 Secure area
14 CNC shop
15 Wood shop
16 Metal shop
17 Spray booth
18 Oven
19 Railroad
Figure 3.1.1: Kullman factory plan schematic 20 Command station

56
 Construction Process

1 Site
2 Factory assembly line
3 Modular frame on jig
4 4 Track for modular buildings

57
Construction Process

5 Welding of an LGS frame

6 Poured concrete floor
7 Workstation
8 Command station
9 CNC shop
10 CNC metal fabrication machine 7

58
 Construction Process

10

59
Construction Process

Setting

Responsibilities and
planning

Kullman coordinates all of the complexities

discussed in this part of the book. It is
important, however, for architects and
clients to understand the building process.
In doing so, architects can more effectively
design for modular and clients can better
understand the cost and value of modular
construction.

Responsibility for the job site is typically

transferred from the general contractor
to Kullman from the setting process
onward. Kullman will then coordinate all
on-site finishing. This provides the most
clear division of responsibility for all of the
parties involved.

There are exceptions to this division of

responsibility for highly specialized on site
construction required after the setting of
the modules such as elevator instillation,
as well as pods delivered to in-situ
construction sites.

The architect is to provide Kullman with a

site plan showing enough context to locate
crane and 18-wheeler approach. The final
craning diagram will be developed by KBC
and the craning company. In the example
at right the architect’s site plan is in black
and white and Kullman’s contribution
is in red. For many projects a simple
spreadsheet or Gantt Chart and craning
site plan are sufficient for planning.

Figure 3.2.1: Craning site plan: Pierson College, New Haven, CT

60
 Construction Process

4D modeling

More complex projects may require that

a digital model simulation be generated
which animates the setting process.
The images shown here were taken from
an animation produced for the Muhlenberg
dormitory project. In this case, the model
identified a conflict between the movement
of the crane’s boom and previously set
modules. The issue was easily corrected;
however, it would have been costly to
correct this conflict if it had not been
identified until the crane was on-site in its
originally planned location.

Figure 3.2.2: Stills from a Catia animation of the Muhlenberg setting sequence

61
Construction Process

Transportation
The Transportation and Field Service
Department at Kullman coordinates the
shipping of modules. The maximum size
of modules is limited by individual state Double Drop Trailer
laws governing semi-trailer transportation.
As well, city and county governments
sometimes impose additional regulations.
These laws place various restrictions
on transportation such as permit
requirements, maximum dimensions, times
of day, roads, route reporting requirements,
and maximum weights. Modules can be
most economically transported if they do
not require a permit and/or escort. There
Single Drop Trailer
are differences between states in terms of
permit requirements.

Dimensions below are generalized. More

specific dimensions are listed by state on
the opposite page.

Max Module Weight: 44,000 lbs.

Double Drop Single Drop

A 40’-0” 50’-0”
B 13’-0” 12’-0”
C 2’-0” 3’-2”
D 15’-0” 15’-2”
E 13’-0” 13’0”

