Modular Steel Construction

Modular economy depends on repetition and on module sizes that fit transport limits. We work with the architect to rationalize module types, standardize corner posts, floor and ceiling beams and connection kits, and align the structural grid with module boundaries. Light-gauge infill combined with hot-rolled or hollow section corner posts often reduces weight, and designing for repeated jigs shortens fabrication time.

Module frames are built in jigs that hold corner posts, floor beams and ceiling beams in position during welding. This controls squareness, diagonal dimensions and corner fitting locations so that modules stack correctly. Welding follows the AWS D1.1, AWS D1.8 where seismic requirements apply, or EN 1090 requirements specified.

Each module receives a unique identifier linked to its location in the building, its lifting configuration and its connection kit, so installation proceeds in a controlled sequence. Openings for services and penetrations are coordinated in the BIM model and cut in the shop, and lifting points are fabricated and inspected as structural components, not afterthoughts, before any module leaves the factory.

Our inspection and test plan for modular frames focuses on dimensional accuracy, because errors accumulate as modules stack. We check squareness, diagonals, corner post plumbness and connection positions for every module against tolerances specified in the design. Materials are traced to mill certificates, welds are inspected visually with further NDT where specified, and lifting points are inspected and recorded. Each module has its own QC record within the project dossier.

Module frames are usually enclosed in the finished building, but they must withstand transport, storage and periods of exposure before closure. We select primer or galvanizing for the expected exposure, often C2 to C3 under ISO 12944 for enclosed frames, with higher protection for external or podium elements. Fire separation between modules is coordinated with the architect, using board systems or intumescent coatings compatible with the frame finish.

Modules are shipped as complete volumes or as flat-packed frames depending on route and destination. We plan module dimensions and weights against road and shipping limits, provide lifting and lashing arrangements, and sequence shipments by installation order and floor level. Connection kits are packed and labeled for each module. Export documentation includes packing lists, weights, centers of gravity and handling instructions for each unit.

Module installation depends on accurate sequencing and lifting. We provide installation drawings, lifting configurations, stacking order and connection procedures to support the installer's method statement. Our engineers can advise on temporary stability during installation and on tolerance control floor by floor. Where agreed, we provide technical supervision or advisory support during installation of the first modules and key floors.