Design Between the Lines: Should You Go Modular?

Example of modular panel construction with heat-welded, coved corner seams

I recently was reminded of a question I often debate while discussing the construction options for cleanrooms (and, in some unique instances, labs): should you go modular or stick-built? These decision factors take many variables into account, and therefore, there is certainly no “correct” answer. However, there are considerations that may tilt the decision one way or the other, and I address several of them herein. While not a comprehensive list, these questions can help point you towards the more appropriate solution for your specific needs and goals.

What is the program?  

What is the program of the space you are considering making modular?  Is it something that is expected to require more space soon, or perhaps a short-term project that has specific configuration needs that may need to be adjusted in six months to a year? The inherent benefit of modular systems is that many of them are capable of being rearranged, oftentimes with more ease than having to demolish gypsum board construction and build new ones. Therefore, if you anticipate the need to either reconfigure or grow your space in the relatively near future, modular construction may be better to help facilitate that. It is important to note that not all systems or walls can necessarily be easily moved. In some setups, the exterior walls are load-bearing for the cleanroom lid, which makes them difficult to move and typically requires the vendor to come in and perform that work; however, the interior walls in this setup may not be load-bearing and, therefore, can be easily reconfigured by the end-users.  

One additional factor to consider is which vendor you select to provide and install the system. I have worked on a project where we tried to add onto a modular system provided by a company that was no longer in business, which became very complicated and nullified any benefit that was supposed to come from the flexibility of modular systems. Therefore, I recommend choosing a company with a proven track record and a large portfolio of work to provide confidence in its long-term reliability.

What are the existing building conditions?  

A benefit of modular systems is that they are oftentimes built as a stand-alone unit. They are stand-alone in the sense of having panels that support themselves, as well as a lid on the space that maintains the cleanroom environment sealed within. This results in the mechanical equipment sitting on top of that lid, below the structural deck of the space. In scenarios where there is not ample room above a self-contained unit for the stand-alone mechanical equipment, it may make more sense to pursue a stick-built design with equipment that is added to the roof or a penthouse/mezzanine. More factors play into this decision and MEP design, so be sure to consult with an MEP Engineer with cleanroom design experience to discuss the feasibility of modular systems vs. stick-built for your specific program and existing conditions.

What is the lease term?  What are the flexibility needs/schedules?

How long is the lease for your space (if renting), and/or when do you expect to move out of your current facility?  One of the benefits of modular construction is that it can be packed up to travel with you to your new location.  Therefore, if you need a cleanroom space in your current facility but also know you’ll be moving within the next couple of years, purchasing a modular system will allow you to invest in the space you need now without forfeiting that investment when you change locations. Conversely, if you either own the space or have a long-term lease, and your design needs result in a less expensive quote for stick-built construction without the need to regularly reprogram the space, that may be the more appropriate solution in this instance. Timelines are an important factor to consider in conjunction with the need for flexibility.

Is it more expensive?

Since I am not a modular cleanroom vendor, I cannot answer this question. However, I encourage anyone considering this building type to reach out to vendors to get quotes. While panelized systems were once considered more costly than stick-built, I have found that that is no longer always the case. There are now cost-effective solutions, particularly when future construction savings are considered in the scenario that many future alterations are expected. It really is situational, so having an open dialogue between general contractors and modular system vendors can help you make the best decision for your renovation or construction project when the time is right.

Involved in the design industry since 2013, Lori has worked as an architectural designer for several years and currently works as the regional director for Ware Malcomb Washington, DC.

All opinions expressed in Design Between the Lines with Lori Ambrusch are exclusive to the author and are not reflective of Lab Design News.