Figure 3.2.3: Truck and module dimensions

62
 Construction Process

State Width Height Length State Width Height Length

Alabama 12' (16') * (16') 76' (150') Montana 12'-6" (18') * (17') * (120')
Alaska 10' (22') * 100' (*) Nebraska 12' (*) 14'-6" (*) 85' (*)
Arizona 11' (14') * (16') * (120') Nevada 8'-6" (17') * (16') 105' (*)
Arkansas 12' (20') 15' (17') 90' (*) New Hampshire 12' (16') 13'-6" (16') 80' (100')
Califonia 12' (16') * (17') 85' (135') New Jersey 14' (18') 14' (16') 100' (120')
Colorado 11' (17') 13' (16') 85' (130') New Mexico * (20') * (18') * (190')
Connecticut 12' (16') 14' (*) 80' (120') New York 12' (14') 14' (*) 80' (*)
Delaware 12' (15') 15' (17'-6") 85' (120') North Carolina 12' (15') 14'-5" (*) 100' (*)
District of Columbia 12' (*) 13'-6" (*) 80' (*) North Dakota 14'-6" (18') * (18') 75' (120')
Flordia 12' (18') 14'-6" (18') 95' (*) Ohio 14' (*) 14'-10" (*) 90' (*)
Georgia 12' (16') 15'-6" (*) 75' (*) Oklahoma 12' (16') * (17') 80' (*)
Idaho 12' (16') 14'-6" (16') 100' (120') Oregon 9' (16') * 95' (*)
Illinois * (18') * (18') * (175') Pennsylvania 13' (16') 14'-6" (*) 90' (160')
Indiana 12'-4" (16') 14'-6" (17') 90' (180') Rhode Island 12' (*) 14' (*) 80' (*)
Iowa 8' (16'-6") 14'-4" (20') 85' (120') South Carolina 12' (*) 13'-6" (16') (125')
Kansas * (16'-6") * (17') * (126') South Dakota 10' (*) 14'-6" (*) *
Kentucky 10'-6" (16') 14' (*) 75' (125') Tennessee 10' (16') 15' (*) 75' (120')
Louisana 10' (18') * (16-'5") 75' (125') Texas 14' (20') 17' (18'-11") 110' (125')
Maine 8'-6" (18') 8'-6" (*) 80' (125') Utah 10' (17') 16' (17'-6") 105' (120')
Maryland 13' (16') 14'-6" (16') 85' (120') Vermont 15' (*) 14' (*) 100' (*)
Massachuetts 12' (14') 13'-9" (15') 80' (130') Virginia 10' (*) 15' (*) 75' (150')
Michigan 12' (16') 14'-6" (15') 90' (150') Washington 12' (16') 14' (16') *
Minnesota 12'-6" (16') * 95' (*) West Virgina 10'-6" (16') 15' (*) 75' (*)
Mississippi 12' (16'-6") * (17') 53' (*) Wisconsin 14' (16') * 80' (110')
Missouri 12'-4" (16') 15'-6" (17'-6") 90' (150') Wyoming * (18') * (17') * (110')

* Determined entirely by route travelled

( ) Indicates maximum possible dimension which requires permits and/or escorts

Figure 3.2.4: State overroad dimensional transportation limitations

63
Construction Process

Temporary weatherproofing
Any section of a module which would be
exposed during transport is covered by a
custom made polyethylene sheet or tarp.
These covers require some engineering,
namely the quantity and placement of
air vents and the method and spacing of
attachment points.

Figure 3.2.5: Tarped module ready for transport

64
 Construction Process

Rigging and craning

The selection of the type of crane is
based on weight and reach. The craning
of modules requires a crane of greater
capacity than those commonly kept on-site
during in-situ construction projects. Site
cranes often have a capacity of less than
5 tons whereas the cranes used for lifting
modules often have a capacity in the range
of 40 - 75 tons.

Various types of rigs or spreader bars

can be used to lift modules. The various
types of rigs each have their own
advantages. Although direct lifting is an
option for smaller modules, spreader bars
are used for most projects in order to
keep forces perpendicular to the module
and reduce the possibility of introducing
unwanted bending forces within the
module.

Figure 3.2.7: 75 ton luffing jib crane, commonly used in

Figure 3.2.6: Module craning with spreader bar modular construction.

65
Construction Process

Placing
For most modular buildings, modules will
be lifted directly from the flatbed trailer
into their final location. Often a scissor lift
or boom lift is used to access the module
interfaces. Kullman’s on-site crew will
guide the modules into place and make
the connection. Ideally, the on-site work
process does not impede the maximum
workflow of the crane. As stated before,
“time is money” but especially so when
renting a large mobile crane.

Once the riggings are in place, the

maneuvering of modules “on-hook” is
typically performed by one or two guide-
ropes. Weather conditions will prevent
the placing of modules when wind speeds
exceed 10 mph. The 1/2” space between
the module frames allows the placing Figure 3.2.8: Setting of a module
process to occur with greater speed.
Finally, any joints or openings which remain
exposed at the end of the day are covered
with a tarp to protect against possible rain
damage.

