Published 2019

Swan Housing Association

Text © Waugh Thistleton Architects,

NU living and Ramboll

Photographs and illustrations

© Waugh Thistleton Architects

Cover design by Fuel

All rights reserved

No part of this publication may be
reproduced without the written permission
of the publisher or the copyright owner.

Printed in the UK
REPEATABLE PROCESS,
NOT REPEATABLE
PRODUCTS
CONTENTS

1   INTRODUCTION 7
1.1 How to use this guide 9
1.2 Swan and NU living 10
1.3 Modular benefits 12
1.4 Sustainability14

2   MODUL AR PROCESSES 19
2.1 Factory process  20
2.2 Design and assembly process 22

3   MODUL AR PRINCIPLES 35
3.1 Transportation36
3.2 Site considerations 42
3.3 CLT panels 48
3.4 Structural principles 52
3.5 Ground floor construction 58
3.6 Waterproofing64
3.7 On site finishes  68
3.8 Roofs72
3.9 Communal stair cores  76
3.10 Fire design principles 80
3.11 Thermal principles 84
3.12 Acoustic principles 88

4   INTERNAL PRINCIPLES 93
4.1 Internal layout of modules 94
4.2 Servicing principles 100

5   INFORMATION FOR MANUFACTURE 107

5.1 Using BIM and 4D 108
5.2 Drawing for manufacture 112
5.3 Room data sheets 116
5.4 Module types 120

6   APPENDIX 125
6.1 Checklist126
6.2 Glossary136
1

INTRODUCTION
1.1 HOW TO USE
THIS GUIDE

This guide sets out considerations for designing

modular housing, based on NU living’s ‘NU build’
modular system.

It aims to give the design team an understanding of

the interrelationship between the consultants, the client
and the factory.

Designing for modular means thinking about how each

module is made, transported and assembled at every
stage of the design development. It does not mean
standardising homes, but considering the standard
process of manufacture.

This guide is not intended as a pattern book, but

instead presents topics for the reader to consider during
the design process, offering guidance notes to aid the
designer in finding solutions. The guide should be used
alongside all relevant regulations and legislation.

9
1.2 SWAN AND NU LIVING

Swan’s mission is to deliver effective services, enterprising solutions and exemplary homes and communities
in Essex and East London, delivering neighbourhoods that are healthy, vibrant and sustainable.

The Swan Group includes Swan Housing Association and NU living.

1.2.1 Swan 1.2.2 NU living

Swan Housing Association was first formed Swan Housing Association was one of the first housing
in 1994 and provides high quality and associations to have its own in-house developer,
affordable homes to rent and buy. NU living. NU living is building homes that are
environmentally, socially and economically sustainable.
Today, Swan operates in Essex and East This commercial acumen means that generated income
London and manages over 11,000 homes. produces gift aid to make a real difference to local
With a secured development pipeline communities by funding the provision of affordable
of 8,000 homes, it is on track to meet its homes, care and support. All profits made by NU living
ambitious plan to deliver 10,000 homes by through its commercial activities, including the sale
2027. of homes, are reinvested in delivering Swan’s social
purpose – that is providing homes and services to those
Swan is committed to growth and innovation who need them.
in delivering excellent services. They are one
of the UK’s leading regenerating housing 1.2.3 NU build system
associations and boast a host of award
winning schemes. Efficient and enterprising, Swan has created an offsite modular manufacturing
they deliver new, high quality housing across approach known as the ‘NU build system’.
all tenures.
The NU build system, operated by NU living, will
Swan Housing Association Limited is deliver stylish, high quality modular homes to meet
registered as an exempt charity under housing need. Going forward, NU living will complete
the Cooperative and Community Benefit many of Swan’s exemplary regeneration projects using
Societies Act 2014 (Registered Number: modular homes built by NU living in their state of the
28496R) and with the Homes and art, high-tech factory in Basildon, Essex, using the NU
Communities Agency (Registered Number: build system.
L4145).

10
 Swan and NU living

At full capacity they will deliver up to 500 and East London. Critically, these homes are part of
homes a year, employing over 60 staff and wider regeneration projects which will see Swan build
supporting the growing local economy in new sustainable communities with much needed health,
Basildon and investing in UK manufacturing. education and infrastructure services, as well as retail
and commercial spaces and high quality public realm.
All are maintained by Swan for the long term.
1.2.4 What makes Swan unique?
Every home sold means that the buyer is contributing to
Swan are leading the way by deliberately the regeneration of homes and communities for others.
focussing on supporting the growing UK
modular construction industry rather than
looking to overseas expertise.

There are many types of modular homes

being built across the UK. Swan’s are unique
for a number of reasons:
somewhere to feel at home
–– The homes are mortgageable.

–– They are built to current building

regulations.

–– They are insurable and warrantable.

–– They are sustainably funded.

–– The homes are built for their own

marketing and sale.

–– The homes are designed to be fully

customisable by the buyer.

Unlike other private developers, all profits

from the sales of homes are reinvested within
the Swan Group to fund their regeneration
and housing activities providing thousands
of high quality affordable homes in Essex
Figure 1 The NU build factory in Basildon, Essex

11
1.3 MODULAR BENEFITS

The UK is suffering from both a housing and a labour crisis. Fewer homes are being built each year and
fewer people want to work in the construction industry yet demand for homes continues to outstrip supply.
Drawing on the efficient production methods and product quality developed by ship, aircraft and car
production, offsite manufacture addresses some of the failings of traditional methods of construction.

1.3.1 Fast

Time on site is significantly reduced as

whole finished homes can be assembled
within a day, reducing the lengthy disruption
associated with a traditional building site.
The manufacturing times of elements in
the factory are also reduced compared
to a traditional on site build. Information
generated by Building Information
Modelling (BIM) allows the factory to order
products ‘just in time’ with the benefit of a
consistent material and labour supply chain.

Figure 2 Fiat’s production line

The controlled factory environment means
that short days and bad weather do not
interfere with production. Reduced
lead times

1.3.2 Quality control Stock Stock

forecasting management

Each module can be constructed in a JUST

IN
clean and controlled environment with the TIME
necessary tools and materials close at hand. Improved Make and
The construction process under factory cash flow hold stock
Secure and
conditions can offer a level of quality and competitive
consistency that traditional construction pricing

cannot compete with.

Figure 3 Modular design with BIM allows products to be ordered ‘just in
time’ which offers a number of benefits

12
 Modular Benefits
Mitsubishi GS platform

1 PLATFORM
1.3.3 Weather tight to site

Modular construction provides the

significant benefit of being able to deliver a
fully weather tight unit to site. MITSUBISHI

1.3.4 Reduced waste

DODGE

The direct link between the BIM model and

ordering materials minimises over supply.
JEEP CHRYSLER
Efficiencies in the use of CLT and other
products can be incorporated into the
design so that off cuts do not go to waste CITROËN PROTON
- refer to Chapter 3.3 : CLT panels for more
information. 14 MODELS

ACROSS 6 BRANDS
1.3.5 Repeatable process not repeatable
Figure 5 The Mitsubishi GS Platform - numerous models across
product many brands

The Mitsubishi GS Platform uses the same building types, rather than a limited number of modules
compact car platform for numerous models that create repetitive buildings.
across many brands. Similarly the NU build
modular system can form the base of a wide 1.3.6 More attractive jobs
range of module types and buildings.
Factories offer workers regular hours along with a safe
The modular process is a way to enable the and clean working environment. Improved conditions
designer to create a variety of products that attract more diverse workers to the construction industry.
can be linked together to create different

Figure 4 CLT modular construction process

13
1 . 4 S U S TA I N A B I L I T Y

The world is in the midst of a housing crisis with unprecedented global mass migration to cities. In order
to deal with this flow of people, more high density buildings are required. The production and installation
of concrete and steel are currently responsible for more than 10% of the world’s carbon dioxide emissions,
a figure that will increase if current trends within the construction industry continue. Alternative building
materials need to be used to address this. (Source: PBL Netherlands Environmental Assessment Agency;
European Commission Joint Research Centre; MIT)

Concrete Cement/clay

Steel Plastics

Shipping Wood

Airlines Glass

Everything else Rubber

Paint

Concrete and steel production is responsible for 10% of all Cement and clay make up 64% of the CO2 emissions
carbon emissions for manufacture of construction materials

(IPCC) (gov.uk)

One million new homes are required between 18 million tonnes of carbon emitted, if constructed from
2015-2020 concrete

Figure 6 Carbon emissions to build one million homes

14
 Sustainability

1.4.1 Context Forests can be replenished as needed and harvested

timber absorbs carbon dioxide as it grows becoming a
The operational energy consumption in carbon store. Using timber for structure, cladding, and
modern buildings is low. Therefore reducing fittings can significantly lower a building’s embodied
the energy embodied in the construction carbon profile.
process is now the major challenge facing
the industry. 1.4.2 What is CLT?

Embodied carbon accounts for almost 70% Cross-laminated timber (CLT) is made from multiple
of the carbon emissions for a residential layers of solid wood. By bonding the longitudinal and
project’s 60 year lifespan. It receives less transverse layers together using environmentally friendly
attention than the carbon emitted in the glue, any warping of the wood - swelling or shrinkage
operation of a building, but it is essential - is reduced to a negligible level and considerably
that we address embodied carbon if we increases the load bearing capacity of the material.
are to transition towards a net zero carbon
economy and meet the targets set out in
the Climate Change Act and Paris Climate
Agreement.

100%

80%
Products
68%
Operations
54%
60%

40%
46%
Products
32%
20% Operations

0%
2018 2035 2050 2078

Figure 7 CO2 emissions caused by the building’s operation and use compared with embodied CO2 from construction (Source: EIA/Richard
Stein, 2011)

15
Sustainability

Forests absorb CO2 from

the atmosphere through
photosynthesis

Wood can be burned Trees are a renewable

for clean energy resource and store carbon

Wood products can be Manufacturing processes

reused or recycled to typically use all parts of
create new products the log, producing no
waste and little pollution

Timber buildings store carbon in Engineered timber

their structures for the period of products require fewer
their maintained life deliveries to site

Figure 8 CLT carbon cycle (Illustration: Yugon Kim)

16
 Sustainability

After extensive research, NU living selected 1.4.3 CLT acoustic and thermal properties
CLT as their material because it is:
The solid panel construction and air tightness of
–– Incredibly rigid. CLT construction enhances the acoustic and thermal
properties of the building fabric: the typical U-value
–– Capable of being manufactured to a of CLT in accordance with EN ISO 10456 is lamda r
fine tolerance. of 0.12W/mK. Refer to Chapter 3.11 : Thermal principles
and Chapter 3.12 : Acoustic principles for further
–– Structurally stable. information.

–– More environmentally sustainable than 1.4.4 CLT can be easily machined

alternative modular systems, such as
steel frame. CLT is processed using automatic profiling and CNC-
controlled joinery machines. The panels arrive in the
–– Able to achieve high levels of air factory and data from the BIM model is fed into the
tightness with relative ease. CNC machine to cut out penetrations such as doors,
windows and service holes.
As CLT is a solid timber panel it has
advantages in terms of sound, airtightness Digital technology can be used to ensure that the
and thermal insulation as well as being easy maximum number of usable panels are cut out of a
to fix to. single CLT panel - refer to Chapter 3.3 : CLT panels for
further information.

Biomass power
Bark + wood chips

Biomass fuel + animal bedding

Kiln drying Cutting + planing CLT panels for distribution

Figure 9 The waste products from CLT manufacture can be reused as a fuel source

17
2

MODULAR

PROCESSES
2.1 FACTORY PROCESS

In order to successfully design for modular construction, the designer should have an understanding of
the way in which the NU living factory operates This will allow elements of the design to be adapted to
compliment the manufacturing process, creating an efficient and easily assembled modular design.

2.1.1 Geographic region

NU living’s state of the art factory is located

in Prologis Park, Basildon and comprises
a 7000 sq m facility which includes the
manufacturing plant, staff and office areas
and an Innovation Centre that is used to
host events and as a creative space for the
Swan Group. The building is sustainably
designed, with performance measured
through environmental certification, reduced
operational carbon emissions and mitigated
embodied carbon emissions. Waste from
CLT panels is used to make wood chips that NU build factory
0 20 km
are used to heat the factory. Modular sites

Figure 10 Current geographic region of the NU build factory

Swan’s modular developments are situated
within a limited geographic region. The
factory’s location in Basildon allows for good 2.1.2 Factory operation style
connections to the M25, providing easy
access to Essex and east London, reducing The NU build system uses a continuous flow production
the distances between the factory and site. model. This is where modules move through a series
of stages around the factory. Jigs and fixtures can be
The factory employs over 50 staff, and utilised to aid tasks and workers are trained to focus on
contributes to local economic growth, specific tasks which improves speed and consistency.
providing jobs in Basildon and helping to Processes and methods that compliment this model
build upon local expertise in manufacturing. should be considered throughout the design process.

20
 Factory Process

ocess 1 ocess 2 ocess 3 ocess 4

Pr Pr Pr Pr

S TA R T FINISH

Figure 11 For a continuous flow model, each factory process should take an equal amount of time, this is known as line balancing

2.1.3 Processes and time If the design requires every panel to be a different
size and shape, consideration should be given to the
In order to produce the optimal number of time and space needed to store the panels before use.
modules, the factory aims for each process Additional time will be needed to coordinate panel
to take as little time as possible, and each locations in order to select the correct panel for each
process should be balanced so that they all part of the design.
take a similar amount of time. This allows
the modules to progress through the factory 2.1.5 CNC programming
at an even pace.
The CNC machine is a five axis machining centre which
This should be considered when specifying allows high speed cutting of CLT. It has two working
any finishes that have a lengthy drying time beds each capable of taking a full sized CLT panel. This
as this can reduce the number of modules allows one panel to be machined on one bed while the
that are produced each day or require next panel is being loaded onto the adjacent bed. The
additional space in the factory to store versatility of the five axes means complex angles can
drying modules. be easily machined with high accuracy and consistency.

2.1.4 Storage programming and design Using data from the BIM model, the CNC machine is
programmed offline using specialist software that can
The manufacturing process can be improved simulate the machining to maximise efficient usage of
if common sizes and shapes of CLT panels the CLT panels reducing errors and waste.
are used. These can be easily stacked,
taking up less room for storage, and will not Unifying the size of openings, such as those for services,
require a complicated system to coordinate windows and doors, makes tooling and programming
the different panel types. requirements less complex.

21
2 . 2 D E S I G N A N D A S S E M B LY P R O C E S S

There are two main benefits of offsite manufacturing: to speed up delivery and to increase quality. However,
to fully realise its potential, it is essential that the design team understands that designing for manufacture
and assembly is fundamentally different to designing for traditional construction, requiring a different
mindset and a different approach from the outset.

2.2.1 A different way of building cost and time implications. If the production line stops
this results in significant financial and programme
Information for manufacture needs to be loses. Figure 13 compares the relationship between the
fully coordinated at the point at which design changes and cost for a typical design and build
production begins. This means that the contract with a modular project.
quality of information produced by the
consultant team far exceeds that produced 2.2.2 RIBA workstages when designing for
for a typical design and build contract - it manufacture
cannot just be design intent and instead
requires a fully coordinated and detailed To understand how to design for the NU build
design. manufacturing process consultants need to
fundamentally change their approach to the design
A design and build contract allows the process. Figure 12 shows a high level comparison of the
contractor to complete the design, resulting work required for a typical design and build contract
in changes and cost savings during the compared to designing for manufacture. During RIBA
construction phase. When designing for workstages 0-5 the consultants’ work is compressed into
manufacture, consultants must understand the pre-manufacture stage and minimal stage 5 work is
that changes to the design or specification done once manufacture starts.
during the manufacturing process has huge

TRADITIONAL SITE BUILT CONSTRUCTION - SEQUENTIAL PROCESS

Design, Permitting, Site Preparation,
FINIS H

Engineering, Approval Civil Engineering, Site Construction, Mechanical Installation, Finish Work
Process Infrastructure

OFF-SITE CONSTRUCTION - CONCURRENT PROCESS

FIN ISH

Site Preparation
Design, Permitting, Engineering, Approval Process Assembly
Manufacturing

Figure 12 Comparison of the work required for a traditional construction and manufacture and assembly

22
 Design and assembly process

The RIBA have produced an overlay to the to set out their fees and scope of services. To assist
2013 Plan of Work where they describe the designers in understanding their modular design
ways in which designing for manufacture process, NU build have devised their own stages.
and assembly (DfMA) should be considered
at each of the RIBA workstages. In addition 2.2.3 NU build modular process
to this, Swan have a suite of documents that
outline the DfMA services to be provided Figure 14 gives a breakdown of the stages of work for a
from each consultant. NU build modular project, leading up to and including
assembly on site. All the stages are interrelated and
When starting a project, consultants should need to be continually evaluated as the design evolves.
refer to the RIBA workstages, the DfMA The NU stages are:
overlay and Swan’s suite of documents,
–– Brief

DESIGN + BUILD –– Logistics

–– Strategy
C O S T I M PA C T O F D E S I G N C H A N G E S

ABILITY TO INFLUENCE DESIGN

–– Performance

–– Detail

–– Information
TIME

DESIGN TENDER CONSTRUCTION –– Manufacture and Transportation

M A N U FA C T U R E + A S S E M B LY –– Assembly
C O S T I M PA C T O F D E S I G N C H A N G E S

Each NU stage is a gateway to the next and must be

ABILITY TO INFLUENCE DESIGN

reviewed before the design can progress. The first five

NU stages should be signed off as a whole by both
the client and the factory before final information is
produced and the modules are manufactured. The last
three NU stages are separated from the earlier stages
to illustrate that the information required by consultants
TIME should be minimal to avoid the large cost and time
DESIGN M A N U FA C T U R E A S S E M B LY
implications of changes once manufacture has begun.
Figure 13 The relationship between the design changes
and cost for design and build and modular

