Hotel Ibis Budget
With a constructed area of 2,340.50 m² over 4 floors and a capacity of 110 rooms, the Ibis Hotel was built using a modular industrialised construction system employing 3D components. The company Modultec manufactured and transported 70 modules and assembled them on site.
Each of these 3D components or modules comprised one room on the façade side and one on the corridor, thereby allowing for the repetition of the same pattern a number of times.
A prototype of a complete room was built in the factory in a controlled environment and, after carrying out all the design, functionality, sealing, noise, thermal and acoustic insulation and installation tests, this module was replicated 55 times.
URPINA RESIDENCE FUNDACIÓN AMPANS
Sant Salvador de Guardiola
Dedicated to the social and workplace inclusion of people with intellectual disabilities in vulnerable situations, this residence comprises 25 rooms spread out over an area of 1,142.33 m² on one floor. It was built by Modultec at its facilities in Gijón, using an industrialised construction system of compatible components (S3C).
The rooms were constructed as 3D modular components, while the slaps, façade and double volume roof areas used 2D elements, and the installations comprised 1D components.
Designed to be integrated into a natural setting of vineyards and nature areas, the Urpina residence was manufactured in 3 months and the assembly carried out in just 1 month, despite the adverse weather conditions of snow and extreme cold, typical of the month of December at this location.
REAL MADRID RESIDENCES
In the Real Madrid “Sports City”, as part of an ambitious project developed by the prestigious Estudio Lamela, two residential buildings were built using industrialised construction systems:
Residence for the First Team
The building comprises a total constructed area of 8,500m² over 3 floors and has 60 rooms, in which both the first football and basketball teams of Real Madrid are housed.
The building was constructed using a mixed system comprising both traditional construction – performed by a partnership between FCC & San José, and building in situ the ground floor housing the common areas, lounges, swimming pool, and rest areas – and the floors of suite-style rooms, which consisted of industrialized 3D components manufactured, transported and assembled on site by Modultec. These rooms are oriented to the training fields and consist of modules 18 m long and 4 m wide, each complete with its own terrace and the proportional part of the corridor.
The use of this mixed construction model reduced the execution period to 8 months, with the assembly of the modules and finishing taking just 2 months.
Residence for Junior Players
The residence has two floors and a semi-basement level. The entire modular structure consisting of 44 modules was manufactured and assembled by Modultec within a period of 2 months, which reduced the total execution time of the building by 40%.
In this project, occupation within the Sports City itself was not such a critical factor, as it is accessed from the outside. The reduction of construction time was thus given priority only for the structural part of the building.
Some modules with a structural function were manufactured but later finished internally on site by the FCC & San José partnership, the construction company with overall responsibility for the works.
LIFE BY MAYENA RESTAURANT
Designed by the architect Toni Montes, the complex has a total floor area of about 2,100m2 and features several themed restaurant floors. The ground floor is an Ice Cream establishment and the other floors house a Gabonese, an Indian and a Mexican restaurant, a banquet hall and, on the covered floor, a disco-bar.
The building was constructed using an industrialised construction system with 3D components, which were manufactured in their entirety by Modultec at the company's facilities in Asturias, before being transported by ship to Libreville, the capital of Gabon.
The most relevant aspect of this building is the complexity of the micropile foundation, which was made necessary by the type of terrain, located in a privileged zone on the capital’s sea front.
The building also features a complex air conditioning system, biometric access control for staff and exquisite thematic decoration.
RUBAN VERT INTERNATIONAL SCHOOL
Libreville - Gabon
This educational complex measures 14,000m2 and is situated within a developed area of 40,000m2 including sports facilities.
It is made up of several buildings that cater for the full English educational system: from nursery education with independent facilities and access, up to the rest of the education levels, and including all respective teaching and sports facilities necessary for completing the educational cycle. There is also a large administration building, a 350-seat auditorium and a full sports centre.