Various arrangements can be made for

placing non-structural pods. Typically
this process is coordinated entirely by
the general contractor. Dimensional
coordination is triple-checked. As well, the
movement of a pod through the site must
be well planned. Where the pod must
move across a floor plate, the weight of the
pods must be calculated as a live load.

66
 Construction Process

Lifting

Until recently Kullman used bolt-on lifting

lugs which were removed before the
placement of adjacent modules; however,
the time required to remove the lugs
slowed the workflow and caused waste.

The new lifting procedure uses a pin and

loop system (patent pending) that is faster
and easier to manage. The top faces
of the corner columns are drilled in the
factory to receive a lifting pin. A looped
cable is lowered inside the column, the pin
is inserted through the loop, rotated and
secured. After the module is set, the pin is
removed and reused for the next lift.

Figure 3.2.9: Lifting pin and loop disengaged

Figure 3.2.10: Lifting pin and loop engaged

67
Construction Process

Stacking

KFS modules use a tool-and-die based

interlocking system (patent pending) that
greatly increases accuracy and reduces
setting time. A circular pin welded to the
base of each corner column fits into the
columns of the module below it. The
tapered pin locates the module below, the
diamond pin registers alignment in one
direction, and the two floating pins allow
for error.

Figure 3.2.12: Setting pin identification, underside of module

Figure 3.2.11: Setting pin section Figure 3.2.13: Blind rivet section

68
 Construction Process

Fastening

Modules are fastened to a 3/8” steel

plate with a 1-1/2” stiffening lip at top
and bottom using 5/8” blind rivets (patent
pending). These rivets have a sheer
strength of 15,950 lbs and tensile strength
of 10,250 lbs.

Figure 3.2.14: Stacking of modules

Figure 3.2.15: Fastening of modules

69
Construction Process

Fireproofing of fastening plate

Fireproofing of the connection plate can

be achieved in a number of ways. If the
module wall build-up is sufficiently deep,
a piece of the same fireproofing board as
used in the module can be placed over
the plate. Alternatively, the plate can be
sprayed or trowelled with fireproofing
material.

Figure 3.2.16: Connection plate fireproofing option

Module fastening end-to-end

Modules can also be fastened together

end-to-end, using 5/8” bolts and a 1/2”
steel connection plate. This method
requires slightly more time and labor, as
bolts need to be hand-tightened.

Figure 3.2.17: End-to-end fastening option

70
 Construction Process

Finishing

Ideally, only minimum field finishing will be

required. Applying the maximum number of
finishes in the factory ensures a high value-
to-volume ratio and results in the maximum
financial benefits of using modular
construction; however some field work is
required in order to cover the interfaces
and mate-lines. All of the material
required for field finishing is included in the
shipment of the modules as ship-loose.
Typically, Kullman performs the finishing
because it simplifies the construction
process and the coordination, as well
as consolidating responsibility. When
the general contractor is involved in the
finishing process, Kullman prefers to use
a closed-door installation, which means
that the modular units will not require any
finishing after the placing process.

Figures 3.3.1: Masonry facade before site finishing Cladding

Installation of the cladding can either occur
in the factory, on site, or a combination
of the two. It is generally not possible
to install all of the cladding in the factory
because of the typical riveting and other
setting requirements. On the other hand,
the cladding can be installed entirely in-
situ using conventional techniques. This
allows for a seamless application of the
cladding and eliminates any mate-line
constraints of the cladding system. The
modular unit will, however, require more
protection during transit and will have a
lower value-to-volume ratio. Most projects
use a combination of the two approaches
whereby portions of the cladding are
installed in the factory and infill pieces
can be placed in situ. This approach will
require some coordination and should be
considered during the design process.
Figures 3.3.2: Masonry facade after site finishing

