Modular is Michelle Kaufmann Designs' chosen means to an end. It is the construction method that allows MKD to achieve the goal of creating thoughtful, sustainable design that is accessible to more people, while still maintaining high-quality.

How much time and money and hassle will it save? How much more sustainable?

Well, MKD did a case study. Michelle Kaufmann built two identical homes—one modular and one site built. Here is MKD's experience. Note that prices below are from 2003 and 2004, and that now MKD builds modular homes in their own wholly-owned factory. This case study was also featured in Allison Arieff's article in the November 2006 issue of Dwell magazine, The Proof Is in the Prefab.

Case Study

In 2001, Michelle Kaufmann and her husband began looking for a place to live in the San Francisco Bay Area. They found nothing that met their needs that they could afford. Not even close. They spent hundreds of hours going to open houses in hopes of finding something. They then spent many additional hours in therapy, asking themselves what bad choices they had made in their lives that they could not afford a place to live. The options available to them were either a $600,000 tear-down (which they could almost afford) or a developer-built mini-McMansion in a subdivision (which they just couldn’t bring themselves to do).

So, they decided to build something for themselves. They found some land (by far the hardest part of building any MKD home), and started site building a simple, sustainable home. Michelle's husband, Kevin, acted as the general contractor and the critique. He was constantly asking, “How can this be made more green?” with every design and material decision they made. As they were building the home, they had friends and colleagues who asked, “Michelle, can you do something like this for us as well?” A good question. Could this home be made in mass-production?

In searching for an answer, Michelle found that there was a whole world of modular factories. They offer so many benefits, yet to date, architects had not embraced the technology.

Michelle found a few experienced, quality factories who have over 25 years of success at building quality residential and commercial buildings. Michelle then had her first Glidehouse client, who decided to build the identical house to hers.

Such was the creation for this case study. While Kevin was building their site-built Glidehouse home, Michelle started working on the first modular Glidehouse. The two homes had identical 3-bedroom floor plans and finishes (with the exception of the siding material). The race was on.

Here are their results. The site built 3-bedroom, standard Glidehouse vs. the first modular 3-bedroom, standard Glidehouse in the Bay Area. Note: your results will vary depending on individual project design, finishes and location.

Cost Savings

The house portion (above foundation) of the site-built home cost about 25% more than the identical modular home. Costs for the site portion of both the site-built home and the modular home (i.e., grading, landscaping, foundation, utility lines, garages and pools) cost the same for both. These results for other projects may vary depending on location, design and finishes chosen.

Additional costs savings can also be:

• General Contractor Project Management and General Conditions over 4 months for the Modular project, versus 14 months for the site built project
• Mortgage payments on the land and construction over 4 months for the modular project, versus 14 months for the site built project
• Construction Insurance for 4 months for the modular project, versus 14 months for the site built project

Time Savings

Very Little Waste

Site Built	Modular
As is typical with site construction, when there are extra or cut materials, they are typically thrown away. Thus, the big trash containers on sites during construction. This is because the contractor typically doesn’t have storage capacity, plus when is the contractor going to use Corten steel again?	The factory has storage capacity, so when there are extra or cut materials, they can be stored and reused for the next MKD home coming down the line. For example, if an 8’ long  2x6 wall framing member is cut down to 6’ to accommodate a high window, that extra 2’ of length is kept and stored so the next time a 2’ long 2x6 framing member is needed, it is there to use. Extra Corten? Yes, absolutely store it for the next Glidehouse home!

High Quality Control

Site Built	Modular
The home was built to meet local and UBC codes requirements. When materials arrive on site, they are stored outdoors, due to lack of covered storage.   Once materials are left outside for more then 2 weeks, rain and sun compromise the materials integrity. Although we had good subcontractors, they didn’t always show up the day they said they would (they were quite busy with other projects as well). This resulted in delays.	The home was built to meet local and UBC code requirements. The home exceeded these requirements by the use of triple rim joists, as well as having all connections being glued (in addition to nailed or screwed per site built codes) to ensure stability and strength for transport. The home has precision cutting and is assembled on horizontal jigs in a systematic factory process, then lifted into position by an overhead grid of lifts. Materials are stored in a covered environment. There is a high level of quality control: all the workers are under constant supervision. The assembly line construction creates maximum efficiently and worker specialization.

For More Information and Ordering

Michelle Kaufmann Designs is represented by Marshall Mayer at LiveModern. After you have reviewed the links above, I would be happy to answer any questions you may have to get you started on the Michelle Kaufmann Design process. Simply contact me using MKD's inquiry form.

We look forward to building your Michelle Kaufmann Designs modern modular home.