In this project, all the educational buildings as well as the dining hall were built using 3D component construction systems, while the auditorium, sports centre and administration building – with differing heights – and the administration building’s curtain wall were constructed using 2D components. These were manufactured in their entirety in Spain by Modultec, and later transported by ship to Libreville, the capital of Gabon.
Given the particular economic and sociological circumstances of the local market at the time, the foundations also consist of pre-cast concrete footings that were manufactured in Spain and transported to their destination.
This project constitutes a clear example of how a large number of modules and the necessary foundations can be serialised and standardised. After being manufactured serially, construction consists of assembly of these elements on site.
POMPEU FABRA UNIVERSITY LECTURE HALL
This project is an example of a mixed implementation of industrialised systems, using a 3D Platform for the classroom area and a 2D Platform for the auditorium.
Designed by Toni Montes at MIBA Architects, it was conceived as a temporary extension for the Pombeu Fabra University Social Sciences and Humanities urban camps, next to the library built inside the historic reservoir of Ciudadella park. The entire building, with a total floor area of 1,950m2, was built off-site by the company Modultec and then transported and assembled on site.
IES LES FRANQUES DEL VALLES
Designed by the architects Gemma Vidal and Rodrigo Alaminos and located in the centre of Corró d’Avall in Les Franqueses del Vallès, this building has a total floor area of 2000m2 and was completed in a period of 4 months.
The need to complete the building on a tight schedule in order to have it ready for the next school year was a key factor for choosing an industrialised construction system using 3D components manufactured by Modultec in Gijón.
Thus, while progress was made in situ with the execution of the foundation and sanitary slab, the Modultec factory built the industrialised 3D components that make up the school. At the same time, the project design called for the execution of the works in two phases: the first to house the entire preschool programme and the administration and services area (L); and the second, with two floors, to be occupied by the primary school classrooms and the gym (I).
These industrialised modules are manufactured using a welded metal structure with floors of corrugated steel sheet and reinforced concrete. The enclosures were made with precast concrete panels on the ground floor and Corten steel sandwich panels with extruded polyurethane insulation on the first floor. The flat roofs are inverted with a Filtron slab finish, and all the interior partitions are laminated gypsum board, with a light auxiliary structure of folded sheet metal profiles insulated with rock wool. The modules were manufactured to a high degree of completion, including the centre’s facilities and all finishes, to optimise the lead time and minimise on-site work.
KFC, BURGER KING AND McDONALD'S RESTAURANTS
The buildings of fast food chains, with their own brands both in design and in operation and management, are highly suitable for being repeatedly replicated on different sites and locations. This makes industrialisation using a 3D platform the most profitable option for this type of building, not just in terms of costs, but also in quality, lead times, sustainability and image.
These buildings are divided, in turn, into two productive or architectural units: the industrial zone (kitchen, cold storage & stock rooms) that is normally composed of 3-4 modules depending on the size, and the restaurant area with ceilings at one or two levels, formed by another 3-6 modules.
The company La Casa por El Tejado developed an interesting and innovative urban design in the centre of Barcelona where, given the scarcity of urban land available for the construction of new buildings, they carried out an exhaustive market study and found more than 100,000m2 of potential additional building space available on the roofs of buildings.
Employing a novel form of agreement with the building owners and neighbourhood communities, they bought up the roof rights and were thus able to not only develop in central areas of the city, but also assist in the rehabilitation of existing buildings.
This system of building extension is called “remontas” and consists of a lightweight industrialised system using 3D or 2D components in steel or wood. These minimise the loads on the building structure and the necessary reinforcements, thereby reducing inconvenience to the existing residents.
A “remonta” can consist of a single rooftop apartment, or even several floors of apartments for sale.
This mixed formula of new construction and the renovation of existing buildings improves the city centre, as it increases the housing supply on the market and provides enormous advantages in terms of energy efficiency, while also improving the liveability of existing buildings.