Modular construction shifts a large share of building work from the jobsite to a manufacturing environment. That change affects design, procurement, schedule, quality control, logistics and field installation.

In volumetric modular construction, a building is divided into three-dimensional units that can include structural systems, envelope assemblies, mechanical and electrical systems, plumbing, fire protection, fixtures and finishes before they reach the site. Those modules are transported to the project location, set on a prepared foundation, connected to adjacent modules and completed through field stitching.

Haskell organizes this process through Design, Manufacture and Installation (DMI). The same delivery framework connects the design team, manufacturing operation, procurement group, logistics team and field installers. That structure gives Haskell direct feedback across the full process, from early design decisions to commissioning.

Step 1: Planning the Modules

A modular project begins by deciding how the building should be broken into modules. That decision controls the work that follows.

Module boundaries are driven by room size, structural loads, transportation limits, lifting points, site access, finish transitions and mechanical, electrical and plumbing (MEP) routing. A poor module break can create difficult field welds, inaccessible pipe connections, misaligned finishes or excess work after the modules arrive.

Designers also plan the temporary conditions required for shipping. A module may need temporary walls, roof panels, bracing or removable protection. Openings that later connect to another module may need support during transport. Finished surfaces may need gaps near seams so crews can complete the final connection on site.

Each module has to function as a finished space and as a transportable assembly. It must support its final building loads, then handle lifting, trucking, port handling, vessel movement and crane setting. Those shipping and handling loads often exceed the forces the module will experience after installation.

Step 2: BIM Design for Buildable Instructions

Modular delivery requires a more complete design package than conventional construction because the plant needs direction before field conditions are in place. Haskell develops the architectural and engineering design into manufacturing drawings, detailed Revit models and installation manuals.

Building Information Modeling (BIM) is the digital coordination layer behind that process. Instead of treating drawings as separate sheets, it combines the building’s geometry with system data, material quantities, clearances and installation logic in a single model. That model is used for coordinate framing, MEP routing, penetrations, access, finishes, module connections and other technical details before production begins. The model also supports takeoffs and procurement by defining what each module needs, when those materials are needed and what must ship separately for field stitching.

Manufacturing workers need clear instructions that show sequence, tools, parts and tolerances. The design package must explain how to install each component and what the finished condition should be.

The design process also relies on datum points, which are fixed reference locations used to measure, align and verify work. Steel frames are built on jigs, with critical dimensions checked before shipment. In high-finish spaces, grout lines, millwork, door openings and ceiling elements may be measured from the center of a room so the finished space aligns correctly after modules are joined.

Step 3: Manufacturing Modules in Controlled Conditions

Once the design is ready for production, work moves into a controlled manufacturing environment.

Haskell’s modular program uses steel-framed volumetric modules. Steel provides rigidity during shipping, crane handling and field setting. It also allows higher levels of interior completion before modules leave the plant.

A typical production sequence starts with the structural frame, then moves through light-gauge framing, floor systems, wall systems, MEP rough-ins, fire protection components, envelope assemblies and finishes. Depending on the project, modules can leave the facility with flooring, paint, millwork, tile, stone, fixtures and other finish work already installed.

The closed manufacturing environment ensures repeatability. Crews work under cover. Materials are staged to match the production sequence. Quality checks occur throughout fabrication rather than at the end of the job. When an issue arises in one module, the team can adjust the process before the same issue recurs in the next set.

Detailed layouts also reduce waste. Tile, drywall, floor panels and other materials can be counted, cut and sequenced from the model. On repeat programs, those improvements compound across multiple buildings.

Step 4: MEP Integration

Mechanical, electrical, plumbing and fire protection systems shape the module plan.

Each module must include sufficient system work to reduce field labor while maintaining proper access for connections, inspection and testing. Designers determine which components are installed inside the module and which will be shipped loose for completion at the project site.

For example, HVAC distribution may be installed inside each module. Interconnecting ductwork can be fabricated separately, shipped with the field materials and installed after modules are set. Plumbing, electrical and fire protection lines can follow the same approach.

The connection points require careful coordination. Pipe connections need access. Electrical pathways need clear routing between modules. Fire protection lines need testing. HVAC systems require alignment between factory-installed distribution and field-installed ductwork.

Haskell’s DMI structure helps manage those interfaces because design, manufacturing and installation teams work from the same model and feedback loop.

Step 5: Early Procurement

Modular construction compresses the time available for procurement. Materials must be approved, contracted, fabricated, shipped and staged before they’re needed on the production line.

That process starts with specifications and samples. Designers, owners, procurement teams and vendors work through approvals for finishes, equipment, furniture, fixtures and specialty materials. Shop drawings may go through several review cycles before fabrication begins.

The procurement plan must align with the manufacturing and installation sequences. A missing component can delay field stitching even when every module arrives on time.

Step 6: Logistics

Transportation affects module size, structure, schedule and cost, and must be considered during the early design phase.

A route survey maps the path from the factory to the site and checks roadway geometry, load limits, overhead clearances, port access, staging options and local movement restrictions. The last mile is often more limiting than the long-distance route, where local streets and site access can create the most difficult constraints.

International work adds customs, freight forwarding, vessel schedules and import documentation. Modular buildings require documentation that ties modules, field materials and shipping containers to one project.

Modules also need protection during transit. Openings are closed with temporary panels. Some modules receive temporary roof, wall or floor elements for stiffness. Exterior wraps protect against water and air movement. For ocean shipping, desiccants may be placed inside the sealed module to control moisture during temperature changes. A secondary tarp can protect the primary weather barrier.

The Field Kit of Parts (FKOP) is the coordinated package of materials and prefabricated assemblies needed to stitch the modules into a finished building on site. It moves through the same logistics plan as the modules and may include MEP tie-in assemblies, finish materials, envelope components and other project-specific parts. Haskell organizes the FKOP by discipline and installation sequence so crews can access the right materials at the right time.

Step 7: Installation and Stitching

The site must be prepared for modular tolerances before modules arrive. Foundations, base plates, embeds, utilities and crane access must be ready.

During setting, each module is lifted into place, aligned, leveled and secured. Crews check datum points, wall alignment, floor elevations, grout lines and system connection points before finalizing the position. Modules are welded to foundation base plates and to adjacent modules, as determined by the structural design.

After modules are set, stitching connects the building structurally, closes the envelope, completes interior transitions and ties MEP systems into full building operation. Haskell’s installation manuals guide this work by detailing each step and inspection point, helping crews avoid scope gaps and preventing work from being covered before it is connected or tested. Commissioning then verifies that factory-installed and field-completed systems perform together as one building.