When we get involved

Ideally, the decision to use precast construction is made before any major design work has begun. In order to take advantage of the efficiencies of precast, an owner or designer is going to want to go over the critical requirements that will maximize the cost-effectiveness of a precast structure. A meeting between the owners’ professional consultants and the Modular design team will allow all parties to best understand how precast can assist in their building structure.

3D Modeling

Once the decision to use precast is made, an initial layout of the building is made. This can be transformed into a 3D model of the structure, showing each potential piece of precast that will be required for construction. Column lines can be confirmed with suite or interior use layouts, and areas of attention are identified for further review. Discussions can also progress on servicing each floor within the precast elements. The more planning that is done, the more work can be included in the precast design to create more efficiencies.

Engineering

Detailed engineering is then done with the modular engineering team in conjunction with the base building engineers. Most clients will choose between our two main systems, a load-bearing sandwich panel or shear wall, or structural frame with isostatic behaviour. The isostatic system is our signature design that allows for flat floor and ceiling surfaces similar to a poured in place structure. Individual piece tickets showing all reinforcing and piece connections are provided to the client for review.

Manufacturing

Once final engineering is approved, our crews go to work in our production facility to fabricate the elements. Using steel moulds and tables, each piece is poured in a climate-controlled facility, mechanically vibrated, into heated moulds which regulate the curing process. Once cured, pieces are stripped and stored using tilt beds which limit the stress on each piece. Finishes are applied on architecturally visible surfaces in hundreds of colours and textures, to create a unique look to each client’s project. Each piece is tagged to allow for easy retrieval from storage and grouping when sent to the site.

Installation

The installation process of fixing the precast pieces at the site is completed by Modular staff in conjunction with the general contractor. This erection process saves valuable time as pieces are installed in conjunction with each other, with connection details designed to go up quickly. Precast installation can save up to 30% of the time for a poured-in-place solution.