Modular Building Case Studies

With Aerofilm Systems’ flexible internal transport system, Maat Feeling Home increased production capacity from 300–400 modules per year to 500–600 modules per year, without expanding the factory footprint.

Nan Inc. required an access system that mirrored the benefits of the modular buildings themselves: pre-engineered, scalable, and rapidly deployable. The chosen solution was RightWay Pro, a modular walkway, stair, and ramp system engineered for rapid deployment and long-term durability.

Despite their differences, both facilities share a common program and design intent. Each includes classrooms, a Movement Matters studio, a STEAM-focused learning lab, and a fully electric commercial kitchen.

The new facility provides firefighters with a durable and realistic training environment while showcasing how modular construction can deliver innovative solutions in urban settings.

The Pomeroy Lodging Employee Housing complex in Kananaskis, AB, is a 24,194 sq. ft., three-story structure with 57 studio units and a communal main-level area, designed for full-time employees and comprised of 36 prefabricated modules.

NexE, the green energy sister company of TECO-Westinghouse, partnered with Falcon Structures to design and build portable enclosures for EV fleet operators interested in re-deployable units that support EV charging depots with significant cost savings. The goal: create durable, relocatable EV infrastructure solutions that sidestep the constraints of traditional construction.

Each living unit at 732 El Camino Real was built in the Autovol plant by a combination of robots and Autovol’s skilled builders. Work was completed for all 134 units in 51 days. The living units left the factory as fully functioning apartments—approved in factory by California inspectors to meet all applicable codes.

To house the end customer’s industrial-strength ovens, Panel Built created over 400 heat-resistant panels, each built to exact specifications and clearly labeled for straightforward placement. Panel heights ranged between 7 and 9 feet, with a uniform thickness of 3.75 inches.

The installation of Solatube TDDs in the new recreation facility successfully met the project’s goals for daylighting, comfort and functionality. The space which houses indoor pickleball and basketball is now naturally illuminated with bright, evenly distributed daylight that enhances visibility and supports safe movement for senior users.

Modular Genius delivered a 25,000+ square foot modular student housing complex made up of 22 buildings to Catholic University: 19 cottage-style units and two larger traditional hall-style dormitory buildings, totaling 124 student beds.