Modularization impact to product end of life cycle

10th International Symposium„Topical Problems in the Field of Electrical and Power Engineering“Pärnu, Estonia, January 10-15, 2011Modularization impact to product end of life cycleViktoria Bashkite, Roman ZahharovTallinn University of Technologyviktoria_bashkite@yahoo.com, roman.zahharov@gmail.com.AbstractThe emergence of green construction solutions asthe combination of environmental and economicopportunities has been driving several constructionrelated industries towards usage of approachesprovided by the green building movement. Withinconstruction industry modularization of buildingand right green engineering of product life cycleemphasizes these and related issues. It is veryimportant to consider every period in a product'slife cycle management due to its use of energy(producing, running, maintaining, recycling anddisposing). The objectives of this paper arecomparison of different modular building typesversus conventional construction and overview ofpossibilities with regards to material consumptionat the end-of-life phase through Design forDestruction approach (DfD). Life cycle expectancyof modular building, regardless of its type, is atleast the same as of conventional one. Whileimportance of sustainability is gaining momentumwith every day, world leading companies in theconstruction industry are as well seeking foreffective solutions, modularity is one of them.There are several fundamental principles intrinsicwith the modular construction process, whichmakes it more eco-friendly than conventionalconstruction. There is no experience with modularbuilding landfilling since 1986.KeywordsProduct life cycle, end-of-life strategies,modular building1. IntroductionWhat humans have not done to destroy and harm thenatural atmosphere and eco-system of this world andwhat a man is not doing to save the earth again? It isa positive sign that many people are heading towardsmuch eco-friendly alternatives in all areas of theirlives. Even the manufacturing sector has realized theimportance of earth saving alternatives and theproductions are now based on reusable resources andmaterials. Yet still the most important role in thiscause can be played by the smart modifications thatshould be employed. The main objective of thispaper is to show on practice how different end-oflifemanufacturing principles can be applied toseveral building construction types through itsmodularization. Speaking more precisely, researchwill touch comparison of different constructionbuildings, product’s life cycle engineeringperspectives, real-life implementation benefits andconsequences and the possible end-of-lifeopportunities [1]. The scope of this paper is todescribe possible real life case study: design fordeconstruction.2. Modular building typesThere are 5 different types of modular buildings:• Type I – typically, concrete framebuildings made of noncombustiblematerials. All of the building elements(structural frame, bearing walls, floors androofs) are fire resistance rated.• Type II – these buildings are constructed ofnoncombustible materials. Typically,masonry bearing walls structures with steelstuds for walls and steel bar joists for floorand roof structures. II-A has fire ratedbuilding elements (structural frame, bearingwalls, floors and roofs). II-B is the mostcommon construction type for commercialbuildings because the building elements arenot required to be fire resistance rated butstill must be noncombustible.• Type III – construction in which theexterior walls are made of noncombustiblematerials and the interior building elementsare of any material permitted by the code(combustible or noncombustible). This istypical of buildings with masonry bearingwalls and wood roofs or floors.• Type IV (Heavy Timber, HT) – type ofconstruction in which the exterior walls areof noncombustible materials and theinterior building elements are of solid orlaminated wood without concealed spaces.• Type V – typically wood frameconstruction. Type of construction in whichstructural elements, exterior walls andinterior walls are made of any materialspermitted by the code.If we look at all these types the definition ofmodular building can be next: “An off-site projectdelivery method used to construct code-compliantbuildings in a quality-controlled setting in less timeand with less materials waste.” This definition is notlimited to Type V construction. While Type Vconstruction is much more prevalent within themodular industry, several companies havesuccessfully designed and built all types of facilitiesfor a multitude of purposes utilizing modularconstruction processes [2].213

