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Typical steps in building a modular home by Middendorf Contracting
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So, you bought yourself a piece of property and want to put a house on it.

Take pictures of it now, because once we get going it is going to be transformed from a beautiful green pasture into a construction site full of mud and piles of dirt. Don't worry, when we're done we will clean up after ourselves.

Let me take you through some of the typical steps in doing a modular home setup.

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The first thing you should do is call us. We will come out and walk the property with you. Help you decide where to place things like the driveway, septic system, electrical service, house, etc...

We also can help you work on your floor plan and choose building materials and methods.

We know who to call, and how to fill out all the paperwork, for permits, perk tests, etc...

dasfdsf Once we know where we are going to put things, we need to get access to the property. So we dig out a nice wide driveway entrance and bury an appropriate sized pipe where it crosses the ditch along side the road.
dsfgdfg Then we start digging out the centuries worth of hay and loam so we can replace it with some good tight packing "bank run gravel". This will make the base for your driveway.
dafdsfds We will be driving all kinds of heavy equipment up and down this driveway over the next few months and get it packed down nice and tight. Then after all the heavy stuff is done we will bring in some topper material and spread a few inches of it over the whole thing.
dsfgdfg Some of those trucks will be bringing us our sand and gravel to build a sand mound with.
dsfgdfg Properly building a sand mound takes the right equipment, knowledge and man power.
dsfgdfg With today's stricter laws about septic systems, sand mounds are getting bigger. This one is 84 feet long, 16 feet wide and varies in depth from 26 inches to almost 4 feet. But the top is level within plus or minus 1 inch from end to end.
fgasfdsf We work closely with any utility companies to coordinate the installation of new hookups.
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This installation opted for a pole to be installed down by the road and have the electric service be delivered from the pole to the house underground.

That meant a ditch had to be dug, PVC conduit laid in it, then filled back in with the appropriate sized holes at the ends for transformer housing and pole placement. All to specifications provided by the electric company.

The big green box you see is the transformer to take the electricity from the primary run to the secondary run that the house can use.

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So, now that we have a driveway. Let's take the excavator and dig out a spot to put us a foundation. We are going to use a "pre-fab" foundation system, so it needs to be built to the specifications of that manufacturer.

We are a dealer for Superior Walls Advanced Concrete Systems and have setup many of them.

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Once the site is prepared to their specifications, the foundation walls arrive.

With a modular home system it is all about timing and coordination between the different suppliers.

As you can see by this picture, this foundation arrived on two trucks with a crane.

fgasfdsf Once the crane is setup, the crew from Superior Walls starts swinging the panels off the trucks and into the prepared area.
fgasfdsf In about 1 hour and 15 minutes we have 9 foot high foundation walls made with 5,000 PSI concrete and insulated with R12 value.
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This house is having a steel I beam running down the middle of it. This was all thought of in the original design and Superior Walls made reinforced pockets in the appropriate spots for the beams placement. This allows for the elimination of all the "lolly columns" that are usually in the basement of a modular home. We are going to end up with one big room that is about 26 by 50 feet with only the steps going to the main floor in it.

Lot's of room to do whatever you want to in it.

fgasfdsf A couple of days later, the house arrives. This house is a "Cape Cod" design. It arrives on three carriers. One for each side and one for the dormers.
fgasfdsf First thing up the driveway is the crane to lift the house off the carriers.
fgasfdsf Once the crane is setup, the sections are brought up one at a time.
fgasfdsf The front section is put on first.
fgasfdsf Now here comes the back section. Look, we lucked out and it started snowing while we were setting the house. How convenient.
fgasfdsf You need a big crane to lift 30+ thousand pounds of house and swing it around.
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They drop it down and everything fits together nicely.

Remember, this is a foundation system made by one company and a house made by a different one. This is the first time they have ever seen each other. They fit together almost perfectly, there was less than 1/2 inch difference in the overall square ness of the two.

