MODULAR BUILDINGS
Scrub sink in theatre suite.
The inspection that occurs once the modules are delivered to site also differs considerably from inspections of traditional builds. In conventional construction, compliance checks can be carried out progressively as the building is assembled step by step, meaning that non-compliances can be identified early and corrected with relatively little disruption. By contrast, modular buildings often arrive in a completed or nearly completed state. At this stage, the opportunity to address compliance issues is much narrower, as retrofitting or altering factory-built components can require major intervention or may simply not be feasible. Consequently, the inspection stage risks becoming a formality rather than an effective safeguard. The author has encountered these challenges first-hand during an on-site inspection of a modular building constructed for a healthcare estate. In this case, the Air Handling Unit (AHU) installed in the facility did not meet the requirements set out in HTM 05-01, the standard governing specialised ventilation systems in healthcare premises. Although the plant was already operational, it presented a clear compliance failure: the design did not provide adequate access for cleaning and maintaining the fresh air intake. This limitation not only represented a breach of the standard but also posed a long-term risk, as inadequate maintenance access could eventually cause the AHU to malfunction. Despite the clear non- compliance, there was little appetite from the client or contractor to carry out modifications, given the scale of disruption and cost that would have been involved. This case illustrates the real- world difficulty of addressing compliance failures in modular buildings once installation is complete.
What is the problem with this system of compliance checking? I spoke with Edward Wright, an experienced Authorising Engineer and currently the engineering manager for DRLC Ltd, and asked his opinion of modular buildings. He said:
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Hospital corridor.
“The concept of modular buildings is not new; they have been around in the UK in force since the second world war. Prefabrication can be traced back to the Romans, though in the 1940s they were called prefabricated buildings, the concept is the same.
“Historically the ‘prefab concept’ did not meet what was actually produced, which was, in the majority of cases, a cold, damp box that was then held onto at great cost to health." I mentioned that the prefabricated houses that sprung up after the end of World War II in the UK had largely disappeared.
“Yes, the boxes have virtually vanished due to legislation and new materials. we still have the element where off-site manufacture does not meet the on-site tolerances/requirements.” I asked Edward what would be needed
to ensure modular buildings were of a high standard and he explained: “Should the process or the
manufacture be completely aligned with the actual build and stay within the tolerances of the build this would be a beneficial way forward as this would improve many elements of the construction industry ranging from the
speed of build, cost savings from materials and reduction of on-site waste. The list goes on and on.” I asked Edward to share his experience of modular buildings:
“From my experience the Modular element either in toilet blocks, prison cells and even modular walls have been challenging where pre-formed holes have not lined up. Then there were the showers where the water runs out of the door, the doorways which were not square. I recall modular pipe runs where one modular frame will not mate with the next and even down to pipes within the modular frame not being in the correct order with the risk of mixing hot and cold water and, if not corrected, could lead to risks of such things as Legionella growing in the tepid water. Yes, this can be resolved, but at what cost not only to the NHS also impacts on the programme and requires additional labour and if the modular parts that are not correct are sent back the programme plan and the final cost.” I asked Edward if he had any
confidence in things getting better in the future:
“Sadly, due to the constant saving and value engineering or investor pressure, the process and manufacture either in the building element or mechanical and electrical off-site manufacture rarely fits the on-site requirements. You could argue this is not so critical on a house build, though still expensive to correct not only financially but also on the program. On a multi-storey building, such as a hospital wing, as the structure is built independently of the offsite modular sections if the tolerances have not been met from both parties it could have serious implications for the compliance of the building.”
Plant room corridor in a hospital.
How could the system of compliance checking be improved? The role of modular buildings within the wider construction industry is well established and not in dispute. Their advantages over traditional methods of construction are numerous and widely recognised. Modular techniques allow for
IFHE DIGEST 2026
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