2.1. Comparison of modular building andconventional constructionModular construction holds many advantages whencompared to conventional construction. Relocateand reuse the modular room is the first seriousadvantage. All the components are 100% reusable.The number one reason for buying modular office isthe ability to take the building down and relocate it.This feature benefits the small firm that leasesbecause the modular rooms always remain theirasset, when it is time to move, the modular roomscan go with them. This feature also benefits thelarger company. Should their needs change and themodular room would be better suited elsewhere thenit can be moved and they never lose their originalinvestment.Companies grow, needs change and so can themodular room; redesign your office - adapt to newrequirements. Whether you need more space or needto change your current modular room configurationyou are not locked into your original design. Allpanels are interchangeable and can be assembled tofit any current need. The non-progressive postdesign provides the ability to swap or replaceindividual panels without disturbing adjacent panels.For example, if a solid wall panel now requires adoor it can be switched out for a door panel in amatter of minutes.Stronger construction - suited for an industrialenvironment. Many rooms today are built usingdrywall and studs, leaving unsupported cavities thatcan be punctured easily. Modular office rooms usemuch stronger materials and utilize an importantdesign feature, fully supported wall substrates usingeither insulated polystyrene or honeycomb cores;this gives the walls true impact resistance for longuseful life. In addition the availability of steelfacings adds even more strength.Better sound deadening than conventional rooms isalso a great benefit comparing to conventionaloffices. Modular enclosures create a comfortablework area even in the loudest manufacturing plants.Installing an industrial modular room is more thanjust putting up walls; it involves utilizing a systemthat will meet the specific requirements of the plant.One of the most important requirements is soundcontrol, without the proper sound control a roomcould be rendered useless.Faster occupancy provides the fast come back tobusiness. Modular building installation is faster upto 75% than stick-built. The standard small modularroom is assembled and ready to move in, in one day,with conventional construction that time can beweeks. Weeks of sub contractors and inspections canput any company behind schedule and this cantranslate directly into money lost. The faster you areback to normal the faster you get back to business.Modular building construction reduces labor costsby up to 50%. This could be a very conservativefigure considering the installation speed of modularoffices products and the reduction in tradesnecessary to build, the savings are tremendous. Ittakes only one crew to assemble a modular officesbuilding, and several trades like glazers, painters,carpenters etc. to build conventionally the larger theproject, the more the savings.Fewer plant disruptions - minimize productivity lossthat can cause expensive loss of productivity. Allconstruction even modular causes plant disruption,however the longer it takes to complete a project themore disruption gets. A serious evaluation of costswould include this often over looked expense; mostpeople are amazed how fast these costs add up. Foran estimate, multiply the number of people in thearea of construction by just 10 minutes ofdistractions, then multiply that by the number ofdays it takes to complete the project, from this youcan determine the number of hours lost, nowmultiply this by the average cost per labor hour. Theloss of productivity is real and expensive.Less mess to contend with construction processmeans lower cost. Sealing off areas, and detailedcleaning of equipment all can be expensive for theaverage industry, but if a company is involved infood processing or clean environments the costs toshut down and handle this are enormous.Permits are not always needed. Small modularrooms within a plant can usually be assembledwithout permit. This is never the case withconventional construction; it always requires apermit and can tie up a project for weeks. Of course,everything depends on country laws where theproject has to be executed.Quality of modular office is much higher thanconventional one. Modular product is qualityinspected before it ships and is manufactured toexact standards. The finished product is neverquestionable, a clear point that conventionalconstruction can not make. How good isconventional construction? It depends on the workcrew. The truth is that most construction, if notclosely watched can turn into a disaster. Table 1describes all the differences between modular andtraditional home buildings.2.2. Costs savingsIt is proved that it is possible to save up to 33% overconventional methods. The reason is high speed andautomated manufacturing processes. Thisproductivity can not be matched by any constructioncrew. As any experienced builder can tell you, siteconstruction is labor intensive and expensive.Simply put, modular products are reusable. Whenthe change is needed there is no lose in investment,re-use it. Compared to conventional methods, that'slike getting materials free over and over. Thousandsof modular building users benefit from thisadvantage every year. There are no dumping fees toremove demolished construction. All these savingsare aside, there is something far more important; theenvironmental impact. Reusing modular buildingbecause of relocation or by changing a configurationis recycling at its best. This is a very importantaspect of modular product life cycle design, becausethe importance of conservation is taken into account.This could be a very conservative figure consideringthe installation speed of modular products and thereduction in trades necessary to build. It takes onlyone crew to assemble a modular offices building,and several trades like glazers, painters, carpentersetc. to build conventionally the larger the project, themore the savings [3].214