23
 BRIEF LOGISTIC S T R AT E GY PERFORMANCE

- Check that site is viable - Access to site - Structural principles - Thermal performance
for modular
- Ground conditions - Servicing principles - Fire performance
- Employer’s Requirements
- Site assembly - Acoustic performance
- Accessible units
- Educate design team on
modular - Transport - Materials
- Lifting principles
- Incorporate lessons from - CLT panel sizes - Finishes
previous projects - Fire principles
- Assembly and installation - Roof type
sequence agreed - Ground floor detail
principles

- Waterproofing principles
C LI EN T

C LI EN T

C LI EN T

C LI EN T
R EV I E W

R EV I E W

R EV I E W

R EV I E W
+

+
FACTOR Y

FACTOR Y

FACTOR Y

FACTOR Y
ED

ED

ED
RE

RE

RE

RE
ED

ED

ED
AD

AD

AD

AD

D E D E D E D
RE RE RE RE
SS AS N SS AS N SS AS N SS

0 1 2 3
R I B A W O R K S TA G E S

Figure 14 The NU build Modular Design Stages

 MANUFACTURE &
D E TA I L I N F O R M AT I O N A S S E M B LY
T R A N S P O R TAT I O N

- Kitchens - 1:20 drawings of each - Protect modules from - Site preparation

module water during transit
- Bathrooms - Accuracy of landing
- 1:10/1:5 details - Timings the modules on the
- Doors foundations
- Room data sheets - Just in time delivery
- Windows - Underground services
- Specification information - Storage alignment and fixing
- Internal finishes such as NBS details
- Details of walls, floors, - Full plans, sections and
roof and foundations - Scaffolding plan
elevations
- On site water
- Schedules management and fire
strategy
C LI EN T

C LI EN T

C LI EN T

C LI EN T
RE V I EW

RE V I EW

RE V I EW

RE V I EW
+

+
FACTOR Y

FACTOR Y

FACTOR Y

FACTOR Y

CLIENT
ED

LY

LY
PR

PR

+
ED

FACTORY G G
O

E RE O RE O
N
AS SIGN OFF SSION SSION

4 4 5 5
R I B A W O R K S TA G E S
 - Educate design team on - Ground conditions - Servicing principles
modular
- Site assembly
modular - Accessible units - Acoustic performance
- Site assembly - Accessible units
- Incorporate lessons from
- Transport
- Incorporate lessons from - Lifting principles - Materials
previous projects - Transport - Lifting principles
previous projects
- Fire principles - Finishes
- Fire principles
Design and assembly process
- GF detail principles
- GF detail principles

The Brief Logistics

–– The client’s employer’s requirements, the –– Understanding site access, ground conditions,
NU build Modular Design Guide and method of site assembly and how the modules
the NU build Modular System Guide are will be delivered to site are key to setting out the
CL I EN T

CL I EN T

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W
CL I EN T

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W
be used to help understand the brief. parameters for designing the modules.
+

+
+
FACTO RY

FACTO RY
FACTO RY

–– The viability of the site location for –– A knowledge of the size of standard CLT panels
modular construction should be also sets dimensional parameters.
R E VI E W

R E VI E W

determined at the earliest opportunity,

D

D
R E VI E W

D
R

R
D D

ED

D
R

R
E

E
E

E A

E
E

DE
E

E
D

D
as not all sites will be accessible for –– These constraints, which are conventionally
D D D
D

D
A

D
E E D E D E
E D E E D E D E E
N R R EN D R NE D E N
E S E S R E R
A S S A SN E SS S A S N S
discussed later in the design development, form
S
modular transportation.
E S A N
S A S S A S S

the basic building block when designing a modular

(Refer to Chapter 2.1 : Factory process; scheme and set out the three dimensional size
Chapter 2.2 : Design and assembly process; constraints of the modules.
Chapter 3.1 : Transportation; Chapter 3.2 :
Site considerations) –– Understand the installation and assembly
sequence.

(Refer to Chapter 3.1 : Transportation; Chapter 3.2 : Site

considerations; Chapter 3.3 : CLT panels)

26
Ground conditions - Servicing principles - Fire performance - Bathrooms - Interfaces
modular
Site assembly - Site assembly
- Accessible units - Accessible
- Acoustic units
performance - Acoustic performance
- Doors - Doors
- Membranes
- Incorporate lessons from
Transport - Transport
- Lifting principles - Lifting principles
- Materials - Materials
- Windows - Windows
previous projects

- Fire principles - Fire principles

- Finishes - Finishes
- Internal finishes - Internal finishes
Design and assembly process
- GF detail principles - GF detail principles

Strategy Performance

–– Establish the layout of the scheme, taking –– The thermal, fire and acoustic performance of the
into account the structural, acoustic and building and the services strategy all need to be
services constraints as well as planning agreed.
CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W
CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W

CL I EN T + FACTO RY R E VI E W
and regulatory considerations. CLIENT
+
–– Consider services strategy. ‘Plug and play’ systems
FACTORY
–– Consider the sequence of construction, for services connections should Sgenerally
IGN OFF
be utilised
including the assembly, lifting and over conventional systems.
connection strategy, to understand how
D E D

E D

D
R

RR

R
D

D
R

RE A

R
DD E

Y
E
E

EA

E
the modules will be set out on site. The –– The type of cladding, secondary structure and
D

L
A

A
D D E E DD E E D E D
DD E E E E DD E DD D E D N
R R
E ES NN E NN E RR
EE S N N E R R
E SE N E S
R O

tolerance gap between modules and insulation should be considered, deciding if

SS S A AS S AA SS S SS S
SA A S SS A S S

the dimension of the structural walls these will be applied in the factory or on site. The
will inform how many modules can fit on implications of site access for installation of any on
the site. Consider if any non modular site external finishes should be considered.
elements are needed in addition to the
modules. –– When the performance criteria are set, these must
be reviewed in terms of the strategic and logistical
–– The location and layout of accessible considerations. For example, if the cladding and
units is a crucial decision to make at insulation is applied in the factory, the impact
this stage. Modular construction is most on the dimension of the module during transport
efficient when it is stacked. Accessible should be reviewed to ascertain if it fits within the
modules are usually larger than others transport constraints.
and may result in non typical structural
design. (Refer to Chapter 3.7 : On site finishes; Chapter 3.10 :
Fire design principles; Chapter 3.11 : Thermal principles;
(Refer to Chapter 3.4 : Structural principles; Chapter 3.12 : Acoustic principles)
Chapter 3.5 : Ground floor construction;
Chapter 3.11 : Thermal principles; Chapter
4.1 : Internal layout of modules)

27
performance
essible units - Doors
- Acoustic performance - Membranes
- Doors - Membranes

ng principles - Windows
- Materials - Windows

principles - Internal finishes

- Finishes - Internal finishes
Design and assembly process
detail principles

Detail Information

–– Many of the detail design criteria are –– The information produced for manufacture must
set out in the employer’s requirements, include everything the operatives in the factory
NU build Modular System Guide and need to build each module.
CL I EN T

CL I EN T

CL I EN T

CL I EN T

CL I EN T
CL I EN T

CL I EN T

CL I EN T

CL I EN T

CL I EN T
CLIENT CLIENT
planning conditions.
+ +
–– The 1:20
F A C Tlayouts and the room data sheets of
+

+
+

+
FACTORY ORY
FACTO RY

FACTO RY

FACTO RY

FACTO RY

FACTO RY
FACTO RY

FACTO RY

FACTO RY

FACTO RY

FACTO RY
–– The fit out of accessible units
S I G NforO future
FF each Smodule
I G N O Ftype
F are key to informing the factory
tenants will need to be considered. process. This will require input from all consultants.
R E VI E W

R E VI E W

R E VI E W

R E VI E W

R E VI E W
R E VI E W

R E VI E W

R E VI E W

R E VI E W

R E VI E W
D
D

D
R

R
R

Y
Y

P
P

P
E
E

E
E

L
L

R
R

R
D
D

D
A

–– Coordination of information between (Refer to Chapter 5.2 : Drawing for manufacture

E E D D E D N O N N O O N
E E D D E D O G O G O G O
R R
N N E SR E S S N E S
R
E S S I O N
R
E S ES SI O
R
A S A S S IN O N N

all consultants is required at this Chapter 5.3 : Room data sheets)

S AS S

stage. The BIM model needs to be fully

coordinated.

–– The setting out of the modules will need

to be considered and agreed by all
consultants and the factory.

–– Following this stage, the client and

factory need to sign the design off. A
thorough assessment of costs must be
carried out.

(Refer to Chapter 3.5 : Ground floor

construction; Chapter 3.6 : Waterproofing;
Chapter 3.8 : Roofs; Chapter 3.10 : Fire
design principles; Chapter 3.11 : Thermal
principles; Chapter 3.12 : Acoustic principles)

28
 - Kitchens - 1:20 drawings

- Bathrooms - Interfaces
- 1:20 drawings

- Doors - Membranes
- Interfaces

- Windows
- Membranes

- Internal finishes Design and assembly process

Manufacture & transportation Assembly

–– Modules will be fully wrapped before –– If large openings are required, temporary support
CL I EN T

CL I EN T

CL I EN T

CL I EN T
CLIENT
transportation+ to prevent water damage. may need to be installed during transportation.
C L I ENT

C L I ENT

C L I ENT

NT
Consideration of how this will be removed needs to
+

+
FACTORY
FACTO RY

FACTO RY

FACTO RY

FACTO RY
SIGN OFF
+

ORY –– The factory will coordinate the delivery of be addressed early in the design phase.
FACTO RY

FACTO RY

FACTO RY

OFF
the modules to site. They will determine
R EVIE W

R EVIE W

R EVIE W

R EVIE W
R

Y
Y

P
P
E

if the modules will be delivered ‘just in –– The sequence of construction is determined by

L
L

R
R
A
R E VI E W

R E VI E W

R E VI E W

E D N O N O
E D O G O G
Y
Y

P
P

N R R R
E S E S S I O N E S S I O N

time’ or stored on site/elsewhere prior factors including site constraints, crane size and the
L
L

R
R

A S S
O
N O N
O G O G
R R
E S S I O N E S S I O N

to assembly. structural stability of the modules during assembly.

If non modular components form part of the build,
–– Delivery strategy to be in line with then how the connection details between these
assembly and installation sequence. and modules impact stability also needs to be
considered. These decisions will have been made
(Refer to Chapter 2.1 : Factory process; during the earlier stages in the design process.
Chapter 3.1 : Transportation; Chapter 3.6 :
Waterproofing) –– Access for operatives to make services and
structural connections needs to be considered
during the earlier stages. Prototyping of typical
connections can assist in understanding the access
requirements for these connections.

(Refer to Chapter 3.7 : On site finishes)

29
Design and assembly process

2.2.4 A note on cost plans 2.2.5 Changes to the design

Designing for manufacture and assembly Change control must be carefully monitored throughout
requires decisions to be made throughout the process. Design development is not always linear
the design phase which, once agreed, can and a clear record of the decision path is vital. Three
have far reaching implications if changed types of change management strategies can be
later in the design process, like a puzzle implemented, depending on the circumstances:
where all the pieces are reliant on each
other to make a cohesive whole. If one piece –– Lessons Learned is a method of understanding
changes it will not fit together, as shown in what could have made the project more efficient
Figure 15. by tracking and recording changes that have not
been implemented to ensure they are considered
A thorough cost analysis of the scheme is for future projects. The knowledge and experience
required by the client at every workstage to gained from each project will be used to update the
ensure the budget is adhered to. If possible, NU build Modular Design Guide and the NU build
tendering to suppliers early in the design Modular System Guide and improve and refine NU
process is preferable as a fully coordinated build’s modular product, as shown in Figure 16.
supply chain is essential for the smooth
operation of the manufacturing process.

Figure 15 Each design decision is reliant on one another to create a cohesive whole

30
 Design and assembly process

t
ec
Pr o j e c t Pr o j
Pr o
je
ct
c
je t
ro
P

Les Less son

Les
s
on
so

ns s

Figure 16 Evolution of the modular system, where the lessons from the previous project help refine and improve the current project

–– The Change Order process is used 2.2.6 Early engagement of consultants

to analyse the advantages and
disadvantages of a proposed change, The early engagement of all consultants is required
and how it will affect the manufacturing when designing for modular so that all disciplines can
process. The production line continues input during design development. For example, the
while this is evaluated. Once the size and location of servicing holes have fundamental
analysis has taken place, the factory impact on the structural design and vice versa.
is consulted to decide if the change
is sufficiently beneficial to warrant In a conventional design development, the services
resetting the production line in order to and structural engineers would wait until the plans
implement it. are fixed before beginning to develop their design.
In designing for modular there are servicing and
–– A Concession Note is used if there are structural parameters that impact on the development
fundamental errors in the design that of the plans and so must be understood early in the
mean it simply does not work and the design development. This is particularly important when
production line may require resetting considering vertical elements such as the stacking of
to rectify it. The process of procuring a risers and servicing penetrations, therefore the design
Concession Note is intentionally difficult should always be considered in three dimensions.
– it can only be signed by Managing
Directors – as the cost and time
implications of resetting the production
line when it is fully staffed and working
at capacity are critical.

31
Design and assembly process

2.2.7 Appointments Key considerations in making appointments include:

Each consultant will agree their own –– Early appointment of all consultants.
appointment. Both client and consultant
should be aware of how the design services –– Close collaboration between consultants is
required by the modular process differ required.
from a conventional contract. Swan have a
suite of documents that refer to the design –– Consultants appraise themselves of the services
process for DfMA. required when designing for modular. Additional
considerations such as input into logistics will be
In traditional construction the temporary part of each consultant’s scope.
works design is usually undertaken by the
contractor, whereas in modular design the –– Complete design and costing to be signed off prior
site assembly works need to be considered to manufacture. The scope for change once the
during the design process by the entire modules are in production is limited.
design team, particularly the structural
engineer. This ensures any site assembly –– BIM level 2 is fundamental to the delivery of the
works are integrated into the design to project. A BIM coordinator should be identified.
minimise on site intervention prior, during
and after module assembly. –– Information provided by Swan’s DfMA suite of
documents and appointment information.

Figure 17 The consultants in the design team need to be appointed early in the design process

32
 Design and assembly process

a different provider such as Premier or NHBC. The client

should confirm the building‘s warranty provider at an
early stage of the design process to ensure the building
is developed to the necessary technical requirements as
these are specific to each warranty provider.

2.2.10 The NU build Modular System Guide

The NU build Modular System Guide will set out a

toolbox to use when designing with the NU build
Figure 18 Everyone involved with the project needs to Modular System. It will show examples of modular
understand the modular process buildings, material specification, typical details and
2.2.8 Training and people standard layouts.

Everyone involved in the project must have The NU build Modular System Guide will include
a thorough understanding of the modular a range of products that have been selected by NU
method of manufacture and how all build and Swan for their compatibility with the factory’s
Informs ...
processes integrate. manufacturing process and on site assembly. This
should be used to inform the project specification and
Teams require skills in industry standard schedule of fixtures and fittings.
software, such as Revit, and an
understanding of standard operating
procedures in the factory. This is essential
to achieve a fully coordinated design and
collaborative team.

2.2.9 Warranties

The NU build modular system is accredited

by the Build Offsite Property Assurance
Scheme (BOPAS). BLP provided the
technical assessment for BOPAS. Separate
accreditations are provided for multistorey
buildings and single family houses.

Building warranty insurance is required for

each project. This may be offered by BLP, or
Figure 19 The NU build Modular System Guide will feed into the NU
build Modular Design Guide, and vice versa

33
3

MODULAR

PRINCIPLES
3 . 1 T R A N S P O R TAT I O N

Transporting modules from the factory to site is the first consideration when determining the dimensions of
modules for the scheme and will impact on nearly every design decision going forward. Therefore, designers
should fully understand the size considerations outlined in this chapter.

3.1.1 Transport size considerations is 5m, this will require special interventions in most
regions, including delivery time restrictions, police
The optimal dimensions of a module are escorts, road closures, temporary removal of kerbs,
determined by the size of the lorry and the street furniture etc.
restrictions associated with the route to the
site, such as road widths and obstructions. The dimensions and weights of vehicles used on British
roads are regulated by the Road Vehicles (Construction
The usual width of a single road lane in the & Use) Regulations 1986 (C&U) Regs and the Road
UK is 3.65m, and a two lane carriage way Vehicles (Authorised Weight) Regulations 1998 (AW)
is approximately 7.3m. A load width of +/- Regs.
2.89m is optimum for ease of transportation.
As a rule of thumb, the wider the load the Special types vehicles (STGO) do not meet the C&U
shorter the length needs to be to allow for and AW Regulations but can be used outside these rules
the geometry of the turning circle. Although under the authority of the Road Vehicles (Authorisation
the maximum load width on a flat bed lorry of Special Types) (General) Order 2003 (STGO).

