High-rise housing going modular
This rendering shows a proposed modular housing development that would stand behind the new Barclays Center in Brooklyn.
February 1st, 2012
09:26 PM ET

High-rise housing going modular

It's an idea that has the potential to revolutionize the construction industry: Use prefabricated modules to build more than 6,000 housing units. If the real estate development firm Forest City Ratner is able to turn the idea into a reality, the firm will build the tallest modular construction building in the world, a 32-story residential tower in Brooklyn, New York.

(Click the audio player to hear more on this story from CNN Radio's Steve Kastenbaum)

Forest City Ratner's director of construction, Bob Sanna, stands next to Brooklyn's Barclays Center arena, on the site where the company plans to build the tallest modular construction building in the world.

Prefabricated houses are not new. They've been around for decades. But modular construction today is principally used for low-rise buildings. Strong winds exert a tremendous amount of force on taller buildings, and lower floors have to support the weight of many floors above. With modular construction, the challenge comes in designing components that can withstand those forces and do it within a certain price range.

"I think we figured out a way to do this," said structural engineer David Farnsworth. He and his colleagues at the design and engineering firm ARUP spent two years researching and developing ways to build a high-rise modular building.

"The first challenge that we had to overcome was how can we make a modular system that can be built at height and withstand the wind loads," Farnsworth said. "You don't want the building to be moving too much in the wind that people feel it and then they get sick."

The other principal goal was to cut costs. "We think that modular saves something on the order of 20%,” Farnsworth said. In New York, the most costly U.S. city to build in, the potential savings are quite large.

Proponents of the idea believe the cost savings have the potential to spur construction in a market that has been stalled for years.

“At the moment, the market rates have come down and construction costs haven’t come down at the same rate for conventional construction,” said Farnsworth, who believes modular construction solves a financial equation. "This brings that ratio to a feasible range where it now can start to make sense to build more residential construction."

It could have huge implications when it comes to building affordable housing in high-cost cities like New York. A third of the apartments at Forest City Ratner’s project in Brooklyn are supposed to be affordable units.

The project, known as Atlantic Yards, was first slowed by several lawsuits, some filed by community groups opposed to the project. Then the bottom fell out in the housing market, the construction industry ground to a halt and financing for Atlantic Yards dried up.

While the centerpiece, an 18,000 seat NBA arena that will be the new home for the Nets, is nearing completion, the rest of the 22-acre site is largely quiet. Forest City Ratner’s director of construction, Bob Sanna, believes modular construction will change that.

"We were determined to find a way ... that we can develop a building type that had a little bit more predictability, a little bit more cost certainty in the delivery mechanism," Sanna said.

In an industry where construction methods have gone largely unchanged over several generations, Sanna sees modular high-rise construction transforming the construction industry.

"It's an evolution that our business needs to approach," Sanna said. "By having all the work going on in the factory, you can really control the amount of material you bring in and have it fabricated to the specifications you need without unnecessary amounts of waste."

When modules are put together in the controlled environment of a factory floor, work is not affected by unforeseen circumstances at the construction site.

"Labor wages are cheaper in a factory then they are on-site," Farnsworth said. "The weather comes into play on-site, whereas when you're doing the work in a factory, it can be storming on-site and you can still just be churning out the module work."

Farnsworth expects about 60% of the work to be done in a factory, everything from creating the frames for the modules to putting up drywall, laying floors and installing fixtures. Then, the finished modules will be trucked to the construction site, where cranes will stack them in place and attach them to a steel supportive structure.

People in the construction industry are watching Forest City Ratner's project with great interest.

"Anything that we can do to reduce the cost of construction is going to help in a very, very challenging situation for housing," said Richard Anderson, president of the New York Building Congress, an industry trade group. "They've agreed to quite a bit of affordable [housing] in their project. They've agreed to building union ... and now they're trying to make it work. Modular potentially is one way to help them make it work financially."

Forest City Ratner executives say modular construction has the potential to create more construction jobs in a slow housing market. But construction unions haven't exactly warmed to the idea yet.

"Insiders will tell you that they are afraid that the unions will not make as much money working in a factory as they would working outside in open construction," said reporter Theresa Agovino, who covers real estate for the publication Crain's New York Business.

Although Forest City Ratner is intent on building its factory in New York, labor unions are concerned that other developers could set up modular construction factories in places where labor costs are much lower and then ship the prefabricated units to more costly cities for assembly. High-paying construction jobs might be lost in that scenario.

"People are incredibly interested in what they are going to be doing," Agovino said about the project. "I know there is a tremendous amount of curiosity among other developers, architects, engineers about will they really in the end be able to do this."