Table 1. Comparison table Modular building versus traditional construction methods [4].Build codesDesignMaintenanceCostResell valueTimeframeAppearanceBuildingprocessModular homesModular homes are treated as traditionalhomes and must follow the local buildingcodes and regulations. Also it must followlocal zoning regulations.No construction occurs until the homeownerspick the design. Most builders provide sampleplans to help guide you in your customization.Modular homes are normally highlycustomized in their interior and exteriorappearances. In some cases it is even possibleto have your personal architect design a homeand then forward the plans to you modularbuilding centre.These homes are built in a climate controlledfactory using high quality materials and moreprecise building techniques that are capableinside a factory. Modular homes areintentional designed with additional insulationand other energy savings to reduce yourmaintenance costs.Modular homes increase in value over time.Once they are completed it is near impossibleto tell the difference between traditionallybuilt homes and modular homes. These homescan also be improved or expanded.This normal timeframe is 8-14 weeks. Thereare some time savings since construction canbegin in the factory at the same time yourfoundation is being created on your site. Alsoweather has almost no impact on the schedule.Appearance can be the same as any traditionalsite-built home. You can add any style ofwindow, door, wall or architectural featureyou prefer. Once completed you can not tellthe difference between modular and traditionalhomes.It enjoys the benefits of assembly-linebuilding. In a manufacturing factory. Theremoves delays cause by the weather andvandalism damages. This more efficientprocess reduces the cost when compared totraditional homes.Traditional homesTraditional homes are subject to the localbuildings codes and to the local zoningregulations.Can be customized to the owner’s preferences.Sometime developers will buy large plots ofland, divide it into smaller plots and buildidentical homes next to each other. You can alsohire an architect to design your home accordingto your preference or purchase home plans onlineand then hire a contractor to follow those plans.Since they are built on-site in all types ofweather the quality of the product varies greatly.Research has shown that traditional homes aremore likely to require repairs and highermaintenance costs.Traditional homes will increase in value overtime. They can be improved and expanded toaccommodate new owner’s preferences.The normal timeframe is several months. Sinceall construction occurs on site, work projects cannot start until the previous project is completed.The work schedule is dependent on the weatherconditions.The appearance can be customized to the homeowners’ preference. Traditional homes canaccommodate any architectural preference.The most costly building process which requiresalmost the entire house to be custom constructed.It will require more people which will take moretime since they do not work on the same type ofhouse everyday. It is also vulnerable to weatherdelays and vandalism costs. This process is themost likely to result in damaged buildingproducts like warped wood from rain exposure.2.3. Seven reasons why modular building isGreenHow are modular structures more beneficial?Modular construction techniques have been shownto be inherently advantageous in 7 major areas:• Less materials waste – pre-fabrication makesit possible to optimize construction materialspurchases and usage while minimizing on-sitewaste and offering a higher quality product tothe buyer. Bulk materials are delivered to themanufacturing facility where they are storedin a protected environment safe from theft andexposure to the environmental conditions of ajob site.• Less material exposure to inclement weather– many of the indoor air quality issuesidentified in new construction result fromhigh moisture levels in the framing materials.Because the modular structure is substantiallycompleted in a factory-controlled settingusing dry materials, the potential for highlevels of moisture being trapped in the newconstruction is eliminated.• Less site disturbance – the modular structureis constructed off-site simultaneous tofoundation and other site work, therebyreducing the time and impact on thesurrounding site environment, as well asreducing the number of vehicles andequipment needed at the site.215