Berm Slope Verge Hard strip Carriageway Hard strip Verge Slope Berm
(A) (B) (C) (D) (E) (D) (C) (B) (A)
Lane 1 Lane 1
(L1) (L2)

E
Road type A B C D D C B A
L1 L2
7.30
Single (S2) Varies Varies 2.50 1.0 1.0 2.50 Varies Varies
3.65 3.65
10.00
Wide single (WS2) Varies Varies 2.50 1.0 1.0 2.50 Varies Varies
5.00 5.00

Figure 20 Carriageway width restrictions in the UK

36
 Transportation

Slim load Wide load

Easy site access

STGO type vehicles

No time restriction
(0700-1900 monday to friday)

No time restriction
(0700-1000 and 1630-1900)

No requirement for vehicle escort

Figure 21 Transportation constraints are determined by the width of the module and restrictions on the route from the factory to the site

Vehicles that do not comply with an STGO form an in depth report that highlights the nuances of
order can be used on the road if Special the route.
Orders have been issued by:
The track analysis should be a ‘live’ document that
–– Highways England regarding abnormal is updated throughout the design and manufacturing
loads not covered by C&U and STGO stages to ensure it captures any changes and alterations
that might arise.
–– The Vehicle Certification Agency (VCA)
regarding special vehicles and divisible
loads such as crane ballast outside the BR ENTW OOD
scope of C&U and STGO

3.1.2 Route to site

R OMFOR D

A track analysis by a transport consultant

ILF O RD
should be undertaken in the Logistic Stage
THUR R OCK
to understand the constraints of transporting
modules to site. This should not simply be
a desktop study, but requires a test run
using the necessary vehicle, taking physical W O O LWICH
measurements and photographs which will
D AR TFOR D GR AY S
Figure 22 Constraints are specific to the route to site

37
Transportation

The tracking analysis report will investigate:

–– Turning circle restrictions.

–– Low bridges and obstacles e.g. trees,

telegraph wires etc.

–– Restricted delivery times.

–– Signage, lighting or street furniture

Figure 23 Understand the constraints specific to the route to site
limitations.
All vehicles with an overall travelling height of over
–– Road closures that might be required. 3m must have the height displayed in the cab. The
highways authority must be notified if loads are over
–– Bridge and power line height 5m high and affect street furniture such as lights and
considerations. gantries. Telecommunications companies that operate
along the route must be notified if transporting loads
This report should enable the designer to over 5.25m.
understand the following:
3.1.3 Calculating the module width
–– The proposed route from the factory.
When calculating widths of modules all projecting
–– Highway authorities responsible for the elements, such as windows or cills, must be included,
route. as well as any finishes applied in the factory, such as
insulation.
–– Time and size constraints imposed by
the relevant highways authority.
TOTAL LENGTH
A standard UK motorway bridge allows (includes protrusions)
(includes protrusions)

a clear height of 5m. Other bridges and

TOTAL WIDTH

overhead power lines at level crossings may

have lower maximum heights and should be
avoided.

Height restrictions are required to be clearly

signposted and should therefore be picked
up during the test run.
Figure 24 The total module dimensions should include any protrusions
and finishes such as window reveals or insulation

38
 Transportation

Figure 25 The overall module size will impact on cost and time

39
Transportation

3.1.4 Oversized modules a single non-driving axle and 11,500kg for a single
driving axle.
Modules larger than the optimal dimensions
can result in increased transportation costs –– A width of more than 2.9 m.
and should be kept to a minimum or avoided.
If the design requires oversized modules, the –– A rigid length of more than 18.65 m.
following additional considerations need to
be taken into account: Abnormal loads are not permitted anywhere in London
during the following times:
–– Police escort
–– Monday to Friday: 07:00 - 10:00 and 16:30 - 19:00
–– Restricted delivery times
–– Saturday: 10:00 - 19:00
–– Road closures
In addition, abnormal loads are not permitted within a
3.1.5 Time constraints three mile radius of Charing Cross station during these
times:
Depending on the size of the module,
constraints that dictate permitted delivery –– Monday to Friday: 07:00 - 19:00
times can be placed on transportation by
local and national highways authorities and –– Saturday: 10:00 - 19:00
the police. Restrictions on time of delivery,
such as during the night, can conflict with Further guidance and information on abnormal vehicle
planning conditions that limit hours of loads can be obtained from the Metropolitan Police,
working. For example, large loads may not Transport for London (TfL) and the Electronic Service
be permitted between 7am and 7pm Monday Delivery for Abnormal Loads (ESDAL).
to Friday. This can conflict with planning
conditions that stipulate hours of working. 3.1.7 Protection of modules during transport

3.1.6 Abnormal loads Modules must be protected from damage during

transportation, particularly if there is a risk of the
An abnormal load is a vehicle that has any module getting wet. Protection against rain and splash
of the following: from the road when in transit is vital. Further information
can be found in Chapter 3.6 : Waterproofing.
–– A weight of more than 44,000kg.

–– An axle load of more than 10,000kg for

40
K E Y C O N S I D E R A T I O N S : T ransportation

–– What are the size restrictions associated with the lorry?

–– Are there time restrictions for transporting the module to site?

–– Has a track analysis report to check the route for obstructions and access considerations been
instructed? NB this should be a test run with a vehicle rather than a desktop study.

–– How do obstructions and access considerations along the route effect the maximum module
dimensions?

–– If the module is oversized, how will this impact on transportation and site access? Will there be
time and cost implications? What arrangements should be made with the relevant authorities?

–– Are protrusions and finishes that are applied in the factory accounted for within the module width
dimensions?

–– How will the module be protected during transportation?

–– Should cladding and insulation be applied in the factory or on site?

41
3 . 2 S I T E C O N S I D E R AT I O N S

The designer will need to understand the constraints of each site and the impact this has on the type of
crane that can be used. This chapter highlights the key considerations for crane selection and outlines
typical strategies for lifting the modules into position.

3.2.1 Access and site considerations The location of the access points will have an impact on
the assembly sequence of the modules. If one corner of
Firstly, the design team should investigate the site is landlocked, the installation is likely to begin
the best location to access the site to deliver there. The construction sequence will always start from
the modules. the least accessible part of the site.

1 2 3 4

5
6
7
8
9

Figure 26 Will over-sailing of adjacent properties

be an issue?
10

One of the first considerations is to establish

what type of crane the site and size of
11

15 14 13 12
development will allow. A thorough survey of
access and neighbouring properties should
be carried out - will over-sailing of adjacent
properties be an issue? SITE
ACCESS

Figure 27 The sequence of assembling the modules on site should start

from the least accessible location

42
 Site Considerations

If modules are to be assembled adjacent 3.2.3 Surveys

to existing party walls, the designer should
consider how the junction between the Ground conditions and site surveys will be required,
existing and modular walls are detailed, and identifying the location of obstructions, underground
if there will be room to install cladding on and overground services etc.
site. If not, the modules may need to be clad
in the factory. Access to install connection 3.2.4 Crane considerations
details and fire stopping also needs to be
considered. Refer to Chapter 3.10 : Fire The crane position and size needs to be assessed.
design principles. The maximum loads the crane can carry as well as the
maximum reach needs to be calculated.
3.2.2 On site storage capacity
The size of the crane is dependent on the crane reach
Storing modules on site can be advantageous required, the angle of boom and the weight of module.
as it frees up space in the factory and makes The designer should consider the cost implications of
delivery and installation times more flexible. the proposed crane size - the cost of a larger crane is
The possibility of on site storage should be considerably higher than a smaller crane so should be
investigated. avoided where possible.
Cost

25 t 50 t 75 t 100 t

Figure 28 Crane weight capacity is determined by weight and reach

43
Site Considerations

questions need to be answered before finalising the

Mobile Static foundation design:
crane crane

–– Does the route of the crane or delivery vehicle cross

Cost
underground services? Can this be avoided?

Loads –– Can the foundations for the whole site be

constructed in one go prior to the modules being
delivered to site? If not phasing may need to be
Foundations
considered.

Size –– Is the crane or delivery vehicle required to drive

over the foundations, if so can the foundations bear
the load of a crane and a module together?
Availability

–– Can the route of the crane avoid the foundations?

The loads of the crane can impose lateral loads
Figure 29 Each project should understand the benefits
to the piles so the route must allow a sufficient
and disadvantages of each crane type distance to avoid this.

A decision on whether the crane will be

static or mobile needs to be made during the
Logistic Stage as the choice has implications
on phasing and foundation design.

The location of power and communications

cables in the vicinity of the site should be
established to ensure that the path of the
crane does not clash with any overhead
services.

3.2.5 Impact on foundation design

If a mobile crane is used to install the

modules, the engineer will need to consider
a number of additional factors when
designing the foundations. The following
Figure 30 Impact of crane loadings on foundations

44
 Site Considerations

Figure 31 Stacking principles - a ‘ziggurat’ form might be most appropriate for structural stability in the temporary condition

–– What is the combined weight of the crane lifting eye. This allows for the modules to be lifted from
plus the load of the heaviest module? the top corners.
How will this affect the requirements
of the hard standing surface needed Multistorey developments are likely to experience higher
beneath the crane? stability forces during assembly, therefore temporary
bracing may be required. This will require more work
–– Can the outriggers of the crane align on site and can prove costly. To avoid the need for
with the building foundations? If not, temporary bracing, the central core can be used to give
will a crane mat be required? additional stability during assembly. Further information
can be found in Chapter 3.4 : Structural principles and
–– If a pile mat is needed, can it be Chapter 3.9 : Communal stair cores.
designed so that it can act as the crane
mat too? 3.2.7 Phasing

3.2.6 Lifting considerations If the space around the foundations is tight and access
is restricted it may be necessary to phase the project.
The centre of gravity of the modules must be A construction phasing strategy and programme needs
calculated and coordinated with the factory to be provided so that the factory can manufacture
prior to lifting. If possible, it is preferable the modules in the correct order. The phasing strategy
for modules to be lifted from underneath. should also describe how the modules are accessed
Otherwise, the connection detail between and uncoupled from the crane.
modules can be designed to double as a

45
Site Considerations

3.2.9 Module assembly strategy

A module assembly strategy needs to be agreed by the

design team in collaboration with NU build during the
Logistic Stage and updated with each stage report.
This should include, as a minimum:

–– Site access strategy.

–– Module delivery/storage strategy.

–– Foundation strategy.

–– Foundation sequencing/phasing strategy.

–– Size and type of crane.

–– Module lifting strategy.

–– Module installation phasing strategy.

Figure 32 Example of craning a module
–– On site water management strategy.
3.2.8 On site CDM, water and fire
strategy

Written phasing, crane requirements and

lifting strategies will be required and signed
off by the principal designer, designers and
principal contractors for pre-construction,
factory and on site CDM reports.

An on site fire strategy will need to be

established, as will a water management
strategy to ensure there is no standing water
on the modules during assembly works -
further information can be found in Chapter
3.6 : Waterproofing

46
K E Y C O N S I D E R A T I O N S : S ite C onsiderations

–– Has site access for delivery been planned?

–– What type of crane is required and how will it impact on the foundation design?

–– Has the foundation design sequencing and phasing been considered?

–– Are services coordinated with crane locations and lifting strategy?

–– Has an on site fire safety and water management strategy been completed during the Strategy
Stage, for review and implementation into DfMA information at the Performance Stage and Detail
Stage?

–– Has a draft module assembly strategy been agreed at the Logistic Stage? Has this been updated
at each subsequent stage?

–– Has a risk assessment method statement been produced?

47
3 . 3 C LT PA N E L S

In order to make the most efficient use of the material, the designer should find out the proposed panel
size at the earliest opportunity, as the size of standard CLT panels can influence the design of modules in
a number of different ways. This information will be provided by the factory.

3.3.1 Panel size 3.3.2 Economic use of panels

There are a number of CLT manufacturers, Setting out the way the panel is cut to minimise wastage
each producing a slightly different range of is essential. To do this the designer must understand the
panel sizes. The designer should establish format of the standard panel size to maximise efficient
if NU living have a preferred supplier for use of the material and minimise offcuts. To aid with
the project and work with the specified this, the CNC machine is programmed using specialist
dimensions. Otherwise it is preferable to software that can simulate the machining to maximise
design the modules to accommodate a efficient use of the CLT panels, reducing errors and
range of panel sizes. waste.

2,950 mm

13,500 mm

50 - 350 mm

Figure 33 Standard panel dimensions

48
 CLT Panels

Designing openings by joining smaller around the factory simpler and will increase the overall
panels together can be a more efficient floor to ceiling height of the module. However in certain
than cutting openings out of a single panel circumstances it may be beneficial to span the floors
which can cause large amounts of wastage. between the walls (balloon construction) which would
Guidance from the factory will help to reduce the overall floor to ceiling height of the module.
establish the most efficient process. Large
offcuts should be reused where possible. The ceiling panel may need to sit below the top of
Small offcuts will be recycled and used in the walls to allow a zone for services to be installed,
the factory’s biomass boiler. covered in Chapter 4.2 : Servicing principles.
2.95

Floor to ceiling height maximised

2.95

1 1 1 1 1
2.95

2 2 2

1 1 Less wastage as off cuts reused

2
Platform construction
1 1
2.95

2
1
2

Figure 34 Panel cut efficiency

Floor to ceiling height reduced

3.3.3 Impacts on module heights

2.95

The height and length of standard panels

should be considered in determining the
floor to ceiling height and length of the
modules. It can be easier for the factory to
build the modules with the walls sitting on
top of the floors (platform construction).
Balloon construction
This makes the transportation of them
Figure 35 Platform construct allows a greater floor to ceiling height than
balloon construction

49
 CLT Panels

3.3.6 Visual quality

CLT is manufactured in three different visual qualities:

EXAMPLE: SURFACE –

EXAMPLE: SURFACE – INDUSTRIAL

–– Non-visible quality C is used mainly for construction
elements that will be covered at a later stage, for
example with plasterboard. Discolouration and
EXAMPLE: SURFACE – SELECTED NORDIC

EXAMPLE: SURFACE – INDUSTRIAL VISIBLE QUALITY

different wood types are permissible.

–– Visible industrial quality BC is intended for use in

20INDUSTRIAL

commercial and industrial buildings. It is provided

EXAMPLE: SURFACE
as standard in spruce with visible industrial quality
METSÄ WOODVISIBLE

on one side and a top layer consisting of a mix of B

and C lamellas in accordance with DIN EN 13017-1.

QUALITY– SELECTED NORDIC

Figure 37 If possible, module walls should be made from –– Visible residential quality AB is used for residential
— LENO®

one span of CLT

buildings, schools and offices etc. The top layer
3.3.4 Vertical or horizontal panels is made of spruce, larch, swiss pine and polished
QUALITY

on one face. It corresponds to a mix of A and B

CROSS LAMINATED TIMBER (CLT)

Using one CLT panel, rather than multiple lamellas in accordance with DIN EN 13017-1.
panels stitched together, is preferable to
avoid transferring shear and moment forces
over CLT joints. However if the height of the 1
module exceeds the standard panel width,
it may be decided to join vertical panels of
CLT. In this case the strength of the wall
panels will be dependent on the connections
between the panels, which may need to
2
be reinforced. This will result in additional
material and labour cost.

3.3.5 € and £ exchange rate

As CLT is procured from Europe, fluctuating 3

exchange rates may impact on the
surface quality.
surface lamellas
side by side withoutlam
spruce lamellas. The s
The outer surface
For visible Selecte
Industrial visibl

possible. spruce lam

appearance.The
All lamellasFor
For cladding on site
Industrial

profitability of the project and should be

considered in the cost plan.

Figure 36 CLT visual quality grades: 1. Non-visible 2. Visible industrial

quality 3. Visible residential quality
surface ha
By using s
All lamell
spruce
The
For visib

surfacesur
surfaceBy
side by Al

Industr
surfaces i

Knots,
are exclus

50
outer

outer
visib
to occ

laye

spr
Th
Fo
Se
sid
qu
lam

di
gl
K E Y C O N S I D E R A T I O N S : C L T P anels

–– What are the standard panel sizes from NU build’s chosen supplier?

–– Can the standard panel sizes achieve the required floor to ceiling heights?

–– Has the CLT been used in the most efficient way to avoid wasted material?

–– Will platform or balloon construction be used?

–– Can the standard panel sizes achieve the required module length?

–– Can the panels be used horizontally or do they need to be joined vertically? If so, how will the
connection design work?

–– What visual quality is required?

–– Are £ and € exchange rates considered in the cost plan?

51
3.4 STRUCTURAL PRINCIPLES

Before starting to design the layout, the whole design team should have an understanding of the key
structural considerations. Early engagement of all consultants is therefore essential.

3.4.1 Typical weights 3.4.2 Lifting considerations

Although timber is considered to be a Consultants should consider how the modules will be
lightweight material, modules can become lifted, how the main structural CLT panels perform and
heavy: larger modules can weigh up to 20 how any connecting elements will perform. Depending
tonnes. on the final configuration of the building, the process of
lifting the module may be the most onerous structural
When undertaking the structural design, case to design for. Because of this, to standardise the
calculations of the typical weight of a connection design all connections may be designed
module must reflect the varying assumed for the heaviest case even though module weights may
densities of timber, as shown in Figure 38: vary.

–– For connection design, a low density

Mean density
value should be used. (Permanent self weight of structure)

–– For lifting, a high density value should

be used.
Fifth percentile density
Density for lifting
(Connection design)
–– The mean density should be used when calculations as per CLT
manufacturer’s European
considering the requirements of the Technical Approval
modules in their final built form.

This will have an impact on the requirements

of the crane, both in terms of load and
reach.

