The emergence of #modular construction as an option for new construction is becoming mainstream. The reasons have been reported on well. However, what has not been reported is that the modular construction industry has had mold and moisture problems, especially, when used in a warm and humid climate like the Southeast US. Both wood frame and steel frame modular construction have experienced problems with crawl space, marriage wall, and ceiling to floor cavity, condensation problems that have not only resulted in deterioration of the wood, corrosion of metal floor pans, deteriorate wallboard and mold.
The greatest risk of modular construction failures has been seen to be when this type of construction and delivery is used for hotels, student housing, senior living, soldier housing, type facilities. In general, facilities that are domicidal or multi family in nature. This is because these types of facilities have inherent similarities in a living unit that requires both an individual cooling/heating unit, bathroom exhaust, and some sort of central HVAC make up air system. In addition, there are many more modular “boxes” in these kinds of buildings increasing the number of marriage wall interior cavities and ceiling to floor cavities that otherwise might not be required in other types of modular construction. The nature of modular construction makes it difficult to repair once it is found to be damaged. Sometimes, the damage can be such that the modular building has to be deconstructed to remove damaged materials and then re-designed and re-constructed using conventional methods. This essentially makes the modular construction advantages dissolve away as the building gets converted to a traditional “stick” building.