71
Construction Process

Materials systems do not require any modification

or special consideration for modular
construction. These systems facilitate
Masonry
placing some panels on the building in the
Masonry facades can be constructed in the
factory and then placing infill panels on
factory on the module. Precast elements
site.
can be inserted on site in much the same
manner. The advantage of some precast
For progressive systems the installation
elements is that their profile may allow
must occur in sequence typically from
additional room for tolerance. Designing a
the base of the building moving upward.
reveal between integrated masonry panels
A number of clip systems fall into this
is perhaps the simplest way of designing
category. If these systems are to be
an interface. For masonry constructed
applied in the factory and on site, special
entirely on site, a clipping vertical track
provisions must be made to provide
is typically installed in the factory which
construction access to the mate-line. The
allows the masonry ties to be placed by the
options include:
mason on site.
• Finishing the bottommost module in the
factory and applying the cladding to
Wet mixes upper floors on-site.
Stucco and EIFS are well-suited for • Designing a reveal of sufficient height
modular construction because factory to allow a field-installed panel to be
processes ensure the high quality dropped in.
Figures 3.3.3: Masonry facade before site finishing
application which is critical to this type of • Designing a special detail to allow field
finish. Using wet mixes requires that a installed panels to be directly attached.
small expansion joint be placed between Gluing is often a viable option.
modules. Both stucco and EIFS can
be used and field finished in modular
construction.

Panels (includes siding)

There are an increasing number of panel
products available on the market. In terms
of relevance to modular construction,
these panel systems fall into two broad
categories: progressive systems and open
systems.

For open systems the installation of panels

can occur in any order. A common type of
open system is a cassette panel. These
are typically sheet metal or polymer
products which have an inward folded
edge around the panel. These types of

Figures 3.3.4: Masonry facade after site finishing

72
 Construction Process

Interior

The mate-lines can be concealed or

revealed as part of the tectonic of the
building.
For walls and ceilings, GWB is the most
common material requiring mate-line
finishing. These joints can be field-finished
using standard GWB finishing techniques.

Flooring can be applied on site, in the

factory, or a combination of the two. For
floors finished entirely in the factory,
standard flooring transitions can simply be
applied on site. A combination of factory
and site finishing is the most common:

• Carpet - Typically the tack board is

installed in the factory and the carpet is
sent as ship-loose.

• Ceramic tile - Tile can be set in the

factory, allowing one tile to be set on-site
over the mate-line. It is generally best to
perform grouting as a single process on
site.

• VCT is set in the factory such that the tile

which will cover the mate-line will be cut
about 1/4” narrower, allowing a precise
fit to be made on site.

• Concrete - Grout or self-leveling

compounds can be placed in the mate-
line joint on site.

• GWB - One full sheet of GWB is left off

of the factory finish and applied on-site.

Figure 3.3.5: Interior mate-line finishing

73
Muhlenberg Dormitory
Part 4 - Examples in detail

Muhlenberg Dormitory 76

Yale College Dormitory 78

SIMPLE Dormitory 80

Pratt Institute Dormitory 82

Competition

Koby Cottage 88

Bathroom pods 92

Clove Lake Center 93

MRI Building

Equipment enclosure 94

75
Examples in Detail

Muhlenberg College Dormitory:

Allentown, PA 2007

Architect:
Spillman Farmer Architects
Bethlehem, PA
A
• If project had used in-situ construction,
the out-of-service cost to the college
would have been $750,000.
• Set in 10 days.
• Total construction in 12 weeks.
• 41,000 square feet.
• 600-ton crane.
Note: See excerpts from the animation of the setting
Figure 4.1.2: Typical upper floor plan: 1:250
process in responsibilities and planning section.

Factory Built
Site Built

Figure 4.1.1: Module breakdown

1
 Examples in Detail

2 3

5 1 Joining plate.
2 Factory set masonry.
3 In-situ set masonry.
4 Concrete on steel deck.
5 Cast in place concrete foundation.
6 Bearing plate with shims.