DENSITY

Figure 38 Graph showing normal density distribution

52
 Structural principles

In some circumstances it may be necessary 3.4.4 Stacking

to introduce bracing for the module lift and
transportation. This is not desirable and A construction sequence for the assembly of the
should be avoided if possible. For example, modules should be produced. Each module will need a
the opening positions could be adjusted unique identification number, which should be agreed
to facilitate lifting without needing further and coordinated with the design team and the factory.
bracing.
In multistorey buildings the modules should ideally be
If bracing is required during the assembly of stacked floor by floor. For example, the ground floor
the modules, interference with the doors and is assembled, followed by the first floor and so on. If
windows should be avoided where possible. site access is restricted and this is not possible, the
structural requirements of the modules while they are
being assembled will need to be assessed to determine
the most appropriate assembly sequence.

It should be noted that proportions of the building

during assembly will have an effect on the connection
design: if it is tall and thin, the connection forces will be
higher than if it is low and wide.

20
Figure 39 Dynamic amplification affects the module 16
Modules should preferably be 15 19
in lifting stacked floor by floor 8 14
7 13 18
6 12
5 11 17
3.4.3 Dynamic amplification 4 10
3 9 3
2 2
1
During the lifting of the modules there is a 4 1
20
dynamic amplification factor to consider. 19 3
18 15 4
20
This is because as the module is lifted it is 17 14 2 19
16 13 10 18 17 3
accelerated and using the formula: 14 16
12 9 1 13 12 15
11 8 5 11 10
7 4 6 9 8
6 3 5 7
Force = Mass x Acceleration (F = ma), 4 3
2
2 2
1 1
1
This means the weight of the module
Alternative sequences must consider the
increases. This additional weight should be stability of the modules during assembly
factored into the connection design.
Figure 40 The assembly sequence should consider the structural
stability of the modules

53
Structural principles

‘Land locked’ module to

module connections that 3.4.6 Structural differences between houses and
are only accessible from multistorey buildings
inside the building

For the NU build Modular System, housing is considered

to be an arrangement of three by three modules, and
multistorey greater than this.

Figure 42 shows the relationship between the height

of the building and the depth of each floor/number of
modules required to ensure structural stability.
Figure 41 ‘Landlocked’ modules
When designing multistorey buildings above five
3.4.5 Layout considerations storeys, it is advised the CLT core walls provide
additional stability. Beyond eight storeys further stability
‘Land locked’ modules, as shown in Figure 41 may be needed, which could be provided by a concrete
should be avoided. This is because the core. Further information is provided in Chapter 3.9 :
connections are not easily accessible during Communal stair cores.
assembly as it is only possible to access the
modules from inside the building.

7
Additional stability walls or core required above 5 storeys

5
No. of modules high

0
0 2 4 6 8 10 12 14 16
Min no. of modules deep

Figure 42 Typical limit for number of modules high versus number of modules deep

54
 Structural principles

Multistorey
3.4.9 Module connections

The steel connections that join the modules are a

Housing
critical component of the modular system, and require
comprehension of a number of factors when designing
them, such as:

–– How will the dynamic amplification of the module

impact the weight of the module, and therefore the
requirements of the connections as the modules are
Figure 43 Elevation of housing and multistorey assembly lifted?

3.4.7 Connection strategy

The connection design is critical to the

success of the module design. This can
be broken down into two main types:
connections for joining CLT to CLT, and
connections between the modules.

The DfMA process also applies to the

connection design. Since the connections
will be repeated multiple times they should BRACKET
(Copyright Simpson Strong Tie)
be optimised to make savings where
possible.

The designer should agree the screw and Fully threaded

standard bracket supplier with the client
and the factory.

3.4.8 Typical connections Partially threaded

Typical connections are used to connect

pieces of CLT to one another. These are
usually the standard connections that can be
found in more traditional CLT superstructure SCREWS
buildings, such as brackets and screws. (Copyright Rothoblaas)

Figure 44 Typical connections

55
Structural principles

–– Can the connections double as lifting –– How will the connection be accessed during
eyes? assembly? Are there any restrictions to access and
can they be avoided?
–– What are the timber settlement
requirements and how will these affect –– Will the connection pond or fill with water on site?
the design of the connection? This is How can this be prevented?
particularly important for multistorey
buildings. 3.4.10 Jointing

–– Can the connections be fabricated at In order to achieve the module lift, the long side panels
scale? Has the designer investigated need to be continuous with the floor and ceiling panels
the steel fabrication process to ensure spanning between.
this is possible?
The position of the half-laps need to consider the
–– Can the weight of the connections diaphragm action of the floor and should avoid
be reduced so that manual handling unsupported edges across door thresholds.
requirements are met?

–– What tolerances are needed for fitting

the connection in the factory? The CLT
is cut within certain tolerances that can Floor and ceiling panels
half-lapped together
affect the connection design.

–– The connection design can be complex

and potentially costly. How can this be
reduced? Has the cost been considered
early in the design process?

In addition to these, the requirements of

the module connections on site should be Long edge to be one
continuous panel to allow
considered, such as:
for module lift

–– What tolerances are needed? Note Half-lap joints to avoid

that these should include any concrete door openings

tolerances at ground or podium levels.

Half-lap joints

Figure 45 The location of joints should be considered in parallel with

the lifting strategy

56
K E Y C O N S I D E R A T I O N S : S tructural principles

–– Landlocked modules should be avoided.

–– If designing buildings taller than five storeys, it may be necessary to use the core for structural
stability.

–– Connection design should be considered at the earliest opportunity.

–– How will the dynamic amplification of the modules during lifting impact on the lifting strategy and
the crane specification?

–– Each module should have a unique identification number.

–– Has an assembly sequence for the modules been produced?

–– Has the position of the half-laps in the CLT been considered, and are they avoiding door thresholds?

57
3.5 GROUND FLOOR CONSTRUCTION

The ground floor construction detail is of paramount importance, particularly if CLT modules are located on
the ground floor of the proposed building. Design solutions that protect the CLT from moisture should be
proposed at the earliest opportunity.

3.5.1 Site ground conditions –– When fully accessible dwellings are required they
can be larger than standard units. Their layout may
An early ground conditions survey will be not stack with units above.
required as water table, ground gas and site
stability could all effect the choice of ground –– Communal spaces, stores, service cupboards and
floor detail. substations require different structural and spatial
requirements.
3.5.2 Ground floor use
The use will determine the construction method of
This will vary depending on whether the the ground floor. If possible, it is preferable to install
design is for single family dwelling or a modules at ground floor to simplify construction.
multistorey development. However, depending on the requirements, it may be
appropriate to install a steel or concrete framed podium.
Normally the ground and upper floors of
single family dwellings line through. It
therefore makes sense to retain the same
structural material at ground, first and
second floors in low rise developments.

Often, in multistorey, the ground floor plan

does not line through with the flat layouts on
the floors above. This can be for a number
of reasons such as:

–– When commercial uses are at ground

Commercial Plant Residential
floor, they are typically set out on a
different grid to upper residential floors.
Figure 46 Various uses of modules at ground floor level

58
 Ground floor construction

3.5.3 Modular ground floor The design of the ground floor also depends on the
strategy for transferring the loads from the upper
It is preferable for the whole building to floors to the foundations. Two ground floor details
be made from modules. This ensures the should be investigated: a concrete slab or ventilated
quality of finish is maintained throughout void foundation under the module. Both have their
the project, on site labour is minimised advantages and disadvantages, which should be
and the efficiency of the modular system analysed and understood when determining the
is maximised. Care needs to be taken to appropriate strategy.
ensure the CLT module is kept dry.
It is important that all four walls of the module are
The relationship between the base of the evenly supported to avoid differential movement. The
timber and the external drainage level and strategy to achieve this is dependent on whether the
the provision of adequate drainage to the module to slab connection is via point loads, line loads
perimeter are key considerations which may or a combination of the two.
have implications on level thresholds and
external landscaping.

Figure 47 Module at ground floor

59
Ground floor construction

3.5.4 Modular foundation options Sitting the module on a concrete slab reduces the
risk of ground water rising up to underside of module,
There are two types of ground floor modular but increases the risk of moisture building up at the
foundation details: perimeter.

–– Sit the modules on a concrete slab with Alternatively, the module can sit on a ventilated
no ventilation. concrete upstand, with breathable insulation fixed to
the underside of the CLT. This requires sufficient space
–– Sit the modules on concrete perimeter around the building to allow cross ventilation under the
upstands and crossbeams with a modules, which might not be possible on constrained
ventilated void below. sites. Drainage to prevent rising ground water reaching
the underside CLT must also be included and maintained
once the building is in use.

In both cases, the underside of the CLT should be a

minimum of 75 mm above external drainage level. With
drainage provided to the perimeter and the corners
of the modules supported on concrete upstands. The
tolerance of slab and perimeter upstands needs to be
+ 0 mm to - 10 mm, meaning that the concrete can be
raised, but not reduced.

3.5.5 Underground drainage

Figure 48 Concrete slab ground floor Adequate drainage needs to be installed across the site
to ensure that ground water is drained away from the
modules.

3.5.6 Waterproofing around perimeter

It is good practice in all projects to install perimeter

drainage. Ensuring the integrity of DPCs and DPMs in
the factory and during assembly is critical.

3.5.7 Disabled units/level threshold

If modules are raised above ground, level access

Figure 49 Ventilated slab ground floor to disabled units is still required. This needs to be
incorporated in the landscape design.
60
 Ground floor construction

3.5.8 Concrete or steel frame ground However the ground floor cannot be volumetric and
floor (podium) fitted out in the factory so NU living have to coordinate
trades on site for the fit out. This is not as efficient as
The CLT modules are raised above the building entirely out of modules.
ground and there is no timber at ground
floor level thereby reducing the risk from Another draw back is access - installation of a concrete
ground water ingress. or steel frame could restrict access to the rest of the
site and needs to be considered in the context of the
A metal deck or concrete slab supports the module assembly strategy.
module at first floor level. Installing a frame
at ground floor level allows flexibility in the
design of the ground floor spaces. It is easy
to achieve a level threshold for disabled
accessible units.

Figure 50 Overview of concrete or steel frame ground floor

61
Ground floor construction

3.5.9 Modules on basement foundation The introduction of basements can impact on

accessibility to the site for craning in modules. This
Installing a basement can be costly, so would need to be assessed in the module assembly
will not be appropriate for all projects. strategy.
If feasible, it can protect the CLT from
moisture, as well as providing space for
plant, storage or parking, freeing up more
area on ground floor.

The CLT modules sit on top of a concrete

slab above the basement, where they are
protected from moisture collecting on the
underside of the timber. There is still a risk
of moisture build up at the perimeter, so this
needs to be considered in the design of the
ground detail.

Figure 51 Modules above a basement

62
K E Y C O N S I D E R A T I O N S : G round floor construction

–– Has a ground conditions survey been undertaken and the results considered?

–– What will the use of the ground floor be, and how will this impact on the construction method
and ground floor detail?

–– Is a basement required? If so, consider site access for module assembly.

–– Is a ground floor podium required? If so, consider site access for module assembly.

–– If modules are at ground floor, is the underside and end grain of the CLT protected from moisture
at external ground level, with drainage around the perimeter and the corners of the modules
supported on upstands?

–– Agree a foundation strategy at the earliest opportunity, and ensure that it is coordinated with the
assembly process.

–– Agree a site wide drainage strategy.

–– Has level access to ground floor units been provided?

–– Are wet rooms required?

63
3 . 6 WAT E R P R O O F I N G

Although it is essential that the waterproofing is managed in all buildings, modular construction varies
slightly from traditional construction. Waterproofing must be considered inside the modules, during
transportation and assembly as well as when the building is in use.

3.6.1 Waterproofing design

CLT needs to breathe, therefore where possible the

construction of the walls, floors and roofs need to
be fully breathable and moisture must be prevented
from entering the fabric of the building. The use of
breathable wall build ups is encouraged.

Dew point analysis is required with all U-value

calculations to ensure moisture does not condense
within the fabric of the building. Further information can
be found in Chapter 3.11 : Thermal principles.

3.6.2 Tanking and wet room design

Kitchens and bathrooms should be lined with a wet room

tanking membrane. This should be applied to all low
level areas to prevent possible damage from dripping
taps or leaks and full height to areas of heavy exposure
such as showers. Additional protection can be added
to high risk areas such as bathrooms by designing them
as wet rooms, where the tanking membrane is linked
to a gully that connects with the main waterproofing
line e.g. tiles and grout. Sanitary ware and bathroom
furniture are then fitted above. This mitigates the risk of
Area of CLT to be covered with protective
waterproof membrane water damage and resulting costs should a tap or pipe
leak or an item of sanitary ware overflows.
Figure 52 Location for robust waterproofing layer in
a bathroom

64
 Waterproofing

Area of CLT to be covered with protective waterproof

membrane

Figure 53 Location for robust waterproofing layer in a kitchen

3.6.3 Waterproofing membranes all cut openings and penetrations. Coloured end grain
sealer can be used to identify where it has been applied.
Details should be drawn to understand the All joints in CLT should be taped with waterproofing/air
thickness and stiffness of waterproofing tightness tape. This improves overall airtightness but
layers, such as membranes, particularly also prevents water from tracking to unprotected end
where they overlap. Each module will be grain.
assembled with its own breather membrane
which will lap with the breather membrane on 3.6.5 Waterproofing during assembly
adjacent modules. This can result in multiple
membrane laps and the thickness of these CLT buildings can be sensitive and susceptible to
should not be underestimated, particularly long term moisture damage during construction. For
at the corners of modules. Coordination with these reasons extra measures and caution should be
the design team and the factory operatives taken to protect the modules during transportation and
on the design and lapping of membranes assembly. Modules should be fitted with an external
at an early stage in the modular process is breather membrane before leaving the factory, however
essential. this can easily be compromised. Therefore additional
protection from rain, moisture and damage, should be
3.6.4 Protection to the end grain of the provided for transportation. This includes protection to
CLT the underside of the modules to prevent water splash
back from the road.
The end grain of CLT is the most vulnerable
to water and moisture ingress. Damage can The client, NU living and the design team should agree
be limited by applying end grain sealer to a method of ensuring that the CLT is kept dry with a

65
Waterproofing

material that is breathable. Refer to Chapter 3.6.8 Gaps between modules and movement
3.7 : On site finishes for the pros and cons
of applying external finishes in the factory. For on site tolerances, and to aid assembly of the
modules, a gap should be allowed between modules.
3.6.6 Maintenance of waterproofing This will typically be around 30 mm. Breather or
protection waterproof membranes must be installed to prevent
water from entering the gaps between modules.
The design life of windows is often
shorter than cladding and other elements In addition, where modules are stacked there will be
of structure. The window installation some movement. The designer must consider how this
should be designed to allow them to be movement will be accommodated in the waterproofing
replaced without damage to cladding or membranes to prevent them from being damaged.
waterproofing. A method statement of how
membranes will be repaired will be required. 3.6.9 Warranties

3.6.7 On site strategy Warranties for all waterproofing methods, systems

and products should be confirmed and understood by
The contractor will be required to produce both the design and client team. Refer to Chapter 2.2
an on site water and moisture management : Design and assembly process for more information.
strategy that will be included as part of the
contract information. This document should
contain :

–– How to manage water after rainfall.

–– Drainage provisions during assembly.

–– How areas and items will be protected

when stored on site.

Should the modules get wet during assembly

they must be allowed to dry and the moisture
level tested and confirmed. Should it be an
acceptable level of around 12% moisture
content, the CLT can be sealed with
cladding, roofing or another module.

66
K E Y C O N S I D E R A T I O N S : W aterproofing

–– Do the internal fit out of kitchens and bathrooms include a waterproof membrane on floors,
behind tiling and to all high risk areas such as showers?

–– Should a floor gully be included in bathrooms or kitchens to provide additional protection?

–– Is sufficient ventilation provided to allow the CLT to breathe?

–– Understand the thickness of membranes and how they will be lapped and fixed, particularly at
the corners of modules.

–– How is the end grain of the CLT protected?

–– Can the initial waterproofing layer be applied in the factory?

–– Can the windows be replaced without damaging the waterproofing membranes?

–– How will the modules be protected from water during transit?

–– How will water and moisture be managed on site?

–– Modules should be dried if wet and moisture levels tested before cladding and roofing can be
applied.

–– Water ingress in the gaps between modules and caused by movement should be prevented.

–– Warranties should be confirmed and understood by both the design and client team.

67
3.7 ON SITE FINISHES

In some circumstances, it may be necessary to install certain finishes on site rather than in the factory. These
will mainly be external finishes, but might also include internal finishes to areas around servicing interfaces
and thresholds between modules. When determining the extent of on site finishes, the designer should bear
in mind that time spent on site is expensive and should be minimised where possible.

3.7.1 Cladding materials When building taller than three storeys, a lightweight
rainscreen system becomes more appropriate, as it
When considering external facing materials, can easily be supported by the modules. The cladding
the designer should first refer to Swan system should consider the building movement and
Housing’s employer’s requirements, where settlement. Movement joints or tiles that move over one
details of preferred materials can be found. another can be employed.
In addition to this, requirements such as
robustness and ease of construction should 3.7.2 Specification considerations
be considered.
On site finishes should be efficient to install while also
Cladding materials can generally be maintaining the quality of the design:
categorised as either a rainscreen system or
a load bearing system. –– Repeatable details and standardised processes
allow for the same detail to be used over multiple
Rainscreen systems include: locations. For example, if all windows have the
same reveal detail, time spent on site installing the
–– Tiles, such as clay tiles or terracotta reveals will be reduced.
tiles.
–– Prefabrication of certain elements can increase
–– Sheet cladding such as cementious efficiency. Elements such as cladding panels or
boards or fibre cement. balconies can be prefabricated offsite, decreasing
the amount of time spent on site and the number of
–– Timber cladding. trades required.