Forest City Ratner would like to break ground on a 32-story modular construction high-rise apartment building in the spring.

"At some point, it’s inevitable that someone is going to bring pre-fabricated components from outside the city," Sanna said. "If we can create that kind of economic engine here, which I think we can, then why not do it?"

Confidence in the idea was recently bolstered by a project in Wolverhampton, England. A 25-story college dormitory was built out of 805 modules in just 27 weeks. It's the tallest modular building in the world. So far, it has been standing up in the wind just fine.

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soundoff (33 Responses)
  1. leeintulsa

    already seeing the bite in the ass here.. or the writing on the wall..

    brace yourselves, middle class. construction is being outsourced to modular factories in india..

    February 1, 2012 at 10:08 pm | Report abuse |
  2. Scottish Mama

    @lee- and all the middle class stacked in a row. Where the wealthy own the land, and we all get scammed.

    February 1, 2012 at 10:21 pm | Report abuse |
  3. WakeUp

    So we're outsourcing real estate development and construction to India too? WHY?

    February 1, 2012 at 10:51 pm | Report abuse |
  4. The Cheese Monger

    Lets move to the moon! We aleady have staked our claim with our flag... . And then we can outsource module construction to the earthings... .

    February 1, 2012 at 11:00 pm | Report abuse |
  5. hamsta

    Welcome to socialist america where evyone lives in the same cheaply made house drives the same cheaply made car wears the same cheaply made clothes and quality is a foriegn word.there are some things that should not be made in a generic factory and home is one of those things.

    February 1, 2012 at 11:40 pm | Report abuse |
  6. hamsta

    Anyone that has seen the aftermath of a hurricane knows that prefab housing is just overpriced crap.

    February 1, 2012 at 11:48 pm | Report abuse |
  7. Scottish Mama

    Did anyone read the last line.lol And it seems to be holding up to the wind just fine.lol Is it particle board or card board?lol

    February 1, 2012 at 11:51 pm | Report abuse |
  8. Scottish Mama

    @Hamsta like a stacked glorified trailor?

    February 1, 2012 at 11:53 pm | Report abuse |
  9. Scottish Mama

    @Hamsta- The stepford middle class.lol

    February 1, 2012 at 11:55 pm | Report abuse |
  10. hamsta

    @scottish mama the sad thing is that they will sell it at almost the same price as a quality handmade home.

    February 2, 2012 at 12:10 am | Report abuse |
  11. banasy ©

    Does nobody have a problem with the fact that now our construction jobs are going overseas too??
    Nah, big business and greed doesn't have anything to do with THAT, does it?
    Let the businessmen who think this is a good idea be the first to move their families in there...
    How much more can big biz cheapen the middle class?
    Modular highrises, indeed...
    I don't THINK so....

    February 2, 2012 at 12:56 am | Report abuse |
  12. Jj

    Vertical trailers !!

    February 2, 2012 at 1:10 am | Report abuse |
  13. death

    interesting, but given that this is happening in the United States, I'm going to assume a strong potential for poor design, cheap fixtures, cheap HVAC equipment, and a lot of undesirable building materials which could cause cancer in either production or in their use.

    February 2, 2012 at 1:14 am | Report abuse |
    • thenewsjunkie

      Oh yeh, right... no thought will go into building this correctly and in an environmentally friendly way. (Yes, that's sarcasm you detect) Why are you so down on this idea? Seems to me you've exhibited a knee-jerk reaction without making an effort to fully understand the idea. Actually, things constructed in a controlled factory environment here in the US (because of the cost of delivery they need to have the factory close to the construction site) are going to have more oversight while still having to meet the same construction standards and codes that all new buildings have to meet in New York. Have you stepped into any new affordable housing that was built with traditional construction methods? Talk about poor workmanship. That's thanks to poorly trained day laborers with little supervision and builders who try to cut corners in order to maximize profit. This project seeks to use skilled union labor in the factor while adhering to precise standards so it all fits together properly and meets the standards all high rise buildings must meet.

      February 2, 2012 at 4:38 pm | Report abuse |
  14. Tyrant

    @leeintulsa... Or you can just check the made in stickers, india,hecho in mexico, made in china, made in japan, but yes your right though it will be out sourced for sure. But than the government will take credit for creating jobs! What a bunch of BC. So nobody in the US will ever notice a thing! And it will be swept under the washington dc rug. In surprised there is still room for anything there

    February 2, 2012 at 2:59 am | Report abuse |
  15. hamsta

    @banasy the more stuff they make overseas the more cargo i must move.

    February 2, 2012 at 8:10 am | Report abuse |
    • banasy ©

      Meaning?

      February 2, 2012 at 8:14 am | Report abuse |
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