Figure 4.1.3: Wall section: 1:250

1 Placing of-site assembled roof.

2 Module frames on assembly line in Kullman factory.
3 Masonry applied in factory.
4 Module set on crawl space foundation.
5 Complex on day 1.
6 Complex on day 3.
6
Examples in Detail

Yale Dormitory

New Haven, CT 2005.

Architect:
Kieran Timberlake Associates LLP.

7,732 square feet

34 modules

• Vertical masonry mate-line expresses

the modular tectonic.
• Set over spring break.

Note: See site craning plan in planning and responsi-

bilities section

Factory Built
Site Built

Figure 4.2.1:Module breakdown

2
2

78
 Examples in Detail

1 Finished photo.
2 Frames are pre-assembled in factory.
3 Setting process.
4 Module on-hook
5 Module on-hook
4 6 Finished interior
4 6

79
Examples in Detail

SIMPLE Dormitory

Architect:
Garrison Architects

• Simple is a prototype dormitory

produced for Kullman. Product can be
reconfigured for specific sites.
• 6 months from call to delivery.
• Passive heating and cooling
• Rainscreen

Figure 4.3.2: Exterior rendering

Factory Built
Site Built

Figure 4.3.1: Module Breakdown

80
 Examples in Detail

Figure 4.3.5: Spring / Fall - air flow and sun angles Figure 4.3.6: Summer / Winter - air flow and sun angles

Figure 4.3.7: Building section - air flow

81
Examples in Detail

Figure 4.3.8: Floor plans in different configurations.

82
 Examples in Detail

3
5

11
7
8

1 Finish floor (varies)

2 Insulation
4
3 2.5” Concrete fill on metal decking
4 5/8” reinforced cement board
5 Exterior cladding (varies)
6 Formed S.H. wall system (beyond cladding)
7 Wide flange steel section
8 Flashing 10
9 Suspended ceiling
10 Sun shading system
11 Operable windows
Figure 4.3.9: Section detail perspective

83
Examples in Detail

Marble Fairbanks’ Kullman Pratt Institute

Competition Entry

Factory Built
Site Built

Figure 4.4.1: Module Breakdown

Figure 4.4.2: Plans of 4 unit types

84
 Examples in Detail

Narofsky Architecture’s Kullman Pratt

Institute Competition Entry

Factory Built
Site Built

Figure 4.5.1: Module Breakdown

Figure 4.5.2: Modular building system

85
Peter Gluck & Partners’ Kullman Pratt
Institute Competition Entry

Factory Built
Site Built

Figure 4.6.1: Module breakdown

Figure 4.6.2: Section

86
Examples in Detail

Garrison Architects’ Kullman Pratt

Institute Competition Entry

Factory Built
Site Built

Figure 4.7.1: Module breakdown

87
Figure 4.7.2: Unit floor plans.

Figure 4.7.3 : Building upper floor plan.

88
Examples in Detail

89
Examples in Detail

Koby Cottage

Montcalm Lake, MI 2007

Architect:
Garrison Architects
New York City, NY

Engineer:
Paulus Sokolowski & Sartor Figure 4.1.5
Warren, NJ A
Figure 4.8.3: Section 1:10
• Two modules.
• 1,200 square feet.
• First application of the Kullman Frame
System (KFS).
• Field joined with glass.
• Site disturbance and remote location
were significant factors in decision to
use modular construction. A A
• Currently under construction.