In a site-built house you can adapt the house to the foundation as you go. With a modular you drop it on and off you go.

fgasfdsf Now for the third carrier. It has the four dormers, roof shingles, siding, etc... on it.
fgasfdsf While they bring the third carrier up, the crane operator "unfolds" the main sections of the roof.
fgasfdsf This allows the install crew to put up the gable end walls. Once the gable walls are up, they use the crane to hoist up anything to the top floor that is going to be needed up there, like the shingles and pieces of the back shed dormer, then they flip the top sections of the roof up.
fgasfdsf The two front cape dormers go on in about 3 minutes each. They are pre-fabed at the plant and literally just have to be placed in the holes on the roof and nailed in.
fgasfdsf The faux dormer over the front door came in sections and had to be assembled on the ground and then lifted in place.
fgasfdsf And here it is. In less than a day we went from nothing to having a house sitting on the property.
fgasfdsf Once the house is on, we need to get it all sealed in from the weather. That means putting in windows in the foundation, finish shingling parts of the roof (where it is folded during shipping) and installing exterior doors.
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This homeowner chose to not get doors from the modular house company but instead had matching oak doors made for both the front and back entries.

This just shows how much customization is available with a modular home. You order what you want, we get it put together for you.

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Here we are a couple of days after the house setting. We are pouring the concrete pad in the basement

Usually this would be done before the house was put on the foundation, but being as it was winter, we wanted to use the house to protect the concrete and help us maintain the temperature for a better cure.

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We have enough people on staff to be able to handle large projects. Here we have two masons working the concrete pour with three helpers using wheelbarrows to get the concrete from the door to the spot it needs to be.

Note the radiant tubing on the floor. This house is having in floor radiant heating on all three floors.

fgasfdsf This is what the top floor looked like right after the house was set. It was ordered completely unfinished.
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While the masons were pouring concrete we had framers upstairs framing in knee walls, putting on the roof ties and making two new walls.

We ended up with three rooms for a total of just under 900 sq ft of usable space.

So, that is 1,450 for the ground floor plus 1,450 for the main floor plus 900 for the top floor for a total of about 3,800.

fgasfdsf The owner of this house was heavily involved in the whole process. After we were done framing they came in and laid out all the radiant tubing for the top floor, filled in the empty areas with sand ( for a heat sink ) and put another subfloor on top of that.
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Now it was time to insulate and drywall.

Note that there is a combination of insulation types being used here. On the vertical walls fiberglass is being used, on the ceiling we used 1 inch P2000 insulation and on the kneewalls we used 5/8 inch P2000. You get over R40 in one inch versus R38 with 12 inches of fiberglass insulation.

Building technology is constantly changing and we keep up with it.

fgasfdsf Here is what the upstairs looked like after dry walling but before mudding.
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Another view of the top floor after dry walling but before mudding.

Note that because this house is a Cape Cod design, and this is the top floor, the walls are vertical for only the first 6 ft then they match the roof pitch.

fgasfdsf When the house is delivered items like interior doors, siding, spare drywall, trim, etc... are shipped stacked inside the house.
fgasfdsf This house was ordered with no flooring. The homeowners chose to install laminate flooring themselves. Once again showing the flexibility available with a modular house.
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The home manufacturer left a square opening between the front room and main entry foyer.

We rounded off the top.

fgasfdsf And installed an archway.
fgasfdsf Here is the 1500 gallon three part septic tank being delivered.
fgasfdsf As was mentioned previously, we brought a lot of large trucks and pieces of equipment up that driveway. This tank alone weighs over 14,000 pounds.
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Like I said in the beginning. Don't worry we will clean up after ourselves.

Once the septic system is in, and we don't need to drive on the yard area anymore, we'll use a bulldozer to shape the property into manageable hills and hide the sand mound, as best as we can, so that it can be maintained with a normal lawn tractor.

Once that is done, we plant grass and mulch hay on top of it. This house took 400 pounds of grass seed and 120 bales of hay.

fgasfdsf Here we are putting artificial stone panels on from www.nextstone.com. They look just like real stone but install much like vinyl siding. This is their Kentucky Gray Drystack model.
fgasfdsf This is what the house looked like three months after the lawn planting.
fgasfdsf Here is another shot of the house the same day.