Factory Built Housing – The Modern Construction Process
Without realizing it, builders have used factory assembly to improve the construction process for years by incorporating factory-assembled components such as pre-hung doors, windows, cabinet modules and roof trusses.
Modular construction is simply a natural extension of that process with large modules, pre-built in our manufacturing facility. From pre-wired electrical and rough plumbing to finished carpentry work, modules are delivered to your site with up to 80 percent of the home complete.
In a manufacturing facility, where building materials are protected from the elements, our craftsmen have access to tools, jigs, tables and material handling equipment which are not viable on a field construction site. These tools and equipment allow us to fabricate high quality, stronger,more durable structures.
Champion manufacturing plants have approximately 20-25 work stations on the assembly line. In addition there are multiple work tables and jigs where smaller components are assembled, and with the use of over head crane systems delivered to the assembly line.. Each station is equipped with the tools and equipment needed to complete the work within the station and increase the efficiency and quality of the workforce.
Starting with a floor assembly each unit will move, resting on a roller system, down the assembly line where additional components such as exterior and interior walls and roofs are installed. As the modules continue to move down the production line a variety of construction tasks are completed. These include cabinet, door, window, and fixture installation as well painting. In addition, systems such as plumbing and electrical are completed and tested. Interior and exterior finishes are applied and the modules are ready for transportation.
In addition to our own quality audits, third party federal or state inspectors inspect the modules at various points of the process and certify that each home exceeds the building code.
Advantages of Factory-built Construction Processes
- Quality control
- Construction speed
- Tighter more energy-efficient structure
- Stronger, more durable structures
- Consistent, well-trained workforce
- Access to equipment and jigs that are not available on-site
- Building materials are protected from the elements
Completed home modules leave the factory on a steel chassis and are delivered to the building site. On the building site, modules are installed on one of three foundation types: Pier, Crawl Space or Basement. Siding and trim are added to complete the exterior where the modules come together. On the inside, some drywall and trim work is necessary to complete the walls and ceiling sections where the modules meet.
The site work is coordinated by the retailer or builder you purchase the home from. They use their own employees, sub-contractors and local utilities to complete other items such as concrete flat work, porches, decks, garages and hookup the home to power, water and sewer systems.