STEP BY STEP
Once you have signed off on the floor plan and elevation, and you have selected all of the products and materials for your house, it’s time to sign the contract with your builder. When your contract is signed the following things happen:
- The house is given a serial #.
- The drafting department draws up the production prints and each department reviews them for final approval. If there are questions or concerns, they are addressed at this time.
- The products and materials are ordered for the house and it goes on the production schedule.
Once the products and materials are in stock and staged (all materials are placed at the designated station) the crew leaders, production manager, assistant production manager, and quality control get together to review plans and make sure that all of the expectations of the builder/client are discussed in length.
It is then put on the line and goes through our 5 stage process.
Each stage or station receives a copy of the permit set of prints. Should a question or concern arise the team gets together and discusses how to proceed. The inspection process of our production line is done by a third party organization. They visit the plant on a regular basis to inspect the units on line and to make sure we follow all policies and procedures set forth by Structural Modulars, Inc.
During production if the builder has requested, the entire process is photographed and filmed. A landing page is designed and the link is sent to the builder and client so they can watch online. Or if the client prefers, they can visit our facility and walk the line with their builder.
We welcome you to stop by and walk the line with your builder.
STATION 1 – Floors, Walls, Ceilings & Roof Systems
- Floors and ceilings are built with continuous LVL up to 64’ to eliminate cracks and bridge any deviations in the foundation
- 2 x 10 Floor Joists @ 16″ on center
- We use 3/4″ OSB tongue and groove sub flooring. All floor decking is glued and screwed
- End & Interior Walls
- Marriage Walls
- Exterior walls are caulked where other walls meet
- Interior walls set
- Ceiling set and caulked where marriage, side,
and end walls meet (Floor coverings are not installed until STATIONS 4 & 5)
- Roof Trusses are manufactured at our facility
STATION 2 – Electrical, Plumbing, HVAC & Drywall
- Rough Wiring
- Electrical – all openings and boxes on exterior walls are caulked
- Rough Plumbing
- Plumbing – all drains on exterior walls are caulked at drywall entry to stop airflow
- Plumbing Test
- Hanging of drywall – install drywall backer at all joints
STATION 3 – Insulating, Sheathing, Painting
- Finish hanging drywall
- Tape drywall
- Coat drywall
- Scrape and sand between coats
- Flash paint between all joints and corners
- Scuff walls after flash coat of paint
- Double back roll paint
- Paint flat ceilings
- R21 Wall insulation
- 7/16” Sheathing of all exterior and marriage walls
- Caulk all seams
- Tear away vinyl bead around all tubs and showers
STATION 4 – Shingles, Windows, Siding, & Exterior Doors
- Insulation of ceiling
- Sheathing and roof shingles installed
- Install air infiltration/moisture barrier on exterior
- Install of siding, windows and exterior doors
- Start floor coverings
- Hang interior doors
- Start trim
- Start cabinets
STATION 5 – Trim, Countertops, Cabinetry & Shiploose
- Finish trim
- Finish cabinets
- Touch Up
- Clean units
- Hot check electric system
- Load ship loose material
- Verify and photograph ship loose material
- Button up units
- Load house on carriers
- Ship Loose is verified and photographed
- Flood test all plumbing drains
- Air test all plumbing supplies
- Gable end panels
- Unique architectural components