How Industrialized Construction Can Transform Hurricane Recovery

Hurricane Helene made landfall on Florida’s Gulf Coast as a Category 4 storm the evening of September 26, 2024. The storm weakened as it moved north but it caused significant impact across the Southeastern United States, especially Southern Appalacians. The storm dropped 15 inches of rain in Asheville, North Carolina. The swollen rivers were already high from recent rains and the runoff from the mountains caused catastrophic flooding, including the rapid erosion of interstate highways. As the storm slowed, the winds died but the rainfall persisted and dropped even more rain in other areas.  

Our thoughts and prayers go out to those affected by the hurricane’s powerful winds, torrential rains, and the storm surge. The loss of life and property is felt far and wide as communities struggle to recover from the devastation. First responders are working tirelessly at rescue efforts and providing relief. 

After the relief effort it will be time to rebuild. The loss of housing in areas already short on housing stock highlights difficulties for a rebuilding effort. It is no small task and it will take time. There was a natural disaster in Wind River’s backyard in April of 2020 when a EF-3 tornado touched down in North Georgia and ravaged through east Hamilton County, Tennessee. For months after the tornado, building supply stores were struggling to keep up with demand for building materials. Years after the tornado, homes and communities were still being rebuilt. 

The rebuilding effort may appear daunting. In this article our team wants to highlight the best practices and technological advancements in the industrialized construction of modular homes that can help alleviate struggles inherent in large-scale rebuilding efforts. Modular building involves constructing homes in a controlled production facility, offering advantages like faster construction times, improved quality control, and potential cost savings. Offsite built modular homes can be customized and are often more energy-efficient than traditionally built homes. Overall, modular construction is a more sustainable option due to reduced waste and efficient use of materials.

There are many challenges to rebuilding in disaster-affected areas. Industrialized construction of modular homes offers solutions. Here are some examples.

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Influx of unqualified construction contractors

In the aftermath of a natural disaster, a surge of construction contractors often floods the market. Whether well-intentioned or not, many of these individuals may lack the necessary qualifications, experience, or licensing to deliver quality workmanship. This influx of unqualified contractors can pose significant risks to property owners, as they may experience poor work, delays, and even outright fraud.

After the strain and hardship of a natural disaster, homeowners are vulnerable as they attempt to regain their basic needs. Fraudulent contractors may employ deceptive tactics to lure homeowners into contracts. The contractors may offer unrealistically low bids, make false promises about timelines, or pressure clients to sign agreements quickly. Once work begins, these contractors may cut corners, use inferior materials, or abandon projects halfway through. The result is often additional financial loss and emotional distress for homeowners.

In the event a new home is needed, industrialized construction of modular homes can help alleviate homeowner risk with programs already established in states like North Carolina. The North Carolina Department of Insurance and the Office of State Fire Marshal has a program for licensing and regulating modular home builders. These programs are fully integrated with state and local building codes through the approval and inspection process. Furthermore, modular home builders are required to apply for licenses and bonding to alleviate nonperformance risk. This increased oversight allows for transparency and accessible public databases, while at the same time providing an offsite construction process that is streamlined and is not impacted by the same supply chain issues as the affected area.

Navigating changing building codes

In North Carolina, municipalities typically update their residential building codes every 3–6 years. This frequency is aligned with the release cycles of the International Residential Code (IRC), a generally accepted code for building standards. Individual municipalities may choose to adopt the IRC in its entirety or make modifications to address local conditions, such as climate, soil types, seismic activity, and wind loads. Building codes change over time. If homes built decades ago were destroyed, the new home being built in its place will have to meet current codes. These codes ensure homeowner protections, but they can be complicated and difficult to navigate for contractors and even code officials. 

Offsite modular homes are built to meet or exceed existing building codes. The inspection and approval programs are already incorporated into the modular construction process and can reduce the time and effort required for on-site inspections and approvals. All modular construction plans are reviewed by the state and incorporate updated plans that are specifically designed to address the unique challenges posed by the disaster-affected area. This can help ensure that new construction is built to the right code but also more resilient and better equipped to withstand future events.

‍Supply chains and skilled labor shortages

After a natural disaster like Hurricane Helene, construction contractors often see a significant strain on labor and supply chains. The devastation caused by such events can lead to a shortage of skilled workers because of demand but also because many workers are experiencing displacement or dealing with personal losses. Additionally, the destruction of infrastructure, transportation routes, and warehouses can disrupt the flow of essential materials and equipment. This scarcity of resources can result in delays, increased costs, and compromised quality in rebuilding efforts.

Offsite modular construction offers a promising solution to these challenges. Offsite construction in a controlled production environment mitigates the impact of labor shortages and supply chain disruptions. Skilled workers can be employed in production facilities far from disaster-affected areas, ensuring a steady supply of qualified labor. Moreover, the standardized nature of modular construction allows for more efficient procurement and logistics, as materials and components can be ordered in bulk and transported to the production facility in a timely manner instead of dealing with transportation and logistics to the disaster-affected area. This approach can significantly accelerate the rebuilding process and reduce the overall cost of construction.

‍Modular construction 

Build it Back was a government program launched in the aftermath of Hurricane Sandy in New York City where there was a significant initiative to rebuild homes damaged by the storm. Among the rebuilding strategies employed was a streamlined modular construction approval process. Modular construction allowed for a more rapid and efficient rebuilding process. This meant that homes could be completed more quickly, providing much-needed shelter to displaced residents. 

Past precedents of modular construction post-disaster demonstrates its potential as a solution for recovery efforts, such as those in the aftermath of Hurricane Helene. By adopting modular construction programs, governments and communities can expedite the rebuilding process and provide much-needed housing to affected residents. To fully realize the benefits of modular construction, joint partnerships between governments, insurance companies, and builders are essential. Governments can provide incentives and regulatory support, insurance companies can develop policies that encourage modular construction, and builders can invest in the necessary infrastructure and expertise. By working together, these stakeholders can ensure that modular construction becomes a viable and widespread solution for rebuilding after disasters.

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