Process—How Your Modular Home is Built for You
Once you have decided on how your house should look and work, the engineering department prepares detailed drawings for your home. The drawing include electrical, plumbing, and all other construction details. The plans are distributed to the quality assurance department, supervisors, and all foreman. At this time, the your home begins construction.
» Floor System Assembly
» Wall Sections
» Roof Assembly
» Insulation and Sheathing
» Final Stages
Floor System Assembly
The strength of any building is determined by its base or foundation. The initial focus in the production of your home starts with the floor system. Each floor section perimeter is outlined in a square metal floor jig. Then the floor perimeter is nailed directly into the face of each joist. A second perimeter band is then glued and nailed to the first one. The floor is then double-checked for square and the floor decking is attached.
As the floor sections are placed on the assembly line, each individual wall is framed, glued, fastened, and dry walled in similar square metal jigs. The walls are accurately placed on the floor system, leveled, and secured to the floor. Each wall is joined together, with a 3 x 5 gang nail to insure the wall remains plumb.
Here your ceiling and roof trusses are being prepared. The system is constructed by using a perfectly flat table where 1/2" or 5/8" drywall is laid face down. A pre-manufactured truss/rafter will now be set into place and drywall adhesive will be sprayed on. The adhesive secures the drywall to the roof section which will insure a flat ceiling with no screws or nails in the face of the drywall.
The ceiling/roof assembly will now be craned and set on top of the floor and wall sections. At each phase of construction, you will find particular details that are used to maintain the structural integrity of the home. On the exterior, a 26 gauge metal strapping is used and each individual ceiling rafter/truss is secured by fasteners into the wall section.
With the framing completed, your home will proceed into the hands of the electrical crew. With detailed wiring diagrams, the electricians will drill the necessary holes, drop, and secure all rough wiring per state and local building codes. Inside your home, there is a separate group of electricians who will install receptacles, lights, and switches which will complete the wiring to a 200 amp panel box. Your home will now be charged and a dielectric and polarity test will be taken.
NOTE: Your home will have 1 x 4 bracing at the top and bottom of each receptacle box secure switches and receptacles for a lifetime of use. This bracing, and the utilization of 5/8" metal sleeves where wire passes through the 2 x 4′s are just some of the added features.
In the inside of your homes, the drywall finish crew will be applying three coats of compound finish. The home will then be prepared for the painting crew. Two coats of primer paint will be applied.
Insulation and Sheathing
With youre home completely framed, the insulation crew will insure that the entire home is insulated properly. The exterior sheathing on the roof and walls will now be applied. Using 4 x 8 sheets of sheathing, the entire home will be completely covered, pneumatically nailed, and the rough openings will be cut out for the exterior doors and windows to be installed.
Your home will proceed through the production line with an organized work force completing the final stages. The exterior of the house will be sided and the roof shingles will be installed.
On the interior of your home, there are several work crews completing interior doors, interior trim, and the installation of kitchen cabinets, bathroom vanities, and any special items orders.
Your homes is now completed, cleaned, and prepared for shipment to your site. Upon final approval of quality assurance, the home will be loaded onto a transportation carrier and scheduled for shipment. You’re state and third party labels are then attached.
The Quality Assurance Department consists of a staff of highly trained inspectors. They are responsible for inspecting each phase of the construction on all homes produced. They verify that the construction is in acceptance with the approved drawings and codes.
In addition to the in-house QA Department, an approved independent third party inspection agency is contracted with. This agency inspects at least one phase of construction on each home produced. This double check serves several purpose, the most obvious being to verify the effectiveness of the in-house inspectors.
If you have specific questions or would like more information call us at 860.349.1758 or send us an email.