Daily production capacity for living space can reach between 600 and 1000 m², though actual output may vary based on multiple interrelated factors.

Key considerations include:

• The automation level and equipment configuration selected by the client, which directly impact efficiency and cycle time;
• The technical proficiency of the workforce and how quickly teams adapt to workflow requirements;
• The project complexity — simpler modular layouts result in higher output, while intricate designs or structural details may require additional time per unit;
• The nature of production tasks: consistent batch production allows for faster throughput, while irregular, custom, or diverse orders tend to slow down the process;
• The quality of planning and logistics, including raw material availability, loading operations, and inventory handling;
• The inclusion of interior finishing works at the factory stage. A broader scope of factory-installed systems (e.g., electrical, HVAC, sanitary fittings) typically extends production cycles.

This production range should be viewed as a realistic performance benchmark, achievable under conditions of stable workflow, well-trained teams, and efficient coordination across departments.

Modular building production lines can reach an automation rate of up to 90%, depending on system design, production strategy, and the degree of integration required.

Many core operations in modular construction can be automated, including:

• material preparation and dosage,
• concrete mixing and flow control,
• internal unit movement and staging,
• packaging and wrapping,
• as well as centralized process monitoring and control.

What’s most critical is that all primary components of the line responsible for ensuring structural integrity and product quality are fully automated.

This includes precise material proportioning, automated mixing, consistent curing conditions, and stable transportation systems.

Such automation helps deliver high repeatability, quality consistency, and efficient throughput with minimal manual adjustments.

That said, some steps — especially those related to custom finishes, technical installations, and manual touch-ups — still require human input.

The achievable automation level is influenced by:

• the share of interior finishing handled in-factory,
• how standardized the modular designs are,
• and the desired ability to scale production or adapt to project changes.

Each automation concept is tailored to align with the project’s technical framework, budget, and operational autonomy goals.

For the modular production line, the recommended facility area is around 8,000 m², but the actual space needed may vary based on final design decisions and project scope.

Several variables will affect the required production footprint, such as:

• Applicable regulations and codes, including workplace safety standards, fire codes, and hygiene requirements;
• Structural layout and technical conditions of the building, depending on the production scale, degree of automation, and the logistical setup — whether materials are moved manually, by conveyors, or using overhead cranes. Important factors include roof clearance, load-bearing capacity, column layout, air circulation, and the availability of technical infrastructure like cable trenches, loading docks, or maintenance access;
• Support infrastructure for staff and operations, which may consist of:
  • personal hygiene and changing rooms,
  • food service areas or staff lounges,
  • control rooms or supervisor stations,
  • dedicated areas for repair technicians and engineering teams,
  • storage for consumables and spare parts.

The final layout will also depend on whether these auxiliary areas are co-located with the production hall or housed separately elsewhere on the site.

Material Supply Zones

Storage space for raw materials must be assessed based on operational logistics and supply reliability. This includes both indoor storage and open yard solutions.

Key aspects affecting the storage footprint are:

• the quantity of materials to be stocked,
• delivery lead times,
• geographical distance from suppliers,
• and dependability of the supply chain.

If the supply system is flexible and deliveries are frequent, storage space can be kept minimal. However, if long intervals or uncertain schedules are expected, a larger buffer may be necessary. The availability of internal logistics equipment and access routes on-site also impact the required area.

Dispatch and Product Holding Area

The dispatch zone accommodates completed modules pending transportation to the final site.

Its scale depends on several factors:

• whether modules are moved directly after production or temporarily stored,
• shipment batching practices,
• number of concurrent projects,
• and the efficiency of the outbound logistics chain.

Proper allocation and layout of this area helps ensure uninterrupted production and timely delivery to construction sites.

Employee Facilities and Amenities

To support workforce well-being, a designated area must be allocated for personal hygiene, dining, rest, and personal storage.

Space planning should reflect:

• regulatory requirements for working conditions,
• maximum staffing levels,
• shift configurations,
• and specific needs such as gender-separated areas or seasonal operation modes.

Providing well-organized welfare infrastructure contributes to employee satisfaction and smooth shift transitions.

The setup period for the production line typically ranges from 30 to 45 calendar days, depending on project complexity and site conditions.

The installation process can be affected by:

• Readiness of the production hall, including foundations, floor plan layout, and utility connections (electrical, water, compressed air);
• The configuration and size of the system, especially when multiple modules or parallel processing stations are involved;
• The degree of system automation, and the time needed to calibrate integrated controls and safety systems;
• Installation logistics, including internal material flow, access routes, and the use of cranes or forklifts;
• The level of collaboration among installation teams, client representatives, and contractors responsible for complementary work (e.g., ventilation, fire systems, IT networks).

This timeline includes equipment installation, commissioning, and trial operation.

A fully prepared site enables completion closer to the lower end of the range. However, added adjustments or third-party dependencies may push the schedule toward the upper limit.

Running a modular housing production line typically requires an estimated 24 to 40 workers per shift, though this number can vary based on several key parameters.

Factors such as the skill level of operators, efficiency of work processes, and experience gained over time all influence labor requirements.