Figure 4.8.4: Plan: 1:250

Factory Built
Site Built

Figure 4.8.1: Module Breakdown

Figure 4.8.2: Site plan: 1:3000

90
 Examples in Detail

Figure 4.8.5: Axonometric

91
Examples in Detail

Figure 4.8.6: Wall section detail: 1:10

1 Special form 14 ga. COR-TEN® steel plank.

2 Cast-in-place concrete foundation wall.
3 Custom form cont s.s. joint closer with backer rod.
4 TradeReady steel floor joist.
5 6” fiberglass batt insulation.
6 Structural steel member.
7 1” Rigid insulation.
8 Steel bearing plates with shims.
9 Waterproofing and vapor barrier layer.
10 Continuous brake form COR-TEN drip cap.
11 Window unit.
12 3’x5” COR-TEN steel angle as coping face anchor with EPDM washer.
13 S.M. flashing elastic caulk weld to coping.
14 3 layer modified bituminous roofing membrane.
15 Tapered roof insulation.
16 3/4” substrate.
17 Shading system fabric.
18 Wd. finish floor.

92
Examples in Detail

93
Examples in Detail

Bathroom pods

Factory Built
Site Built

Figure 4.9.1: Module Breakdown

Figure 4.9.2: Common bathroom pod plans with integrated mechanical shafts.

94
 Examples in Detail

Clove Lake Center MRI Building

Staten Island, New York 2007

Architect:
Victor Famulari Architect P.C.

Engineer:
Structural Workshop LLC.

Factory Built
Site Built 7

Figure 4.10.1: Module Breakdown

8
2
6

1 Equipment room.
2 Waiting room.
3 Reception.
4 Toilet
5 MRI scan room
6 Control/viewing room

Figure 4.10.2: Common bathroom pod plans with

integrated mechanical shafts. 9

95
Examples in Detail

Equipment enclosure

Factory Built
Site Built
Figure 4.11.1: Module Breakdown

1 Kullman equipment shelters on ship.

2 Kullman equipment shelter unloaded in Afghanistan.
3 Kullman equipment shelter craned into place.
4 Interior of equipment enclosure.
5 Axonometric of a typical equipment enclosure. 4

96
Appendix

Glossary a higher risk than a mortgage for various Factory time efficiency: Refers to the
reasons including the lack of collateral increased efficiency of factory conditions
and the inherent risks of the process of when compared to in-situ construction.
Bridging documents: Documents
construction. These loans typically have a
(drawings and specifications) which are
higher interest rate than a mortgage. Feedback loop: The aspect of system
created by an architect and are passed-
off to a third-party for completion. In which identifies the differences between
Construction scheduling efficiency: the actual output and the desired output
the context of modular building, these
Refers to the time saves gained by which allows for self correction.
documents are typically at a level of
the ability to do site preparation and
completion similar to 50% construction
foundation work simultaneously with the Floating pin: A type of setting pin that is
documents.
construction of the building because the designed to be smaller than the connection
latter is occurring offsite in the factory. point as to allow for error.
Belly band: The portion of exterior
cladding that is left absent to allow for the
connection of modules and then applied Construction-to-permanent loan: Gantt Chart: A chart that depicts progress
on site. Construction Loan and Mortgage in relation to time, often used in planning
combined into one package which and tracking a project.
reduces closing costs.
Building information modeling (BIM):
Garrison Architects: A an architecture
“an object-oriented building development
Craft: The act and quality of construction. firm in New York City which was founded
tool that utilizes 5-D modeling concepts,
in 1991 by James Garrison. The firm is
information technology and software
Critical-path: A scheduling concept studio-based and works on a broad scale
inter-operability to design, construct
that calculates the least amount of time of projects. Some of the key emphases
and operate a building project, as well
required to complete a project, using a list of the firm are modern architecture,
as communicate its details” (definition
of activities and their relationships to each sustainable design, and modular building.
provided by: Associated General
Contractors) other in terms of time and dependency.
Huck bom: A blind rivet that is used to
Design-Bid-Build: A type of procurement rivet the connection plate to the modules.
Clear span: Refers to the length of
in which the architect and client bid The major benefits of the huck bom over
uninterrupted space that can be left
the construction contracts to modular traditional bolting are its increased strength
when designing intermodule connection,
manufactures after the design has been and ease and speed of application.
passage or space.
completed.
In-situ: Construction which is carried out
Construction loan: line of credit used to
Design build: A type of procurement that on the building site using raw materials
pay the costs of the construction process.
charges the module manufacturer with the
The individual dispersals of funds by this
task of design as well as construction. Interface: The location of any portion of
type of loan are called “draws”. Interest
an individual module which must be or
on the loan is calculated based on the
Diamond pin: A type of setting pin that is has been brought into a relationship with
individual draws rather than the entire line
designed to contact the connection point another component or module on site.
of credit. The borrower typically only pays
on only one axis as to disallow rotation.
the interest on the loan. The principal
Interstitial Module: A small uninhabitable
of the loan is typically paid-off by the
Draw cycle: The regular time period module placed between two inhabitable
mortgage when the building receives a
between disbursements from a modules to proved space for MEP
certificate of occupancy. These loans are
construction loan or other funding systems, ducting, or structural support.
considered by the lending institution to be
mechanism.