• Safer construction – modular construction is asafer alternative. Conventional constructionworkers regularly work in less than idealconditions dealing with temperature extremes,rain, wind, or any combination of naturalconditions. This, by its very nature, is a muchmore challenging environment to work safelyin. Additionally, the potential for injuryincluding falls, the most common work siterisk, is much higher. In a factory controlledsetting, each worker is typically assigned to awork station supplied with all the appropriateequipment needed to provide the safest workenvironment possible. Off-site constructionalso eliminates the hazards associated withmaterials, equipment and an incompleteconstruction processes typical of constructionsites that can attract curious and unwelcome“visitors” (i.e. students on a school expansionproject).• Flexibility – when the needs change, modularbuildings can be disassembled and themodules relocated or refurbished for theirnext use reducing the demand for rawmaterials and minimizing the amount ofenergy expended to create a building to meetthe new need. In essence, the entire buildingcan be recycled in some cases.• Adaptability – modular buildings arefrequently designed to quickly add or removeone or more “modules” minimizingdisruptions to adjacent buildings andsurroundings.• Built to code with shorter build times – thebottom line is that with modular constructionyou can get a facility built to the same localcodes with construction quality as good as orbetter than a comparable site built building inmuch less time. Additionally, the abbreviatedconstruction schedule allows you to get areturn on your investment sooner whileminimizing the exposure to the riskscommonly associated with protractedconstruction schedules [5].3. Modular building end of life cycleplanningUnder ideal circumstances, buildings would bedesigned for deconstruction and built using materialsrecovered from other buildings that themselves hadbeen designed for deconstruction. In reality,unfortunately, it is not yet possible to achieve aclosed-loop building life cycle (i.e., to eliminate theneed for any new materials or systems). Butadhering to life cycle construction principleswhenever possible can provide meaningful benefitsby reducing the energy and resource consumptionrequired to produce the necessary building materialsand systems and by reducing solid waste. In the nearterm, three specific life cycle construction practiceswill be offering the greatest potential:• Demolition – destruction of older buildingsthat were not designed for deconstruction,with reuse of salvaged materials in otherbuilding projects whenever possible;• Design for Deconstruction (DfD) andMaterials Reuse – construction of newbuildings using DfD principles and, wherepossible, incorporating salvaged buildingmaterials; and• Green Building – retrofitting and newconstruction of buildings to include greenbuilding elements such as sustainable siteplanning, energy efficiency, safeguardingwater and water efficiency, conservation ofmaterials and resources, and improved indoorenvironmental quality. The main idea ofGreen Building is the closed-loop life cycle ofit. The life cycle of it is known from thebeginning till the end.In this article, the DfD will be described moreprecisely; due to the result of this procedure is moreperspective from every point of view; economicaland environmental.4. Design for DeconstructionThe ultimate goal of the Design for Deconstruction(DfD) movement is to responsibly manage end-oflifebuilding materials to minimize consumption ofraw materials. By capturing materials removedduring building renovation or demolition and findingways to reuse them in another construction projector recycle them into a new product, the overallenvironmental impact of end-of-life buildingmaterials can be reduced. Architects and engineerscan contribute to this movement by designingbuildings that facilitate adaptation and renovation.What was yesterday a functional building is today aworthless pile of rubble sitting on the site for all tosee. However, the real benefits of deconstruction –including Designing for Deconstruction (DfD) – isabout closing the loop of resource use. It is aboutreusing these “waste” resources to avoid logging ormining new virgin resources from our ecosystems.Designing for Deconstruction is about designing insuch a way that these resources can be economicallyrecovered and reused. In contrast to the conventionallinear model of extraction, use, and landfilling, DfDenvisions a closed cycle of use and reuse [6].4.1. What determines if buildings getdeconstructed?Deconstruction is often discussed primarily as astrategy to meet environmental goals, but it can meetsocial and economic goals as well. There must be aninfrastructure of contractors skilled in deconstructingbuildings, the cost of deconstruction and therecovered materials must be competitive withalternatives, and there must be a market for therecovered materials. Some of the key factorsdetermining if buildings are deconstructed include:• The local cost of landfill tipping fees• The local cost of labour and equipment• The ease of disassembly which affects labourcost• The value of the materials recovered• Having adequate time available fordeconstruction216