Load bearing systems are typically limited –– It is preferable to use dry trades where possible,
to masonry, and will only be applicable in ensuring a clean, quiet site environment.
buildings that are less than three storeys
high.

68
 On site finishes

–– The need for scaffolding should be width for transportation. Applying the insulation on
reduced where possible as it is expensive site avoids potential transportation issues and also
and time consuming to erect. means that there is less opportunity for the insulation
to become wet.
3.7.3 Installing cladding and insulation
When there is a requirement for external finishes to
Cladding will typically be installed on site, be non-combustible, the designer should ensure that
as it is currently difficult to achieve a high cladding materials are compatible with non-combustible
quality finish with offsite cladding. insulations such as mineral wool.

When specifying the cladding, consideration

should be paid to the module to module
connection. Modules will move over time due
to compression, so cladding materials that
have a tolerance to absorb this movement
will be more successful.

Insulation can be applied in the factory,

but it may be beneficial to install it on
site, particularly if larger module widths
are required: installing the insulation in
the factory increases the overall module
Figure 55 Examples of lightweight rainscreen cladding. (Photograph:
Will Pryce).

Figure 54 Lightweight rainscreen cladding systems can be supported by the modular structure, whereas loadbearing masonry cannot

69
On site finishes

3.7.4 Balconies and external walkways 3.7.6 Drawing on site elements

Projecting balconies and external walkways Consultants should ensure that on site elements are
should be lightweight to avoid unnecessary clearly represented in all relevant drawings. See
loads on the modular structure. Chapter 5.2 : Drawing for manufacture.

Prefabricating these elements will save

time on site and will allow a greater level
of quality control. Considerations include
whether the elements can be self supporting
and the interface between the module and
the balcony/walkway.

3.7.5 Internal finishes

The extent of internal finishes carried out

on site will depend on parameters of the
design, but might include:

–– Servicing access hatches in walls and

floors - refer to Chapter 4.2 : Servicing
principles.

–– Finishes around service access hatches.

–– Servicing cowls and grilles.

–– Interfaces between modules such as

door jambs, threshold strips and floor
finishes.

When designing these details, the sequence

of construction should be considered to
provide a solution that is easy to install on
site.

Figure 56 On site and offsite elements of a module interface with door

jamb clearly shown in drawings in green.

70
K E Y C O N S I D E R A T I O N S : O n site finishes

–– Which elements need to be installed on site? Can these be reduced?

–– Investigate which on site elements can be prefabricated, either in the factory or by an external
supplier.

–– Will insulation be applied in the factory or on site?

–– Is the building greater than three storeys? If so, a lightweight cladding system may be more
appropriate.

–– Explore how on site elements such as door thresholds and window reveals can be repeatable so
that they are quick and easy to install.

–– Can the use of scaffolding be minimised?

–– How will internal finishes between modules be installed?

–– How will on site elements be differentiated from offsite elements on drawings?

71
3.8 ROOFS

When designing roofs for modular construction, the impact of the choice of structural material, cladding
material and the geometry of the roof on the manufacturing process needs to be considered, as does the
transportation of the modules and how they are assembled on site. In addition to this, designing a suitable
waterproofing detail is of paramount importance as preventing water ingress on to CLT is essential.

3.8.1 Roof type and geometry 3.8.2 Flat roofs

The first consideration should be the type If flat, the roof must be designed to meet manufacturers’
of roof that the design requires i.e. a flat recommendations and as a minimum, should be laid to
roof or a pitched roof. Each roof type has a 1:40 fall in order to achieve 1:80 fall. Standing water
different design parameters and can be and ponding is not acceptable.
manufactured and assembled in different
ways. Flat roofs should be laid to falls by pitching the CLT
panel, which will help to protect water collecting on the
Transport considerations as detailed in timber. The CLT must still be protected with a waterproof
Chapter 3.1 : Transportation should inform layer during transportation.
the design of roof modules. The geometry
of the roof module must not exceed the 3.8.3 Pitched roofs
maximum module size. Likewise, protrusions
such as flues or rooflights must not protrude There are a number of different ways of fabricating a
outside the limiting dimensions. pitched roof, either as a trussed rafter or using CLT
panels. The choice of roof structure will be informed by
considerations such as:

–– Will the roof void be used for habitable rooms?

–– Will services be located in the roof?

–– What process is most suitable for the factory?

–– What are the transportation requirements?

Figure 57 Geometry of the roof must take transport

requirements into account

72
 Roofs

3.8.4 Roof membrane requirements

A range of cladding materials can be applied to CLT

modules as long as the following factors are considered
when detailing the roof membranes:

–– There will be a tolerance gap of around 30mm

between each module when assembled on site.
A strategy of ‘zipping up’ or filling in the gaps
between the modules with the roofing material must
be devised. A continuous surface between modules
must be maintained, or rain water outlets need to
be provided to each module at roof level.

–– For flat roofs, single ply membranes should generally

be avoided as they can be easily damaged allowing
water onto the timber. A multi layer, cold formed
system may be preferable as it allows the fully
bonded underlay to be applied in the factory and a
top sheet on site.

The designer must consult with the CLT supplier to

ascertain what the maximum moisture content of the
timber should be prior to installation of roof membranes.

3.8.5 Protection during transportation

Ideally the underlay of a roofing membrane system or

the breather membrane will be applied in the factory in
order to protect the module from water ingress during
transportation.

3.8.6 Verge support/edge and parapets

To minimise height and damage during transportation

it may be beneficial to add parapets and verge details
on site.
Figure 58 Comparative analysis of roof types

73
Roofs

3.8.7 Insulation

Both warm and cold flat roof build ups are

possible. Insulation for cold roofs will be
installed on site whereas insulation for warm
roofs could be applied in the factory with
the membrane fixed to the top. If cladding
is applied to pitched roofs in the factory,
insulation will be integral to the build up.

3.8.8 Rainwater outlets and service

penetrations

Rainwater outlets should be carefully

positioned to allow the roof to drain
during installation and after completion.
Rainwater outlets need to be set below
the waterproofing line to avoid ponding
around the outlet. Routing out the CLT to
accommodate the rim of the outlet is the
preferred method of achieving this. CLT
must be laid to a falls to ensure water drains
to the correct outlet.

Where there are service penetrations

through the roofing membrane extra care
must be taken to seal the penetration.
Think carefully about taking rainwater pipes
internally and ensure that where there are
service penetrations through the roof there
is adequate access to the underside to
check for defects.

It may be preferable to cluster service

penetrations in one location to minimise the
number of individual penetrations through
the roof.

74
K E Y C O N S I D E R A T I O N S : R oofs

–– What type of roof is appropriate? Does it fit within the transport requirements? Will it be
manufactured in the factory or installed on site?

–– What insulation is required and how might this be applied?

–– What roof cladding material will be applied?

–– What measures are required in order to protect the module during transport?

–– Are parapets and verge supports manufactured in the factory or installed on site?

–– CLT on modules with flat roofs must be laid to a fall of at least 1:40 for flat roofs to avoid moisture
build up that leads to rot and decay in deflected areas.

75
3 . 9 C O M M U N A L S TA I R C O R E S

In multistorey residential buildings, the designer should consider whether the stair cores and other communal
areas can be prefabricated and manufactured in the factory then assembled on site, or installed on site
using traditional construction methods. Where possible, prefabricating elements is generally preferable as
it allows for a greater level of accuracy and higher quality workmanship.

3.9.1 Prefabricating elements in the

factory

Communal areas such as lobbies and

corridors can be constructed from
prefabricated CLT panels that are cut in
the factory. Stair flights can be cut and
manufactured in the factory and then
assembled quickly on site. Likewise, CLT for
lift cores and service risers can be panellised
and cut in the factory.

Finishes to stairs can also be applied in the

factory, providing they are robustly protected
for transportation. Transport requirements
for these elements are the same as for
modules - see Chapter 3.1 : Transportation
for more details.

When considering the design and

specification of the wall build up for core
and communal areas, the designer should
pay careful attention to the fire strategy
as these areas may have more onerous
requirements. For more information refer to
Chapter 3.10 : Fire design principles.

Figure 59 Stairs can be cut and fabricated in the factory before

assembling on site

76
 Communal stair cores

CLT modules
Core constructed from
4 panellised elements

Figure 61 Panellised core elements can offer structural stability

3.9.2 Core requirements during assembly

5
The core can be used to provide support to the modules
during assembly, as shown in Figure 60. This also
allows the core to be used by site workers to access
modules. Ideally, the modules should be assembled
before the panellised core is installed. This sequence is
6
then repeated for the subsequent storeys,

Careful consideration is required for the interface

of the modules to the panellised elements. Module
connections can be used for this purpose in some
instances.

Figure 60 Corridors can be used to access modules

during assembly

77
Communal stair cores

CLT core is used to support the modules from heights of five storeys A concrete core may be required to support the modules
above heights of eight storeys

Figure 62 Corridors and stair cores offer structural support during assembly, the requirements vary depending on the building’s height

3.9.3 Structural requirements If it is decided that these areas are to be modular,

careful thought should be given to the requirements of
Above five storeys the core should be used these spaces, and the impact that this will have on the
to provide additional structural stability. design, such as:
Beyond eight storeys a concrete core
may be necessary to provide the required –– Is there a requirement for services such as water
stability, as shown in Figure 62. For further provision or heating in these areas, e.g. a tap in a
information, refer to Chapter 3.4 : Structural cycle store?
principles
–– Is a level threshold between the module and the
3.9.4 Ancillary areas external pavement required?

Some communal facilities can be –– What level of finishes are required? How robust do
constructed from modules, depending on these need to be?
their requirements and size, such as refuse
stores, cycle stores and plant rooms. –– Are there additional fire requirements?

78
K E Y C O N S I D E R A T I O N S : C ommunal stair cores

–– What elements of the stairs, cores, lift shafts etc. can be made from prefabricated panels cut in
––
the factory?

–– Can the core be used to give structural stability to the modules during assembly?

–– Can the core be used to access the modules during assembly?

–– How can work on site be reduced?

–– Can ancillary areas such as cycle stores or refuse stores be assembled from modules?

79
3.10 FIRE DESIGN PRINCIPLES

Fire safety in dwellings is of paramount importance and must be considered in detail by all members of
the design team. The fire strategy should be established in the early stages of the design process, then
continually re-examined and readdressed for the duration of the manufacture and assembly process, as well
as during the installation of any on site elements.

3.10.1 CLT and Fire 3.10.2 Methods of fire protection to CLT

As a timber product, CLT is considered to There are three main categories of fire protection to CLT
be a combustible material. How timber structures:
performs in fire is extensively documented
and well understood, and its inherent –– Non-encapsulated is where the CLT is left
material properties can be utilised to help untreated. The CLT will begin to char once it is
protect from fire. exposed to temperatures of 300°C and above. As
the sacrificial layer on the face of the timber chars,
the layer of wood immediately below is heated,
and begins to thermally decompose. This is known
as the pyrolysis zone. Beyond this, the wood is
unaffected and will structurally function as normal.
The structure needs to be designed to allow the
required charring rate under the correct loading
requirements.

Outline of CLT panel

–– Partial encapsulation is when layers of
encapsulation and the charring capability of the
CLT are combined to provide fire resistance. This
Sacrifical (char) layer
should be calculated using the method outlined in
the Eurocodes.
Pyrolisis zone (heated wood)
–– Fully encapsulated is when the required fire
resistance is provided solely by a secondary material
Residual section - structural capacity retained
in the form of an applied surface treatment, such as
a wall lining, entirely encapsulating the timber.
Figure 63 Section showing pyrolysis zone of a CLT panel

80
 Fire design principles

When specifying a fully encapsulated as often there are small gaps between modules for
strategy it is important to undertake a tolerance. It is vital these cavities are protected. Many
calculation of how the material will behave items that provide fire breaks to services, such as fire
under a partial and non-encapsulated collars, require annual inspection. It is important to
situation in order to understand the risk reduce the number of these required where possible.
should a layer of encapsulation be removed Information regarding this, and all other relevant fire
during the life time of the building. strategies, should be included in the homeowner’s
manual.
3.10.3 Natural performance of CLT.
3.10.6 Sprinklers and other suppressive systems.
CLT has a material class B2 in accordance
with DIN 4102-1, and a reaction to fire class The relevant building regulations should be referred to
D-s2, in accordance with EN 13501-1. in order to determine if a sprinkler or other suppressive
system is required. The client should be consulted, as
3.10.4 Connections they may want to include sprinklers as part of their
employer’s requirements. Further to this, it may be that
Connections to, from and between timber the design team decide to include them as part of the
panels are of critical importance. If the building’s fire strategy.
connections fail then the performance of the
walls and the stability of the building will be
undermined.

Most connectors are fabricated from steel,

which reduce in capacity with increasing
temperatures. Typically, the solution is to
treat the connectors with an appropriate
method of fire protection, such as an
intumescent coating or encapsulating
them in a fire resistant material. In many
cases both coatings and encapsulation are
employed due to the severe consequence of
failure.

3.10.5 Cavities

Modular construction can produce more Indicates location of

fire stopping material
cavities than traditional construction,
Figure 64 Locations that might require cavity protection

81
Fire design principles

If it is decided that such a system is timber frame construction sites. This was updated
appropriate, the designer should consider in 2014 to include all structural timber construction.
how the system will be installed, how
connections will be made between modules –– ‘Design Guide to Separating Distances During
and how it will be maintained. Construction’ - Published by the Structural Timber
Association in 2014, this document provides advice
3.10.7 Fire during modular assembly on minimum safe distances between exposed
CLT surfaces on a construction site and adjacent
A fire strategy is required during construction buildings. Where it is not possible to achieve
on all building sites, not just for CLT, as these minimum distances, it is necessary to include
the storage of materials and use of many fire protection to the external surfaces to reduce
different forms of equipment make assembly the potential for heat transfer. In these cases a
a high-risk period. specialist consultant will be required to advise on
necessary measures.
With a low surface area to volume ratio,
CLT panels themselves will not easily
catch alight and start a fire, however there
are many other sources for the potential
ignition of a fire on a building site, such as
stored flammable materials, construction
equipment and poorly managed site waste.

Under the Construction (Design and

Management) Regulations 2015 all
designers should pay particular attention to
the risk of fire during the manufacturing and
assembly process and during the installation
of elements on site when preparing risk
registers and design information.

Two useful documents when considering on

site fire safety are:

–– ‘16 Steps to Fire Safety’ - first published

by the Structural Timber Association in
2008 which specifically addresses the
prevention and suppression of fire on
Figure 65 Key documents to be referenced

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K E Y C O N S I D E R A T I O N S : F ire design principles

–– Where are the areas of risk?

–– Should a fire engineer be appointed?

–– Have the relevant guidance, documentation and legislation been consulted?

–– What method of encapsulation will be used to protect the structure?

–– Can the number of items that require maintenance and inspection, such as fire collars, be reduced?

–– Connections to, from and between modules are often a weak point - suitable protection should
be designed.

–– How will cavities between modules be protected from fire? Have all openings been considered?

–– Is there a strategy for prevention and risk mitigation for fire during the assembly and installation
process?

–– Is all information regarding fire safety that will be relevant to the occupier included in the
homeowner’s manual?

83
3.11 THERMAL PRINCIPLES

Offsite construction using modern, high performing building materials and accurate manufacturing methods
can optimise the thermal performance of building elements. To do this, the designer needs to understand
the inherent material properties of the CLT and how these are affected when designing for manufacture
and assembly.

3.11.1 Thermal performance

The key way to improve the thermal

performance in most buildings is through
insulation to the external envelope.
Thermal line outside CLT Thermal line inside CLT

The performance requirements for insulation

may vary depending on whether it is
applied offsite or on site - for example, if
installed offsite, it will need to be sufficiently
robust to withstand minor impacts during
Thermal line is broken Thermal line is broken
transportation.
CLT
Thermal line
3.11.2 Location of thermal line
Figure 66 The thermal line should always be on the outside of the CLT

Timber can deteriorate if it becomes wet for 3.11.3 Benefits of thermal modelling
a sustained period of time - if the moisture
content exceeds 20% for long periods it will The accurate manufacturing methods used in the
be susceptible to rot and mould damage. factory can increase the thermal efficiency of the
modules, often surpassing those found in traditional
To prevent moisture reaching the CLT, it is construction. By thermally modelling the building’s
important to calculate where the dew point typical connection details, such as doors, windows and
within the wall build up will be and ensure wall junctions, highly accurate thermal transmittance
that interstitial condensation does not form values can be calculated. These can be used as a
within the timber structure. To achieve this, design tool to maximise the thermal efficiency of the
the thermal line should sit on the outside building, potentially exceeding the thermal standards
face of the CLT. prescribed in the building regulations.

84
 Thermal principles

Understanding how to optimise the thermal

performance of the wall can reduce the
thickness of the build up, thereby increasing
the internal floor area. Examples of ways to
achieve a reduced wall thickness include:

–– Optimised airtightness values that

exceed those required to meet Part L of Tape to horizontal
the building regulations. + vertical joints

Airtight breather
membrane
–– Improved PSI values can reduce the
required U-value of a wall, and therefore
Figure 68 Airtightness enhancements such as taped joints can be
its thickness. included in the detailing of the CLT junctions

–– Improving the thermal performance of 3.11.4 Air tightness

elements other than the walls, such as
roofs and windows. The airtightness achieved in NU build’s modules is
typically far higher than traditional values. This is
due to the accurate CNC cutting of the CLT and the
greater level of accuracy with which elements are fitted
together. Airtightness can be further enhanced with
tape applied at the joints between panels, ensuring
penetrations are all appropriately sealed.
20oC

Most panels can be used to create a high performance

hygroscopic airtightness layer without the need for
additional membranes, therefore reducing the required
U-value of the wall construction.

