Process

Design

Systemized Approach

FullStack Modular has created a complete building system utilizing our proprietary chassis design.

Flexible Components

Just a few module types recombine to produce all unit types, with a pair of special modules for circulation.

Unit Types

Our systemized approach allows us to create multiple layouts out of our unit types.

Unit Combinations

Starting from the basic one-bedroom unit, our modular system adapts easily from studio to three-bedroom layouts and includes elevator and stair modules to create an entire building.

Sub-Assemblies

We have developed a specific set of structural, MEP, millwork, facade and cladding sub-assemblies which have increased our efficiency in the factory

Design Layout Tool

FullStack Modular has developed parametric layout application using our module types for rapid design iterations. Click on the link to study building footprint potential and choose typical floorplate unit configurations.

Manufacture

Chassis

The Chassis is the building block and main structural component in our system. Steel is prefabricated, flat-packed and shipped to our factory for assembly.

Sub-Assembly

Using digital instructions created by our design platform, all sub-assemblies, including kitchens, bathrooms, facade elements, and MEP systems are first assembled before moving onto the main Mod assembly.

Assembly

All sub-assemblies are brought together in the final Mod assembly, and final drywall and paint are applied once finished. FullStack Modular’s factory can produce 10-15 Mods per week at normal operating capacity, and Mods can ship with more work finished in the factory than the competition.

Construct

Transport

Once Mods are complete, they are wrapped in waterproofing membrane and loaded on flatbed trailers for transport. Transport is often done at night so that Mods are ready for stacking at the start of the workday.

Stacking

Mods are stacked by a crane and rigging crew and attached using FullStack’s proprietary mechanical connection system. Vertical MEP risers are also connected. Facade elements are self-sealing and require no scaffolding for exterior work.

Mateline

Once assembled, final interior fit-out is completed using kits manufactured and created in our factory, including mateline finishing and all horizontal electrical and sprinkler runs.

Finish & Inspection

The final roof membrane is field-applied and the building is inspected. Work in the factory is treated as an “as-built” condition and does not require site inspection.

Onward

Library

A product library is created out of the project design information, which greatly reduces design time on future projects.

Post Construction Analysis

The building is then connected to data collection sensors which relay information regarding the use, energy efficiency, and other performance metrics.

Digital Twin for Operations and Maintenance

The connected building can now be monitored and managed through the new digital twin interface created out of the building’s design information. This allows owner-operators to reduce their cost and lower the carbon footprint of the building even further

Process

Go from vision to highrise, faster and more precisely with our modular construction technology.

Process

We bring a data-driven, end-to-end approach to developing multi-story urban buildings.

We merge modular building with new construction technologies to bring a higher level of control, predictability, and scalability to development.

In an industry ripe for innovation, our team of design, construction and manufacturing professionals brings an unprecedented level of thought-leadership and ingenuity.

The design-to-build process.

Process - 1. Initial Assessment

Initial Assessment

Run swift analysis on our proprietary site modeling technology.

Get precise projections for design, cost, and schedule.

Generate an optimal modular building design to meet your proforma.

Process - 2. Definitive Programming

Definitive Programming

Define and detail a Modular Blueprint Agreement.

Create an overview of project management, construction and manufacturing design.

Drawings and specs, production plan, logistics, final delivery and erection, and building completion.

Process - 3. Calculated Design

Calculated Design

Develop a detailed digital modular design that meets your program.

Designed for manufacturing, ensuring efficiency in cost and materials, as well as complete quality control.

Proceed with all necessary steps for compliance and implementation.

Process - 4. Optimized Production

Optimized Production

Our 3D model and drawings contain data to drive a seamless, coordinated production process.

Our technological planning systems leave nothing to chance.

Factory production of mods and sub-assemblies begins simultaneously with the site-work.

Process - 5. Accelerated Assembly

Accelerated Assembly

Completed mods are transported to the building site and stacked by an on-site team skilled in modular assembly.

Minimal on-site work needed, including mateline connections, finishing the hallways, final roof installation, and elevator installation.

Commissioning of building systems.

Learn more about our approach.

See benefits

Taking construction to new heights.

FullStack Modular
63 Flushing Ave, Unit 293
Brooklyn, NY 11205
Higher quality. Cost and time predictability. Safer. Less waste. Reduced on-site work. Speed to market.
© 2020 FullStack Modular | All Rights Reserved.
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