97
Appendix
Intumescent paint: A Fire retardant coating
that expands in the presence of heat
to form a tough char barrier fire cannot
penetrate.
Jig: Any of a large class of tools in
woodworking, metalworking, and some
other crafts that help to control the location
or motion (or both) of a tool.
Kullman Buildings Corporation:
A modular building fabricator based
in Lebanon, NJ which was founded in
1928 by Sam Kullman. The company
specializes in modular steel construction
for multi-family residential, institutional,
commercial, and industrial projects.
Lean fabrication: An operational strategy
oriented toward achieving the shortest
possible cycle time by eliminating waste.
Kanban method This is a visual signal
system, typically a card, (used how and by
whom) which contains all of the information
necessary to order a given material.
Life cycle assessment: an objective
process to evaluate the environmental
burdens associated with a product,
process, or activity by identifying energy
and materials used and wastes released
to the environment, also used to evaluate
and implement opportunities to affect
environmental improvements.
Lifting lug: A fabricated steel component
which is attached directly to a module and
used for lifting the module by crane.
Luffing jib crane: A crane with an
additional movable boom attached to the
end of the primary boom.
98
Mate-line: The interface between modules.
Mass customization: The use of computer
technology in order to produce individually
customized products while retaining the
benefits of mass production.
Modularization: The act of converting
a traditionally designed building into a
modular design.
Modular construction: Primary structural
volumetric components of a building which
have been built in a factory setting.
Mock up: A prototype or example module
unit that is constructed in order to test and
demonstrate design decisions, and expose
construction issues.
Modular components: The individual units
that make up a modular building.
Negotiated bid: A type of procurement
that involves the selection of the module
manufacturer and/or general contractor
and the beginning of the design process.
One-piece flow manufacturing method:
A type of manufacturing method that
is akin to the assembly line where the
manufactured item stops at a succession
of stations where a single part of the
construction process occurs.
Piloti: Type of basement consisting of piers
or supports such as columns, pillars, stilts,
by which a building is lifted above what is
underneath.
Prefabrication: A method of construction
where various elements of a structure are
pre-assembled in a manufacturing facility,
and are then transported to the site of
the structure. This method is often used
instead of the more traditional method of
first transporting the mass of materials to
the site, and then assembling them on-site.
Procurement: The act of obtaining a
service agreement. There are different
types of procurement and each implies
a different working relationship and
delegation of responsibilities.
Redundancy: Refers to the duplication of
structural elements in order to achieve the
needed robustness.
Robustness: A structure’s ability to
withstand a variety of forces including
forces exerted during the transportation
process.
Setting: The placing of modules on site.
Ship-loose: Materials that are shipped to
the site as separate yet to be constructed
or applied items.
Shimming: The act of applying a shim. A
shim is a thin and often tapered or wedged
piece of material, used to fill small gaps
or spaces between objects. Shims are
typically used in order to support, adjust for
better fit, or provide a level surface.
Soft cost: Construction industry term
for expense item that is not considered
direct construction cost. Soft costs include
architectural, engineering, financing,
and legal fees, and other pre- and post-
construction expenses.
Spreader bar: A device designed to allow
lifting cables to be perpendicular to the
object rather than at an angle, eliminating
internal tensions within the lifted object.
 Appendix