3.11.5 Ventilating the timber

When designing the wall build up it is essential to

ensure the timber structure is able to breathe. This will
allow it to dry out should any moisture penetrate to the
timber from rain during construction, humidity variations
0oC
or leakage.

Figure 67 Modelling building elements produces highly

accurate thermal performance analysis

85
Thermal principles

If the timber is in contact with free air then 3.11.7 Cold bridging
it will always be able to dry, reverting to an
acceptable moisture content of around 12%. When the thermal line of the external envelope is
If the timber itself forms the airtightness line broken or reduced, such as where steel connections
then, providing there is a ventilated cavity penetrate the timber, a cold bridge can be formed. It is
to absorb the moisture, the panels will dry crucial that these locations are modelled to ensure the
naturally should they become wet. performance is understood and that the dew point does
not lie within the CLT panels, as this can increase the
If a membrane is used it is vital that it is risk of condensation forming on the timber.
breathable to avoid trapping moisture in
the CLT. For more information on protecting When these locations are identified and modelled, the
the timber structure from moisture damage, necessary protection can be applied to mitigate the risk
please refer to Chapter 3.6 : Waterproofing of damage to the timber.

3.11.6 Breathable wall construction.

When building with CLT, a breathable wall

insulation is recommended and should be
incorporated into the proposed wall build up
in the early stages of the design.

Breathable insulation allows moisture to

migrate to the external surface minimising
fluctuations in internal humidity and reducing
the amount of internal condensation,
avoiding the possibility of mould growth.
The overall effect is a healthier and more
robust construction. Examples of breathable
wall insulation include mineral wool, sheep’s
wool and wood fibre.

In order to achieve a ventilated wall

construction, products such as polyurethane
rigid foam (PUR) and polyisocyanurate foam
(PIR) should be avoided, as they are not
sufficiently breathable.

Figure 69 Take extra care to investigate cold bridges to steel

connections

86
K E Y C O N S I D E R A T I O N S : T hermal principles

–– Optimise the benefits of modular technology to reduce the wall thickness and increase the internal
volume as much as possible.

–– Does the thermal line sit outside the CLT?

–– Has the dew point of the wall build up been calculated?

–– Is the wall build up breathable and the timber ventilated?

–– Can thermal performance be increased through thermal modelling, optimised air tightness and
improved PSI values?

–– Take extra care to investigate cold bridging, particularly via steel connections. Condensation risk
analysis should be undertaken to avoid moisture forming on steel screws within the timber.

87
3.12 ACOUSTIC PRINCIPLES

All residential developments require a carefully considered acoustic design strategy. There are, however,
some key differences in the way modules behave acoustically when compared to other types of construction,
and the designer should ensure they have a full understanding of this when developing the design.

3.12.1 External design considerations partition, plus the noise that travels via the flanking
routes i.e. over, under and around the partition, via
An understanding of the employer’s the ceiling/floor/walls. Noise may also travel through
requirements, building regulations and service penetrations and ductwork connecting the
planning guidance is the starting point spaces.
for acoustic design. Swan always aim to
achieve high levels of sound insulation in Acoustic separation is provided by a wall build up that
their buildings. A site assessment of the consists of materials with a variety of densities such as
background noise around the site should be CLT, airspace and a wall lining material.
carried out to establish potential issues.

3.12.2 Modular design considerations

In many ways the acoustic design

for modular follows the principles of
conventional acoustic design. It could be
assumed that each module is self contained
box, independent of one another. However,
the connections between the modules form
an acoustic weak point, therefore it is useful
to think in terms of designing a box within a
box: the CLT modules will be lined with an
independent lining.

The level of noise transmittance through a

party wall or floor is a combination of the
noise transmitted through the separating
Figure 70 Flanking and airbourne sound

88
 Acoustic Principles

There are some key considerations that 3.12.3 Early considerations

make designing for modular different:
Modular buildings should be designed on a case by
–– The mass of CLT is not as great as case basis. Some detailing decisions need to be taken
concrete, brick or block. It is more early in the design development, particularly during the
lightweight and has embedded sound Strategy Stage, to establish the build up of walls and
insulation properties. floors, set out room sizes and understand floor to ceiling
heights.
–– Each module is rigidly fixed to another
to provide stability. The connections Things to consider at this stage include, but are not
between models need to be designed to limited to:
prevent flanking and reverberant sound
transmission if required. –– What decibel (dB) reduction should be achieved
for external walls, internal separating walls and
–– There are more service connections internal party walls?
in modular construction due to the
connections between the modules. –– Smaller wall build ups that utilise high performing
These need to be acoustically sealed. materials take up less floor area. However, this is
likely to increase costs so needs to be addressed
–– CLT modular offsite manufacture is new alongside budget constraints.
and there is currently limited acoustic
test data for similar constructions. –– If the modules need separating/decoupling

Low density Module 1 Module 2

3 1 1 2 2 1 1 3

1 Low density material

2 Medium density material
3 High density material

Figure 71 A typical module to module wall build up Figure 72 Indicative detail of decoupling modules
showing the gap between the modules

89
Acoustic Principles

to achieve the required acoustic –– Where are the service routes and what size access
performance, what impact will this have panels are required? How will these be acoustically
on the structural design? sealed?

–– What will the floor build up be and how –– Is a mineral wool insulation required between
will it affect the manufacturing process? modules? Can this be installed on site?
For example, a screed floor improves the
acoustic performance but is a wet trade It is not always possible to accommodate the highest
and will slow down the manufacturing if performance build ups for walls, floors and ceilings. It
applied in the factory. It may also crack may require the client to confirm their risk profile and
during transportation. the quantity surveyor to provide costs for different
options in order to arrive at a balance between risk,
–– Should all floors be ‘acoustically quality and cost.
floated’ such as acoustic cradle and
batten systems? 3.12.4 Testing

–– Will the wall linings need independent Prototype testing of new acoustic build ups in the
support systems or will resilient bars be factory is recommended where there is no pre-existing
adequate? Is insulation required? What test data.
is the impact of this on the internal floor
area?

–– How will the wall build up impact on

tenants’ ability to hang items on walls,
such as pictures and screens?

–– What will the ceiling lining be? What

is the minimum depth of a suspended
resilient acoustic ceiling grid? How
will this affect floor to ceiling heights?
When ceiling and floor build ups are
accounted for can a standard CLT wall
panel be used and still achieve the
minimum floor to ceiling heights?

90
K E Y C O N S I D E R A T I O N S : A coustic P rinciples

–– What are the client’s acoustic requirements?

–– How do the acoustic requirements impact on wall build ups and the floor to ceiling height of
modules?

–– How do the connections impact on the acoustic performance?

–– Can the wall build up consist of a mix of materials with a variety of densities?

–– How do the materials specified impact on cost?

–– Can the acoustic engineer undertake a desk top study of the sound reduction of different build
ups?

–– Can the proposed wall and floor build ups be acoustically tested prior to mass production?

91
4

INTERNAL

PRINCIPLES
4 . 1 I N T E R N A L L AYO U T O F M O D U L E S

The external dimensions of the module, which are primarily defined by the transportation requirements,
form the ‘building blocks’ of the project, and internal layouts must be rationalised to be compatible with
these parameters. The external dimensions will be defined early in the project and therefore analysis of the
internal layouts and their minimum dimensions should be undertaken then too.

4.1.1 Building guidance and regulation

In all residential projects, internal layouts have to

conform to local and national guidance and regulation,
as well as any additional standards or requirements
prescribed by the client. Some of the legislation that
layouts must comply with includes:

–– Building regulations.

–– The London Plan.

–– The Mayor of London’s Housing Supplementary

Planning Guidance.

–– Technical Housing Standards.

–– Employer’s requirements.

–– Local council requirements.

4.1.2 Module widths

Chapter 3.1 : Transportation and Chapter 3.3 : CLT

panels outline the principle module size limitations
- these chapters should be read before beginning to
design internal layouts
Figure 73 Example documents to be considered

94
 Modular Size and Layout

The rest of this chapter goes on to outline external dimension is the defining parameter - once this
other factors that could influence the size is understood, along with the anticipated wall, floor
and configuration of the individual modules. and ceiling build ups, the internal dimension can be
determined.
Based on transport and CLT panel
constraints, it makes sense to limit the 4.1.3 Internal module heights
external width of modules to less than 3.85m
where possible. Occasionally oversized The height of the modules is decided by the size of
modules are necessary, but these should the CLT panels. The designer should ensure that this
be limited and agreed with the factory. The dimension allows the minimum floor to ceiling heights

LIVING, DINING + BEDROOM

KITCHEN

HALL BATHROOM

External dimension of module

restricted by transportation
requirements

Dimension determined by
regulations/guidance
STORE

Allow for all necessary structure,

linings and finishes when
calculating dimensions

Figure 74 Measuring internal and external dimensions of module

95
Modular Size and Layout

4.1.4 Wheelchair accessible units

Wheelchair accessible dwellings are required in every

development. These units are bigger than standard
dwellings and can impact on the standardisation of
the development. Factors to consider when designing
wheelchair user dwellings include:

–– Where should they be located?

–– If wheelchair accessible units can be located on

upper floors, can they all be stacked?

–– Is there a requirement for them to be situated on the

ground floor? If so, they might be a different size
to the units above and will not easily stack - will a
transfer structure be required? Further information
can be found in Chapter 3.4 : Structural principles,
Chapter 4.2 : Servicing principles and Chapter 5.4
: Module types.

4.1.5 Balconies and deck access

Figure 75 Balcony location should be considered -
recessed or protruding
If balconies are required, consideration should be given
that are set out in the relevant housing to whether they should be inset or protruding and how
design guidance and building regulations. this will impact on the structural strategy.
When working out floor to floor heights
consider the following: It is preferable that balconies are positioned along the
short side of modules so that the structural connection
–– Acoustic ceiling build up. can be made directly into the structural connection
brackets. Further information can be found in Chapter
–– Number of layers of plasterboard 3.4 : Structural principles and Chapter 3.7 : On site
required for fire protection. finishes.

–– Services cross overs in ceiling voids. Where deck access is required, ensure no boiler flues
cross this area – vertical boiler flues are preferable
–– Floor build up. in these situations. Sufficient floor build up should be

96
 Modular Size and Layout

allowed for where there is deck access or

inset balconies. The levels may need to be
adjusted to allow for insulation on deck and
inset balconies.

4.1.6 Allowing for structure and services

Openings align
between storeys
When planning internal layouts, structural
and servicing constraints should be
considered.

Structural connections will be located at

the corners of the modules: these require a
sufficient area of CLT to hold the connection
and distribute the forces. This means that
it is not possible to locate vertical or
horizontal penetrations at module corners, Openings do not align
between storeys
and the conventional solution of installing
service risers in the corners of flats must be
reconsidered.

To simplify load paths, the location of

openings between modules should align and
be of a similar size. If this is not possible, Figure 76 Openings should align between storeys, with the largest
openings on the upper storeys
larger openings should only be used on
upper storeys, as shown in Figure 76. The guidance documentation and the client’s employer’s
detail of the linings of openings between requirements to determine if dwellings need a sprinkler
modules need to be considered as these will system. If required, there may be more flexibility with the
be wider than conventional openings. design of internal layouts as the units may not require
protected lobbies.
For further considerations, refer to Chapter
3.4 : Structural principles and Chapter 4.2 : The CLT can reduce in thickness on upper storeys of
Servicing principles. the building. Kitchens and bathrooms should be set
out in such a way so that the internal dimensions of
4.1.7 Internal layouts the module can increase as the CLT thickness reduces.
Further information can be found in Chapter 5.4 :
The designer should consult the necessary Module types

97
Modular Size and Layout

4.1.8 Coordinating with external finishes Consideration should be given to the top newel post - it
is likely to be installed on site as it will protrude above
Modules should be set out to brick the module. This detail should be agreed at the earliest
dimensions and or cladding dimensions possibility.
early in the design process. This will help
to keep window locations consistent in flat The designer should also carefully consider the
types that are repeated elsewhere in the interface between the upper and lower modules, how
building. See Chapter 3.7 : On site finishes. the horizontal opening for the stairwell will be aligned
during assembly on site and what tolerances should be
4.1.9 Stairs within a module allowed.

When stairs are required between modules, Different stair manufactures have different dimensional
such as in two storey houses or duplex flats, requirements, so it is important to agree the supplier at
the designer should consider the fabrication an early stage.
of the stairs at an early stage of the design
process: 4.1.10 Fixtures and fittings

–– Can the stair be prefabricated in the When designing rooms with a large number of fixtures
factory? or fittings, such as kitchens or bathrooms, consideration
must be given to how versatile the items are in terms
–– Will an ‘off the shelf’ stair be procured of how they will fit into a variety of room shapes and
from an external supplier? If so, who will sizes. This is particularly important if the person who will
this be? occupy the home is able to customise the specification
of the fixtures and finishes prior to manufacture. For
–– Can offcuts of CLT be reused to example, if there is a choice of a basic sink or a luxury
fabricate the stair elements? sink, the designated space should accommodate either
sink type and the design should reflect this.
–– Will any elements of the stair need to be
installed on site? Extensive information on suitable fixtures and fittings
will be found in the NU build Modular System Guide.
When the method of fabricating the
stair has been determined, component
dimensions such as the width, tread depth
and riser height and baluster size should be
considered to ensure that the space allowed
for the stair is sufficient for both installation
and end use.

98
K E Y C O N S I D E R A T I O N S : M odular S i z e and L ayout

–– What are the structural constraints to planning the module?

–– What are the services constraints to planning the module?

–– Have module widths and internal ceiling heights been agreed?

–– Disabled units are a different size to standard units. Where will these be located in the development?
How will they be structurally accommodated?

–– Can the balcony and deck access fixing details be made directly into the structural connection
brackets?

–– Are lobbies required?

–– Have windows, doors and openings been set out to cladding dimensions?

–– Do openings stack?

–– Are vertical and horizontal penetrations in the modules located away from the corners?

–– Is the internal setting out affected by CLT thickness?

99
4.2 SERVICING PRINCIPLES

A well coordinated service strategy can help deliver comfortable, sustainable homes which are easy to
assemble and simple to maintain. Many early design decisions concern the MEP strategy, so the early
appointment of a services engineer is essential. It is beneficial if they have an understanding of ‘plug and
play’ systems and can provide detailed construction information rather than performance specifications.

4.2.1 Service strategy be omitted from the design? As gas connections

currently need to be certified from the meter to
As numerous modules make up one flat, there source, access panels or areas of ceiling need to be
are more service connections in a modular left unfinished in the factory to allow for connection.
project than in a conventional project. Each
service and connection requires complex –– HVAC systems require connections between
details that, if considered from the early modules and penetrations through the facade.
stage of design, can be managed and Natural ventilation systems can significantly
simplified. The following principles can help reduce the amount of service penetrations and
reduce complexity: coordination. Each penetration between modules
will require fire protection so the fewer there are,
–– Simplify the service strategy by reducing the less work there is to do on site.
the number of services required in each
module. –– Early engagement with statutory authorities is
essential. Many will not have standard systems
–– Can a communal services strategy in place for applications using modular and CLT
be employed? While this may require connections. Early engagement allows queries to
extra equipment for redundancy to be dealt with in a timely manner.
alleviate any potential maintenance
issues, it can significantly reduce the –– It is beneficial to keep services within the module
amount of connections and penetrations that they first enter and reduce the travel distance
required. A basement or the ground and connections within each module. For example,
floor construction can be used for the if a boiler requires a gas connection, it is always
required plant. simpler if it is located in the same module that the
gas enters, rather than an adjacent module.
–– Can gas provision to each module be
avoided or can individual gas boilers

100
 Servicing Principles

Typical penetration
exclusion zone

Figure 77 Typical module service penetration guidance in plan

4.2.2 Service locations and penetration the overall strength of the panel and so a few smaller
guidance groups rather than one large group of penetrations is
preferred.
Typical exclusion zone at Typical lintel exclusion Typical permissible opening
For easy corners
access, services should be
of modules zone within lintels for servicing
rationalised to the entrance side of a A penetration guidance document should be generated
module. by the structural engineer and coordinated with the
service engineer during the Strategy Stage of the
Service zones (kitchens, bathrooms and project.
service cupboards) should be grouped
together to reduce the amount of As most of the structural stress transfers through the
connections and penetrations. While it can module connections, typically located at the module
be useful to group penetrations to reduce corners, penetrations should avoid these areas.
the number of locations for connections, Refer to Chapter 3.4 : Structural principles for further
larger penetrations can significantly reduce information
Typical spacing of Typical exclusion zone
servicing openings beneath lintel bearing

101
Typical penetration
exclusion zone
 Typical penetration
exclusion zone
Servicing Principles

Typical exclusion zone at Typical lintel exclusion Typical permissible opening

corners of modules zone within lintels for servicing

Typical spacing of Typical exclusion zone

servicing openings beneath lintel bearing

Typical penetration
exclusion zone

Figure 78 Typical module service penetration guidance in elevation

Areas above doors, windows and other circular holes for circular services and rectangular holes
openings provide strength to the panel and for rectangular services.
should remain free of further penetrations.
Ceiling voids
Speed of services installation should If increased ceiling voids are required for service cross
also be considered and ‘plug and play’ overs, lowered ceiling areas should be confined to the
services strategies should be prioritised. following areas, in the following order:
Where using service frames for bathrooms, 1. Storage areas
these may add extra material cost but can 2, Bathrooms
significantly reduce assembly time. 3. Hallways
4. Kitchens
It is easier and quicker to install and seal Also note any reduced ceiling height restrictions
the correct shaped service in the correct imposed by local legislation, as described in Chapter
shaped hole. Therefore, where possible, use 4.1 : Internal layout of modules.