Landfill tipping fees – charges for depositing wasteon a landfill – vary greatly by region from less than€35 ton to over €45 ton in states. In areas with hightipping fees, deconstructing buildings can avoidsubstantial tipping fees, which can help offset theadditional labour needed to disassemble thebuilding. Labour and equipment costs also varygreatly by region, and significantly affect theeconomics of labour-intensive deconstruction. Thevalue of the materials recovered is also a key factor.The booming salvaged wood market has spurredincreased competition for buildings containing largetimbers or high quality old-growth lumber. Manyhomeowners are willing to pay a premium forrecycled wood that has a story and “character.”Salvaged components such as antique fireplacesurrounds, light fixtures, hardware, and otherornamental pieces can be shipped to a nationalmarket and command high prices, as a quick searchon E-Bay will show. Designers can increase thelikelihood that a building will be deconstructed ifthey choose quality materials that will have a highvalue in the future. Deconstruction does take longerthan demolishing a building with heavy equipment,if this is not considered, it likely will not happen. Ifdemolition of an existing structure is part of aconstruction contract for a new building, thecontractor will often want it down as quickly aspossible to start on the new project and meet thatschedule. It often makes sense to issue a separatecontract prior to and separate from the new work torelieve some of the schedule pressure. If the buildingto be demolished is in use or generating revenuefrom a lease, these can present real obstacles. Theease and speed of deconstruction is a key factor thatthis Handbook most directly addresses. How canarchitects, engineers, and builders put buildingstogether that are easier to take apart? Do thefastening methods allow disassembly, and are theseconnections accessible? Are there too manymaterials or are they assembled in a complex,intertwined manner? Are hazardous materialsintermixed with the valuable ones? Are thecomponents visible or identifiable on existingdrawings? Are glues and composite materialsavoided? The designers and builders of ourstructures have a major impact on how readily theycan be deconstructed. Often a simple mental shift tojust think about the ease of disassembly duringdesign and construction reveals numerous strategiesthat can be easily adopted.Deconstruction strategies:• Maximize clarity and simplicity• Minimize building complexity• Minimize different types of materials• Minimize number of components (fewer,larger elements)• Minimize number of fasteners (fewer,stronger fasteners)• Use mechanical fasteners in lieu of sealantsand adhesives• Simplify connections• Make connections visible/accessible• Separate building layers or systems• Disentangle utilities from structure• Use materials worth recovering• Minimize toxic materials• Minimize composite materials• Use of modular buildingcomponents/assemblies• Provide access to components/assemblies(windows, etc)• Provide access or tie-offs for work at height• Accessible information:• Construction drawings & details• Identification of materials and components• Structural propertiesModularization and prefabrication can promotereuse and recycling at a larger scale – whethermodules of assemblies or their component materials.However, modules and components should bedimensioned for reuse. It only makes sense tomodularize a particular assembly if it makesconstruction and deconstruction easier. And ifmodularization complicates assembly or if itinvolves the modularization of overly specificpieces, then it may in fact force creative reuse at best[7].5. ConclusionsThe green engineering design and manufacturing areaffecting every aspect of our life. The greenrevolution will be even bigger than the Internetrevolution is. Greening has already attracted a widearea of research topics and will attract more andmore. At the moment the most important thing whatengineers can do is to provide the sustainableproduct life cycle strategy. As above mentioned casestudies proved the life cycle engineering holds theguiding product life cycle management. Our goal isto promote the product life cycle engineering ingreen way by using successful practices fromdifferent industrial areas all over the world.References1. Sundin, E., Larsson, M., Nielsen, A. Design forfunctional sales – a case study of forklift trucksat BT industries. Proceedings of EcoDesign-05,Tokyo, 2005.2. Modular Building Institute. Rethink modular:Assessing the durability and life cycle ofmodular construction. Modular Industry Report.September 2009, [www] http://www.modular.org3. National Partitions. Case studies 2010, [www]http://np.com/advantages/why_modular/mod_vs_conv.aspx4. Key, T. Insider’s guide to modular home. 2009.[www] http://www.modulartoday.com5. Kobet, R. J., Modular Building and theUSGBC’s LEED; Building rating system. Ver.3.0, 2009 .6. Guy, B., Gibeau, E. A Guide to Deconstruction,[www]http://www.deconstructioninstitute.com/files/learn_center/45762865_guidebook.pdf, 2003.7. Guy, B., Shell, S., Design for Deconstruction andMaterials Reuse. Proceedings of the CIB TaskGroup 39 – Deconstruction Meeting edited byAbdol Chini and Frank Schultmann. CIBPublication 272, 2002.217