Strategic partnering: A form of services Acronyms and

procurement that implies a long lasting
relationship that will span over several Abbreviations
projects.
A/C: Air conditioning
Sustainability: Varying degrees of positive BIM: Building information modeling
environmental impact on earth. CHPS: Collaborative for high
performance Schools
Systems basis: A type of industrialized CNC: Computer numeric control
construction which pre-defines a portion Db: Decibel
of the design (especially detailing) and Docs.: Documents
methods of construction. EA: Energy and atmosphere
EIFS: Exterior insulation and finish
Tapered pin: One of the type of setting system
pins. The tapered pin is designed to fit EPA: Environmental Protection Agency
snugly in the module below and act as the ESCP: Erosion and sedimentation
main locating pin. control plan
EQ: Indoor environmental quality
Time and Motion Study: A study which is FSC: Forest Stewardship Council
usually conducted in order to decrease the GC: General contractor
amount of time and the number of steps it GWB: Gypsum wallboard
takes to complete a task, while increasing HVAC: Heating, ventilation, and
productivity. air conditioning
HUD: Department of Housing and
Value engineering: Value engineering Urban Development
is a systematic method to improve the IAQ: Indoor air quality
“value” of goods and services by using an IIBC: Interstate Industrialized Buildings
examination of function. commission
KFS: Kullman Frame System
LEED: Leadership in energy and
environmental design
LGS: Light gauge steel
M: Module
MEP: Mechanical, electrical, plumbing
Mfg: Manufacturer
MR: Materials and resources
PS&S: Paulus Soloski and Sartor
SS: Sustainable sites
TPS: Toyota Production System
TRA: T.R. Arnold and Associates (3rd
party inspector)
UL: Underwriters laboratory
USGBC: United States Green Building
Council
VCT: Vinyl composition tile

99
Appendix
Bibliography
Mark Anderson, Anderson, Peter. Prefab
Prototypes: Site-specific Design for
Offsite Construction. New York: Princeton
Architectural Press, 2007.
Arieff, Allison. Prefab
Buchanan, Michael. PreFab Home.
Codrescu, A. Mobile: The Art of Portable
Architecture. New York: Princeton
Architectural Press, 2007.
Davies, Colin. The Prefabricated
Home. London: Reaktion Books ltd., 2005
Gibb, G.F. Alistair. Off-site Fabrication:
Prefabrication, Pre-assembly and
Modularization. Whittles Publishing, 1999.
Herbers, Jill. Prefab Modern. New York:
Harper Collins, 2004
Hutchings, Jonathan F. Builder’s Guide to
Modular Construction
Kieran, Stephen. Refabricating
Architecture: How Manufacturing
Methodologies are Poised to Transform
Building Construction. New York: McGraw
Hill, 2004
Steel Takes LEED with Recycled Content.
Steel Recycling Institute. Pittsburgh, PA
2006
100
Tatum, C. Constructability Improvement
using Prefabrication, Preassembly, and
Modularization. Construction Industry
Institute, Source document: 25. 1987.
Modular Construction using Light Steel
Framing: An Architect’s Guide (SCI
Publication P272). The Steel Construction
Institute. 1999.
Modular Construction using Light Steel
Framing: Design of Residential Buildings
(SCI Publication P302). The Steel
Construction Institute. 2001.
United States Truckers Regulations on:
Oversized Loads & Pilot Car Directory,
Volume VIII. Hawkeye Specialties, Clear
Lake, IA. 2007
Urban impact (SCI Report RT1098). The
Steel Construction Institute.
Kehmlani, Lachmi Ph.D..
Labor Productivity Declines in the
Construction Industry: Causes and
Remedies. AEC Bytes Viewpoint #4, April
14, 2004