How Modular Homes Are Manufactured: Inside the Industrial Factory
Step-by-step insight into EN 1090-2 certified structural steel welding, wall build-ups, bathroom pod integration, and factory-level inspection test plans (ITP).
1. CAM Engineering & Structural Steel Framing (EN 1090-2)
Manufacturing begins directly from locked 3D BIM models exported into CNC cutting and drilling code. High-grade structural steel profiles are robotic-welded on precision jigs to ensure less than 1.5 mm diagonal tolerance across 12-meter frames.
All steel frames undergo shot-blasting and receive multi-layer anti-corrosion primer coatings complying with ISO 12944 C3/C4 atmospheric durability classes.
2. Envelope Layers, Wet Pods & Inspection Test Plan (ITP)
Floor, wall and ceiling build-ups incorporate certified non-combustible rockwool insulation, acoustic isolation membranes and vapor-permeable air barriers.
Pre-tested sanitary pods with installed ceramic tiles and leak-proofed membranes are secured inside the module frame before wall closure. Every step is signed off in an Inspection and Test Plan (ITP) before dispatch packaging.
Technical Data & Benchmark Matrix
Stage 1: Frame Assembly
Stage 2: Corrosion Protection
Stage 3: Thermal Envelope
Stage 4: Wet Pod & MEP
Stage 5: Finishes & Glazing
Stage 6: Dispatch Packaging
| Production Stage | Key Operations & Materials | Tolerance / Quality Standard |
|---|---|---|
| Stage 1: Frame Assembly | CNC Sawing, Robotic Tack & Seam Welding | EN 1090-2 Execution Class EXC2/EXC3 (±1.5 mm) |
| Stage 2: Corrosion Protection | Shotblasting SA 2.5, Epoxy Primer & Topcoat | ISO 12944 C3/C4 (DFT ≥ 160 μm) |
| Stage 3: Thermal Envelope | Rockwool 0.035 W/mK, Vapor Barrier, OSB/Fermacell | Class A1 Non-Combustible, Airtight Taped Joints |
| Stage 4: Wet Pod & MEP | Pre-assembled Pods, PEX Piping, Sockets | Hydrostatic Pressure Test @ 6 Bar for 24h |
| Stage 5: Finishes & Glazing | 3-Pane Argon Windows, Flooring, Paint | EN 14351-1 Window CE Certification |
| Stage 6: Dispatch Packaging | Heavy-Duty UV Protective Shrink-Wrapping | Weatherproofed for Maritime Ro-Ro / Highway Transit |
Explore Related Engineering Guides
Volumetric 3D Modular vs 2D Panelized Systems: Choosing the Right Offsite Method
Kitchen, Bathroom & MEP Scope: Pre-Tested Factory Wet Pods & Plug-and-Play Utilities
Transport & Mobile Crane Logistics: From Factory Gate to Final Placement
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