102
 Servicing Principles

BATHROOM STORE + SERVICES

BEDROOM

HALLWAY

LIVING, DINING KITCHEN

Servicing intake

Services transferred to adjacent modules

Lowered ceiling for crossover

of services

Figure 79 If needed, lowered ceilings should be limited to storage areas, bathrooms, hallways and kitchens

4.2.3 Connections inside the module. If this is the case, the module
will need to be placed down over a protruding pipe
The ability to connect services after the connection. Extra care will need to be made to ensure
module has been installed needs careful this is not damaged during construction.
consideration and planning.
4.2.4 Vertical and horizontal connections
Below ground connections need to be set
out with a greater level of accuracy than Using telescopic connectors can reduce the number of
a site team might usually allow for. Either access panels needed, as they only require a panel on
the connection will need to be made below one side of the connection. This requires robust fixing
the module, and therefore access will be of the connection to one side, but can be an efficient
required, or the connection will be made method of providing connections.

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Servicing Principles

4.2.5 Access for servicing Locations of access panels that generally should be
avoided include behind kitchen units and behind
Service risers generally require a high level sanitary fittings. For example, locating an SVP riser
and a low level access panel for connecting behind a shower will mean that the fixtures and finishes
and inspecting pipes and ductwork on site, to this area will have to be installed on site. It also
as well as a horizontal opening in the floor creates a weak point in the waterproofing strategy, and
slab. Access panels should be located in could become an area where moisture collects. Where
areas that will be easily accessible on site as possible, it is preferable for panels to be located in
well as in the factory and should not clash areas such as storage cupboards.
with fittings and fixtures, as this will mean
these elements cannot be manufactured in
the factory.

High level and/or low

level access hatch

Storage cupboard - items such as boilers, washing

machines etc. can also be located here.

SVP

Figure 80 Service hatch location guidance

104
K E Y C O N S I D E R A T I O N S : S ervicing P rinciples

–– More detailed services design is needed earlier in the design process compared to traditional
construction - have MEP engineers been appointed at an early stage?

–– Can the number of services required in each home be reduced?

–– The servicing strategy should be agreed during the Strategy Stage - penetrations should be set
out and shown in the BIM model using spaces and zones.

–– Can the number of servicing connections between modules be reduced?

–– Do penetrations conform to the penetration guidance document produced by the structural

engineer? For example, are they located away from module corners and openings?

–– How will the services be connected on site and how is access for maintenance provided?

–– How will fire protection to service penetrations be provided? Will it need maintaining?

105
5

INFORMATION

FOR

MANUFACTURE
5.1 USING BIM AND 4D

For Building Information Modelling (BIM) to succeed it is important that it is used to assist the delivery of
the project at all design stages. This chapter explains what must be covered in a BIM Execution Plan (BEP),
and highlights some points that can help in successfully implementing a BIM strategy. The BEP must be
drafted and shared with all design team members early on.

5.1.1 Common data environment for establishing the protocols for information exchange
and managing the BIM process and coordination, via
A common data environment must be used the project’s BEP.
to ensure all members of the project team
- design consultants, client and the factory 5.1.3 Common data exchange formats
- have access to the correct and latest
information and have the ability to comment. Using standard and common data exchange formats
Due to the multidisciplinary nature of the allows members of the design and client team to
modular design process it is imperative to access and comment on information effectively. Current
have a clear information transfer strategy recommended formats are:
that tracks changes. For this reason a 3D information - .IFC
product like ASITE should be used. 2D Information - .DWG .PDF
Spreadsheet information - .XLSX
5.1.2 BIM manager
Design consultants may sometimes wish to vary the
A BIM manager must be appointed at the agreed processes to exchange information more quickly.
earliest opportunity. They will be responsible This should be avoided as it can exclude members

Product data, as
Space, system and built
equipment layout layout, tag and
serial no. warranties
and spares

DESIGN BUILD OPERATE

Figure 81 BIM should be used to assist in the delivery of a project through all workstages

108
 Using BIM and 4D

of the team who may not have the same contracted to provide BIM information, therefore this
software and can lead to confusion during should be avoided where possible.
the design process by creating contradicting
information. 5.1.6 Purpose at every stage

5.1.4 Early test run It is important for all consultants to understand the
benefits of BIM at all phases of the design.
All projects need to conduct an early test
procedure, swapping a few file types and Brief and Logistics:
test objects back and forth between team
members to ensure: –– Model to show mass of modules.

–– All members have the ability to share the –– Model to count the number of modules.
information.
–– Start understanding assembly sequence.
–– All members can view the shared
information. –– The thickness of the wall build up can start to be
included.
–– All members can comment on the shared
information. Strategy and Performance:

–– Information stays in the same location –– Use zones and spaces to define areas for
in the model. coordination.

–– No information is being lost in the –– External and internal module size information
exchange. should be provided by the architects.

–– The .ifc is a manageable file size for all –– Exclusion zones for connections, and their sizes
consultants to use. and locations, should be provided by structural
engineer.
5.1.5 Hands on consultants
–– Openings such as windows and doors, their sizes
Changes are made more quickly and team and locations should be provided by the architects.
discussions over models are more efficient if
each consultant has an in-depth knowledge –– Builders work hole requirements, for both horizontal
of their information. Difficulties are created and vertical penetrations, should be provided and
when additional consultants are sub led by services engineer.

109
Using BIM and 4D

–– Assembly phase sequence and on site Following completion, the model should be transferred
installation sequence should be started. from the project delivery team to the building
maintenance team
Detail:

–– Builders work holes.

–– Assembly phase sequence developed.

Information:

–– Produce coordinated module information

for manufacture and assembly.

–– Offsite and on site construction phase

sequence finalised.

–– Issue project data sheets generated by

the model.

Manufacture and transportation

–– The model can be used by assembly

Figure 82 Services can be integrated into the building model
teams to understand sequence of
production and to workshop the process
step by step.

–– The model should show panellisation

and the CNC programme.

Assembly:

–– On site phase sequence model can be

used to understand the sequence of
product and query the assembly process
on site.

110
K E Y C O N S I D E R A T I O N S : U sing B I M and 4 D

–– Has a common data environment been established?

–– Is a BIM manager appointed?

–– Have common data exchange formats been agreed?

–– Has the team developed the BEP together?

–– Has an early test run been carried out?

–– Is the BIM information being produced by the person designing it?

–– Are the team clear about the benefits and requirements of BIM at every stage of the project?

111
5.2 DRAWING FOR MANUFACTURE

When drawing for manufacture, a high level of detail and coordination is required at an early stage - details
that are usually associated with construction information for design and build contracts will be required
prior to manufacture.

5.2.1 Module information packages agree responsibility for certain aspects of the design
to avoid confusion between information. For example,
In addition to standard construction should the RCPs be produced by the MEP engineers
information, for the manufacture of each or the architectural design team? This should be
module a set of drawings at a scale of determined prior to each team’s appointment.
1:20 will typically be required from both
the architectural design team and the MEP In addition to the 1:20 drawing set, a set of all the
design team. These should include, but not relevant details and schedules needed to manufacture
be limited to: the modules should be provided. This might include:

–– Setting out of walls and partitions. –– Window and door details

–– MEP locations, both on plans and on –– Tile setting out

reflected ceiling plans (RCPs).
–– Wall and floor build ups
–– Sections showing suspended ceilings
and window and door openings. –– Window and door schedules

–– Room plans and elevations, particularly –– Kitchen and bathroom schedules

for serviced areas such as bathrooms
and kitchens, showing services and A draft set of documents should be issued towards the
finishes. beginning of the work stage so that the client and the
factory can comment and agree the extent and number
Clash detection and sharing information of drawings needed.
from each team’s BIM models will be
required to ensure information is sufficiently
coordinated. Design teams should also

112
 Drawing for manufacture

MEP STRUCTURES ARCHITECTURE

- 1:20 drawings - 1:20 drawings - 1:20 drawings

- Details - Details - Details
- Schedules - Schedules - Schedules
- Room data sheets - Room data sheets - Room data sheets

MANUFACTURE

Figure 83 All consultant information needs to be of the same scale and level of detail and fully coordinated in order to manufacture
the modules

113
Drawing for manufacture

5.2.2 On site/offsite elements 5.2.4 Dimensions variants

Consideration should be given to how on If the thickness of the CLT varies between module
site and offsite elements are illustrated in types, a suitable system for communicating this on the
the drawing package. If this is not clearly drawings must be established. For example, the variant
denoted, it could cause confusion during the could be calculated in a schedule and referred to on
manufacturing process. the drawings using a generic system, such as +X or +Y.
Alternatively, a key could be provided on each drawing
Graphic representations such as colour outlining all variants. It is important that the system is
coding, hatches and labels could all be trialled and tested throughout the Information Stage to
employed to determine the difference ensure that it is easily understood by the factory and all
between on site and offsite elements. In the members of the design team. Further information can be
BIM file, layers, components and classes found in Chapter 5.4 : Module types.
can be used to separate on site and offsite
elements. The design team must agree
a suitable system with the factory prior to
producing drawings for the Information
Stage which will be used by all consultants.

5.2.3 Setting out point

The setting out point (SOP) must be agreed

between the design team and the factory.
The SOP needs to be in a location on the
inside of the module - it is not suitable for
it to be located on an outside corner. If
possible, locate the SOP in relation to MEP
penetrations. If the thickness of the CLT
varies between storeys, it is important that
a strategy for locating the SOP is agreed at
the earliest opportunity. It will be simplest if
the SOP is in a consistent location across all
modules. The SOP must always be clearly
marked on the 1:20 drawings.

114
K E Y C O N S I D E R A T I O N S : D rawing for manufacture

–– What drawings are required for the module information packages during the Strategy Stage?

–– Have on site and offsite elements been graphically represented?

–– Have the setting out points been agreed between all members of the design team?

–– Are the design team sharing information regularly using BIM files?

–– Has the design team and the factory agreed a way to show dimension variants, if required?

–– Are the presentation standards and styles consistent between consultants?

–– Are the drawings and information sufficient to manufacture?

115
5 . 3 R O O M D ATA S H E E T S

The information from the BIM model can be used to generate room data sheets which will be used by the
building management team to coordinate maintenance and repairs when the building is in use. A strategy
for inputting and managing this information in the BIM environment should be considered from an early
stage in the design.

5.3.1 Uses of room data sheets will communal areas. These could be further broken
down into rooms if needed.
Room data sheets give a detailed
description of finishes, fixtures and fittings Room data sheets will primarily be used by the building
and mechanical and electrical requirements management team to keep track of building elements
that will be required for each room or space that might need to be maintained, serviced or replaced
in the project. Typically each flat or house during the building’s use. For example, if a light fitting
will have an individual room data sheet, as was found to be faulty, the room data sheet will be

ELEMENT ID ELEMENT ID
ELEMENT ID ELEMENT ID
TAG TAG
TAG TAG
REFERENCE REFERENCE
REFERENCE REFERENCE

ELEMENT ID
TAG
REFERENCE

ELEMENT ID
TAG
REFERENCE

Figure 84 Information should be embedded within the BIM components

116
 Room data sheets

Flat type Flat number Element ID Tag Manufacturer NBS Product Colour Barcode
FT-21 18 ID_06_L 042E63-15D7-9A40 Vicaima 25-50-20/122 C PORTARO ® FD Painted white 9 125869 486628

FT-21 18 D3_2_D-ZC 19D85E-34-444CB Velfac 25-50-20/120 A VELFAC 200 White 7 125869 486628

FT-21 18 ID_07_R 276053-67ED-A548 Vicaima 25-50-20/122 B Easi-Fit® RAL 9001 6 125869 486628

FT-21 18 ID_09_R 283B18AF-CD-3A2A Vicaima 25-50-20/122 A Easi-Fit® Painted white 4 125869 486628

FT-21 18 ID_03_D 7CA725-C817-2E4C Vicaima 25-50-20/122 D Easi-Fit® Painted white 3 125869 486628

FT-21 18 ID_01_L BCD45-6B-7846-8 Vicaima 25-50-20/122 A Easi-Fit® Painted white 2 125869 486628

FT-21 18 ID_03_D 7CA725-C817-2E4C Vicaima 25-50-20/122 D Easi-Fit® Painted white 3 125869 486628

FT-21 18 ID_01_L BCD45-53B-7846-8 Vicaima 25-50-20/122 A Easi-Fit® Painted white 2 125869 486628

FT-21 18 WR_01 286E0A-D9C-EB4E Portico 45-30-80/429 v150r Painted white 9 125869 486628

FT-21 18 WR_01 286E0A-DEC-EB4E Portico 45-30-80/429 v150r Painted white 9 125869 486628

FT-21 18 F/F_02 A287873E9-D340 Zanussi 45-35-15/493 ZBB24430SA Stainless steel 8 125869 486628

FT-21 18 WM_01 F3A53-73-FF43-A Zanussi 45-35-47/374 ZWD71460NW N/A 7 125869 486628

FT-21 18 C_01 FF6186-1-C045-9 Electrolux 45-35-15/490 EFP6500X N/A 6 125869 486628

FT-21 18 DW_03 329AF6-AD-304E-5 Zanussi 45-35-15/478 ZDT26030FA N/A 9 125869 486628

Figure 85 Sample room data sheet

used to find out the manufacturer, product Typically this might consist of:
reference, installation date and warranty
period. –– Doors and windows

Some information will be provided by –– Boilers or heating systems

the design team before issuing the room
data sheet to the factory, who will input –– Sanitary ware
the remaining information during the
manufacturing process. –– Kitchen units

5.3.2 Elements and information –– MEP components such as light fittings, ductwork
interfaces and sockets
As part of their employer’s requirements and
appointment documents, Swan Housing –– Fitted appliances such as refrigerators and cookers
and NU living will provide the designer with
details of what will be included on the room Information about the room including its name, number,
data sheets. location and use might also be included.

117
Room data sheets

5.3.3 Data categories In order to allow for a data transfer to be smooth and
coordinated, it would be beneficial to allow for the
The factory and the client will specify what production of test room data sheets at the earliest
data categories should be provided for each opportunity.
element. This might include:
5.3.6 Use in the factory
–– Element ID
While manufacturing the modules and installing the
–– Manufacturer reference fittings and fixtures, the factory staff will input specific
data such as product bar codes into the room data
–– NBS reference sheets.

–– Colour

–– Bar code
MEP STRUCTURE ARCHITECT

5.3.4 Format

The information for each element should

be embedded within the components
and objects in the BIM environment,
and extracted in the form of an editable
spreadsheet, such as an .XLSX file, for use in
the factory and by the building management
team.
ROOM
5.3.5 Coordination between the design D ATA
SHEET
team

All members of the design team should

contribute information to the room data
sheets. Early in the design process it is
particularly important for those responsible
for the architectural and MEP design to FACTORY DURING
MANUFACTURE
agree a unified strategy for specifying
model component information.

Figure 86 Information for the room data sheets must be produced by all
members of the design team

118
K E Y C O N S I D E R A T I O N S : R oom data sheets

–– Has the client provided a list of what will be included in the room data sheets?

–– Has a format for the room data sheets been agreed by the design team and the factory?

–– Does the design team understand what information will be needed to be associated with each
element and ensure that this is included in the BIM components?

–– Work with the whole design team to create a way of sharing and exporting room data information
from a single model.

–– Does the design team have the capacity to include product and project specific information in
their BIM model?

–– Has the data been added by the design team into a test room data sheet at an early stage in the
project?

119
5.4 MODULE TYPES

The modular design process can be streamlined by reducing the number of module sizes and module types -
fewer types allow for a quicker and simpler manufacturing process. This does not need to restrict the design
as a small number of types can be arranged in multiple ways to create a variety of flat layouts and house
plans.

5.4.1 Reusable types

Where possible, the designer should

investigate the possibility of repeating
module types - for example, a module
consisting of a bathroom, bedroom and
hallway could be used in all flat types,
and additional module types could simply
be added as necessary. This strategy is
applicable for both single family housing
and multistorey residential.
Figure 88 Modules should accommodate a variety of layouts

1 3 1 2 3 4 2 3

Figure 87 A limited number of types can create a wider variety of flat layouts

120
 Module types

B B B
A A A
B B B D B C
A A A C A D
B D D
A C C

Figure 89 Module types should be consistent between floors

5.4.2 Tenure types should be relatively straightforward to ensure that riser

locations are consistent. However, if a different module
Information on tenure will be provided type is required between one storey and another, for
by Swan Housing. Swan’s employer’s example where wheelchair accessible flats are required
requirements should be consulted to on the ground floor, it can be difficult to ensure riser
establish specification requirements for locations and penetrations are in the same location in
each tenure type. each module.