During initial commissioning and testing phases, teams may be larger to ensure smooth startup. As processes stabilize, staffing can often be scaled back.

The automation level and equipment package selected play a crucial role in defining how many personnel are needed. Higher automation and integrated systems reduce dependence on manual work and allow for leaner staffing models.

In modular construction, interior finishing — including electrical, plumbing, tiling, painting, and fixture installation — can be partly or fully completed within the factory.

The extent to which these works are completed in-house will affect labor needs. A greater scope of factory finishing will require either specialist technicians, cross-trained staff, or outsourced labor.

Some companies may prefer to use temporary crews or subcontractors to handle specialized work during peak periods or for custom projects.

Even with advanced automation, the system still relies on human oversight for key tasks such as monitoring production, calibrating machines, performing inspections, and responding to issues in real time.

Manual input is also common in module handling, assembly alignment, and custom finishing stages, depending on project demands.

Nonetheless, direct labor costs account for a relatively small share of the total cost per square meter. Thanks to high efficiency and fast cycle times, even a slight increase in workforce size typically has minimal financial impact on the overall product cost.

The modular production setup requires an installed electrical capacity in the range of 300–400 kW, depending on project-specific factors.

This estimate is indicative and will be updated based on the finalized layout and technical design.

Key variables include the scope of installed equipment, the degree of automation, power ratings of production units, and logistics infrastructure such as cranes, conveyors, or robotic systems.

Beyond the primary production machinery, attention should be given to supporting infrastructure, including:

• indoor and outdoor lighting,
• ventilation and air handling,
• optional cooling systems,
• water supply and treatment pumps,
• compressed air solutions, and more.

A thorough energy usage analysis will be carried out during the engineering and design phase to ensure that all aspects of power consumption are properly accounted for.

Approximately 55 tons of water per day are needed to support the manufacturing process at a modular housing facility.

This figure may fluctuate based on design complexity — such as wall thickness, partition density, and the size and quantity of structural openings (e.g., windows and doors).

The bulk of the water demand is linked to the preparation of foam concrete, while a smaller amount is allocated for equipment washdown and general cleaning.

In modular production environments, irregular workflows — including frequent halts or restarts — can significantly increase the need for cleaning cycles.

Therefore, it’s essential to ensure adequate water availability at all times, and to evaluate backup supply options in areas where water access may be limited.

For modular building production, daily cement consumption typically averages around 120 tons, but this can vary depending on project scope and production settings.

Several factors influence this value:

• Daily output — more modules produced means greater material demand;
• Module design complexity, including thickened walls, integrated floor slabs, structural reinforcements, and built-in services;
• The cement type and freshness — recently manufactured cement with high activity yields better performance with lower quantities, whereas aged cement may lead to increased dosage;
• Work performed in-house, such as casting sanitary cores, internal walls, or floor structures — these add to the total cement volume;
• Automation and mix control systems, which ensure dosing precision and reduce waste;
• Environmental conditions, which may call for variations in water-cement ratio or mix composition.

Thus, while 120 tons per day is a standard reference under optimal operating conditions, real-world consumption will depend on the production pace, design variation, and cement characteristics.

In modular construction, galvanized light-gauge steel plays a central role in forming the load-bearing frame of each volumetric unit.

The most commonly used steel grade is S350GD + Zn275, manufactured in accordance with EN 10346.

• The Zn275 coating ensures a high level of corrosion resistance,
• The S350GD grade delivers a yield strength of 350 MPa or higher — essential for maintaining rigidity during lifting, stacking, and transport.

The material is delivered in coil format and then slit and shaped using precision roll-forming machines.

Most steel suppliers provide coil slitting as a service, though our company can also supply slitting equipment as part of a fully integrated modular production solution.

Steel thickness may vary depending on project requirements — typically from 0.8 to 1.5 mm, based on module dimensions, structural spans, and interior load demands (such as mezzanines or built-in wet areas).

For multi-story or heavy-load projects, reinforced sections made from steel up to 4 mm thick may also be used.

The use of LGSF profiles in modular production provides:

• consistent structural performance across units,
• compatibility with factory-installed finishes and utility systems,
• and lightweight construction that facilitates transport and on-site assembly.

All materials used in the frame fabrication meet recognized international standards, ensuring performance, durability, and long-term value.

The structural infill for modular units is typically produced using foam concrete, which combines lightweight composition with strong thermal and acoustic insulation performance.

This material is ideal for factory-assembled modular construction due to its dimensional stability, crack resistance, and ability to integrate with embedded systems such as electrical and plumbing installations.

With the use of our high-performance foaming agents (protein-based) and specialized admixtures, developed specifically for our equipment and production systems, the density and physical properties of the foam concrete can be adapted to project-specific criteria.

In special cases, where design loads or transport limitations require enhanced weight efficiency, lower-density mixes can be achieved through recipe optimization.

Our company supplies the entire chemical package needed for production — including tested and proven additives — ensuring consistent quality control, process stability, and compatibility with our automated dosing systems.

In every delivery, we include full technical training, along with on-site adjustment of the recipe and process, performed by our team on the client's equipment. This guarantees stable output, predictable material behavior, and a smooth production ramp-up.