When determining module types, the tenure This can be made simpler if one module type, e.g.
of the flats must be known - if two modules module type A, is consistently located above the same
have the same layout, but have different module type, e.g. module type C.
tenures, these must be considered to be
different module types, as the finishes, 5.4.4 Handing
fixtures and fittings will not be the same.
Handed module layouts (and bathroom and kitchen
5.4.3 MEP coordination layouts) are unique module types when it comes to
factory manufacture, therefore handing layouts results
Ideally, MEP riser locations should be in a greater number of modules types.
consistent between all unique module types.
If module types are vertically stacked, it

121
Module types

DIMENSION 1

DIMENSION 2

DIMENSION 3

CLT thickness 1

CLT thickness 2

CLT thickness 3

Figure 90 A system for identifying module variants should be agreed with the factory

5.4.5 Variation in CLT dimensions

If the thickness of the CLT varies, the designer should
Sometimes it will be more structurally efficient be aware that this could impact on repeating module
for the thickness of the CLT walls to reduce types. A strategy for coordinating the variation in the
on upper storeys of the building where loads internal dimensions of the module types should be
on the walls are less. Depending on the discussed and agreed with the factory at an early
size of the project, this might offer savings stage of the design process. Thought should also be
to the client when procuring the CLT. The given to how the dimension variants impact on MEP
time to produce and coordinate additional penetration locations. Refer to Chapter 5.2 Drawing for
information that identifies the variations Manufacture.
will need to be considered. The client and
the factory will inform the designer of their
preference.

122
K E Y C O N S I D E R A T I O N S : M odule types

–– Can modules be repeated?

–– What is the tenure of each dwelling?

–– Do risers line up vertically?

–– Are all modules with handed layouts or differing thickness of CLT drawn as unique modules?

–– Has a strategy for explaining different external wall dimension variants been agreed?

123
6

APPENDIX
6.1 CHECKLIST

This section lists some common questions that should be interrogated and resolved during the design
process. The checklist here can be used by design team, in conjunction with the NU stages, to ensure that
the key considerations of modular design are understood, leading to successful modular buildings. Note
that this is not an exhaustive list and should be added to by the designer as needed.
BRIEF LOGISTIC S T R AT E G Y PERFORMANCE D E TA I L MANUFACTURE T R A N S P O R TAT I O N A S S E M B LY

- ERs - Access to site - Structural principles - Thermal performance - Kitchens - 1:20 drawings - Wrapping the underside as - Site preparation
well as the top and sides
- Educate design team on - Ground conditions - Servicing principles - Fire performance - Bathrooms - Interfaces - Accuracy of landing the
modular - Timings modules on the foundations
- Site assembly - Accessible units - Acoustic performance - Doors - Membranes
- Incorporate lessons from - Just in time - Underground services
- Transport - Lifting principles - Materials - Windows
previous projects alignment and fixing details
- Storage
- CLT panel sizes - Fire principles - Finishes - Internal finishes
- Scaffolding plan
- GF detail principles - Roof type - Roof details
‘Zipping up'
C L I EN T

C L I EN T

C L I EN T

C L I EN T

C L I EN T

C L I EN T

C L I EN T

C L I EN T
Transportation - Chapter 3.1
+

+
FACTO RY

FACTO RY

FACTO RY

FACTO RY

FACTO RY

FACTO RY

FACTO RY

FACTO RY
CLIENT

–– What are the size restrictions associated with the lorry?

R E VI E W

R E VI E W

R E VI E W

R E VI E W

R E VI E W

R E VI E W

R E VI E W

R E VI E W
+
D

D
R

Y
Y

P
P
E

E
E

FACTORY

L
L

R
D

R
A

E D E D E D E D N O N O
E D E D E D E D O G O G
SIGN OFF
N R N R N R N R R R
E S E S E S E S E S S I O N E S S I O N
A S S A S S A S S A S S

–– Are there time restrictions for transporting the module to site?

–– Has a track analysis report to check the route for obstructions and access considerations been
instructed? NB this should be a test run with a vehicle rather than a desktop study.

–– How do obstructions and access considerations along the route effect the maximum module dimensions?

–– If the module is oversized, how will this impact on transportation and site access? Will there be time and
cost implications? What arrangements should be made with the relevant authorities?

–– Are protrusions and finishes that are applied in the factory accounted for within the module width
dimensions?

–– How will the module be protected during transportation?

–– Should cladding and insulation be applied in the factory or on site?

126
Site considerations - Chapter 3.2

–– Has site access for delivery been planned?

–– What type of crane is required and how will it impact on the foundation design?

–– Has the foundation design sequencing and phasing been considered?

–– Are services coordinated with crane locations and lifting strategy?

–– Has an on site fire safety and water management strategy been completed during the Strategy Stage,
for review and implementation into DfMA information at the Performance Stage and Detail Stage?

–– Has a draft module assembly strategy been agreed at the Logistic Stage? Has this been updated at
each subsequent stage?

–– Has a risk assessment method statement been produced?

CLT panels - Chapter 3.3

–– What are the standard panel sizes from NU build’s chosen supplier?

–– Can the standard panel sizes achieve the required floor to ceiling heights?

–– Has the CLT been used in the most efficient way to avoid wasted material?

–– Will platform or balloon construction be used?

–– Can the standard panel sizes achieve the required module length?

–– Can the panels be used horizontally or do they need to be joined vertically? If so, how will the connection
design work?

–– What visual quality is required?

–– Are £ and € exchange rates considered in the cost plan?

127
Structural principles - Chapter 3.4

–– Landlocked modules should be avoided.

–– If designing buildings taller than five storeys, it may be necessary to use the core for structural stability.

–– Connection design should be considered at the earliest opportunity.

–– How will the dynamic amplification of the modules during lifting impact on the lifting strategy and the
crane specification?

–– Each module should have a unique identification number.

–– Has an assembly sequence for the modules been produced?

–– Has the position of the half-laps in the CLT been considered, and are they avoiding door thresholds?

Ground floor construction - Chapter 3.5

–– Has a ground conditions survey been undertaken and the results considered?

–– What will the use of the ground floor be, and how will this impact on the construction method and
ground floor detail?

–– Is a basement required? If so, consider site access for module assembly.

–– Is a ground floor podium required? If so, consider site access for module assembly.

–– If modules are at ground floor, is the underside and end grain of the CLT protected from moisture at
external ground level, with drainage around the perimeter and the corners of the modules supported
on upstands?

–– Agree a foundation strategy at the earliest opportunity, and ensure that it is coordinated with the
assembly process.

128
–– Agree a site wide drainage strategy.

–– Has level access to ground floor units been provided?

–– Are wet rooms required?

Waterproofing - Chapter 3.6

–– Do the internal fit out of kitchens and bathrooms include a waterproof membrane on floors, behind
tiling and to all high risk areas such as showers?

–– Should a floor gully be included in bathrooms or kitchens to provide additional protection?

–– Is sufficient ventilation provided to allow the CLT to breathe?

–– Understand the thickness of membranes and how they will be lapped and fixed, particularly at the
corners of modules.

–– How is the end grain of the CLT protected?

–– Can the initial waterproofing layer be applied in the factory?

–– Can the windows be replaced without damaging the waterproofing membranes?

–– How will the modules be protected from water during transit?

–– How will water and moisture be managed on site?

–– Modules should be dried if wet and moisture levels tested before cladding and roofing can be
applied.

–– Water ingress in the gaps between modules and caused by movement should be prevented.

–– Warranties should be confirmed and understood by both the design and client team.

129
On site finishes - Chapter 3.7

–– Which elements need to be installed on site? Can these be reduced?

–– Investigate which on site elements can be prefabricated, either in the factory or by an external supplier.

–– Will insulation be applied in the factory or on site?

–– Is the building greater than three storeys? If so, a lightweight cladding system may be more appropriate.

–– Explore how on site elements such as door thresholds and window reveals can be repeatable so that
they are quick and easy to install.

–– Can the use of scaffolding be minimised?

–– How will internal finishes between modules be installed?

–– How will on site elements be differentiated from offsite elements on drawings?

Roofs - Chapter 3.8

–– What type of roof is appropriate? Does it fit within the transport requirements? Will it be manufactured
in the factory or installed on site?

–– What insulation is required and how might this be applied?

–– What roof cladding material will be applied?

–– What measures are required in order to protect the module during transport?

–– Are parapets and verge supports manufactured in the factory or installed on site?

–– CLT on modules with flat roofs must be laid to a fall of at least 1:40 for flat roofs to avoid moisture build
up that leads to rot and decay in deflected areas.

130
Communal stair cores - Chapter 3.9

–– What elements of the stairs, cores, lift shafts etc. can be made from prefabricated panels cut in the
factory?

–– Can the core be used to give structural stability to the modules during assembly?

–– Can the core be used to access the modules during assembly?

–– How can work on site be reduced?

–– Can ancillary areas such as cycle stores or refuse stores be assembled from modules?

Fire design principles - Chapter 3.10

–– Where are the areas of risk?

–– Should a fire engineer be appointed?

–– Have the relevant guidance, documentation and legislation been consulted?

–– What method of encapsulation will be used to protect the structure?

–– Can the number of items that require maintenance and inspection, such as fire collars, be reduced?

–– Connections to, from and between modules are often a weak point - suitable protection should be
designed.

–– How will cavities between modules be protected from fire? Have all openings been considered?

–– Is there a strategy for prevention and risk mitigation for fire during the assembly and installation
process?

–– Is all information regarding fire safety that will be relevant to the occupier included in the homeowner’s
manual?

131
Thermal principles - Chapter 3.11

–– Optimise the benefits of modular technology to reduce the wall thickness and increase the internal
volume as much as possible.

–– Does the thermal line sit outside the CLT?

–– Has the dew point of the wall build up been calculated?

–– Is the wall build up breathable and the timber ventilated?

–– Can thermal performance be increased through thermal modelling, optimised air tightness and
improved PSI values?

–– Take extra care to investigate cold bridging, particularly via steel connections. Condensation risk
analysis should be undertaken to avoid moisture forming on steel screws within the timber.

Acoustic principles - Chapter 3.12

–– What are the client’s acoustic requirements?

–– How do the acoustic requirements impact on wall build ups and the floor to ceiling height of modules?

–– How do the connections impact on the acoustic performance?

–– Can the wall build up consist of a mix of materials with a variety of densities?

–– How do the materials specified impact on cost?

–– Can the acoustic engineer undertake a desk top study of the sound reduction of different build ups?

–– Can the proposed wall and floor build ups be acoustically tested prior to mass production?

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Internal layout of modules - Chapter 4.1

–– What are the structural constraints to planning the module?

–– What are the services constraints to planning the module?

–– Have module widths and internal ceiling heights been agreed?

–– Disabled units are a different size to standard units. Where will these be located in the development?
How will they be structurally accommodated?

–– Can the balcony and deck access fixing details be made directly into the structural connection brackets?

–– Are lobbies required?

–– Have windows, doors and openings been set out to cladding dimensions?

–– Do openings stack?

–– Are vertical and horizontal penetrations in the modules located away from the corners?

–– Is the internal setting out affected by CLT thickness?

Servicing principles - Chapter 4.2

–– More detailed services design is needed earlier in the design process compared to traditional
construction - have MEP engineers been appointed at an early stage?

–– Can the number of services required in each home be reduced?

–– The servicing strategy should be agreed during the Strategy Stage - penetrations should be set out and
shown in the BIM model using spaces and zones.

–– Can the number of servicing connections between modules be reduced?

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–– Do penetrations conform to the penetration guidance document produced by the structural engineer?
For example, are they located away from module corners and openings?

–– How will the services be connected on site and how is access for maintenance provided?

–– How will fire protection to service penetrations be provided? Will it need maintaining?

Using BIM & 4D - Chapter 5.1

–– Has a common data environment been established?

–– Is a BIM manager appointed?

–– Have common data exchange formats been agreed?

–– Has the team developed the BEP together?

–– Has an early test run been carried out?

–– Is the BIM information being produced by the person designing it?

–– Are the team clear about the benefits and requirements of BIM at every stage of the project?

Drawing for manufacture - Chapter 5.2

–– What drawings are required for the module information packages during the Strategy Stage?

–– Have on site and offsite elements been graphically represented?

–– Have the setting out points been agreed between all members of the design team?

–– Are the design team sharing information regularly using BIM files?

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–– Has the design team and the factory agreed a way to show dimension variants, if required?

–– Are the presentation standards and styles consistent between consultants?

–– Are the drawings and information sufficient to manufacture?

Room data sheets - Chapter 5.3

–– Has the client provided a list of what will be included in the room data sheets?

–– Has a format for the room data sheets been agreed by the design team and the factory?

–– Does the design team understand what information will be needed to be associated with each element
and ensure that this is included in the BIM components?

–– Work with the whole design team to create a way of sharing and exporting room data information from
a single model.

–– Does the design team have the capacity to include product and project specific information in their
BIM model?

–– Has the data been added by the design team into a test room data sheet at an early stage in the
project?

Module types - Chapter 5.4

–– Can modules be repeated?

–– What is the tenure of each dwelling?

–– Do risers line up vertically?

–– Are all modules with handed layouts or differing thickness of CLT drawn as unique modules?

–– Has a strategy for explaining different external wall dimension variants been agreed?

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6.2 GLOSSARY

Air tightness The performance of the building fabric in relation to restricting the
movement of air from inside to outside. Measured as air leakage
rate per house per square metre.

Assembly Connecting modules on site.

Assembly works Temporary works required on site during the module assembly
process.

BIM Building Information Modelling. The collected data of the building.

Often containing a 3D representation.

BEP BIM Execution Plan. Sets out the requirements and management
processes for the delivery of BIM information for a project.

BOPAS Build Off-site Property Assurance Scheme.

Breathable Fabric that allows water vapour to pass through it, also referred to
as vapour permeable and hygroscopic.

Carbon Used as a collective term for green house gases. Often measured
in Carbon dioxide equivalents (CO²e).

CDE Common data environment where project information is stored and

shared with the project team.

CLT Cross-laminated timber.

CNC machine Computerised Numerical Control. A drilling and machining tool

controlled via digital input.

Collaborative design The close working and partnership of everyone involved in the
design and construction of a building, often facilitated by BIM.

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Common data environment The common data environment (CDE) is a digital location where
information from consultants is combined.

Decibel (db) Measurement for the intensity of sound.

Dew point The atmospheric temperature below which water droplets begin
to condense and dew can form. When air cools to its dew point
through contact with a surface that is colder than the air, water will
condense on the surface.

DfMA Design for Manufacture and Assembly. Design for the ease of
manufacture of parts and for the ease of assembly.

DPC Damp proof course. A layer of waterproof material that prevents

the ingress of moisture.

DPM Damp proof membrane. A membrane material that is used to

prevent the transmission of moisture into a building.

Dynamic amplification Multiplication of stress caused on a static load when a dynamic

load is applied.

Employer’s requirements Document produced by the client setting out their brief in terms of
requirements and specification.

Encapsulation The approach of protecting building elements by the application of

fire lining.

Eurocodes The ten European standards specifying how structural design

should be conducted within the EU.

Factory operatives NU build’s team of factory workers who have the skills, and
expertise to manufacture high quality modular homes.

Homeowner’s Manual A document provided by the client for occupants where they can
find information regarding the maintenance and performance of
the home (modules).

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HVAC Heating, ventilation and air conditioning. The technology to control
the internal environmental comfort.

Installation On site works.

Manufacturing Building the modules within the factory environment.

Module connections Method of connecting modules on site. Often made of steel.

NU build Swan Housing Association’s modular construction brand, operating

from Basildon, Essex.

NU build system System developed by NU build following their standard operating

procedures.

NU living Swan Housing Association’s in house developer.

NU stages Work stages for the NU build modular design process.

Offsite Term for assembly and fabrication of items for construction away
from the building site.

On site fire strategy A required strategy outlining measures to prevent and manage fire
during the construction phase both on site and offsite.

On site waterproofing strategy A required strategy outlining how water will be managed on site
during the construction phase both on site and offsite.

On site Work carried out on the construction site, as opposed to work

carried out in the factory.

Plug and play MEP services that are intended to work immediately when first used
or connected, without reconfiguration or adjustment by the user.

PSI value (ψ) The linear thermal transmittance of an element, which is used to
calculate the heat loss or gain through a thermal bridge.

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STGO Special types vehicles - Oversized vehicles described under the
authority of the Road Vehicles Order 2003.

SVP Soil and vent pipe. A vertical pipe that removes sewage and
greywater from a building.

Swan Housing Association One of the UK’s leading regeneration housing associations,
operating in Essex and east London. Parent company for NU living
and NU build.

Thermal (cold) bridging A path of least resistance for heat transfer, created by a component
or area which has a higher thermal conductivity than its surrounding
materials.

Volumetric modular The stacking and joining of factory manufactured modules to form
a building.

U-Value Measurement of the transmission of heat through a building

element.

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The information provided in this book is intended for guidance only and should not be used without reference to relevant legislation, best

practice and professional judgement. The authors will not be liable for any losses or damages resulting for the use of this book.
Swan Housing Association NU build Factory Waugh Thistleton Architects

Pilgrim House Unit 1, Prologis Park 77 Leonard Street

High Street Honywood Road London
Billericay Basildon EC2A 4QS
Essex CM12 9XY Essex SS14 3TS

www.swan.org.uk www.nubuild.co.uk www.waughthistleton.com

information@swan.org.uk info@nubuild.co.uk info@waughthistleton.com
+44 (0) 300 303 2500 +44 (0) 800 819 9390 +44 (0) 20 7613 5727
This guide sets out considerations for designing
modular housing based on the NU build modular
system.

It aims to give the design team an understanding

of the interrelationship between the consultants,
the client and the factory.

Designing for modular means thinking about how

each module is made, transported and assembled
at every stage of the design development.

This guide is not a pattern book, rather it provides

the tools for the designer to develop their own
unique project.