Modular Buildings, Sky-Building Machines, and Construction Robots

With rapid advances in technology, modern construction sites look very different from the dusty, labor-intensive places of the past. Today, many sites resemble high-tech hubs, equipped with automation and smart machinery.

Modular buildings, sky-building machines, and construction robots are transforming the industry—boosting productivity and making what once seemed impossible, like “mass-producing houses,” a practical reality.

New Modular Systems for High-Rise Buildings

High-rise buildings are starting to use modular construction — which means the building is made from factory-built “blocks” or modules, then stacked and joined together at the site, like giant Lego. This method makes construction faster, cleaner, and often cheaper.

There are two main types of modules:

• Steel modules: They’re lightweight, easy to move, and quick to connect. They’re good for flexible layouts and open spaces.

• Concrete modules: They’re heavier, but very strong, durable, and fire-resistant, which makes them better for long-lasting homes.

Researchers are now testing new hybrid modules that combine steel and concrete. These give the benefits of both: they’re strong, safe, fire-resistant, and still light enough to build quickly. Special fast-joining techniques are being developed so workers can connect these modules securely in less time.

Factories are also looking at automation (robots, machines, precision tools) to make modules faster, more accurate, and more customizable. This means future skyscrapers could be built more safely, more sustainably, and in much less time than with traditional methods.

LG Expands Its Smart Cottage Series With Budget-Friendly Modular Homes

On October 2, LG Electronics introduced new additions to its LG Smart Cottage lineup — affordable modular homes designed to meet the needs of people embracing flexible lifestyles such as “Five Urban, Two Rural Days” and “Workation” (a combination of work and vacation).

Modular homes are built from prefabricated sections, or “modules,” that are manufactured in a factory and then assembled on-site, offering faster construction and consistent quality.

The new lineup features two models: the MONO Core 27, an open-plan 27㎡ (8-pyeong) single-story unit, and the MONO Core 54, a larger 54㎡ (16-pyeong) single-story layout with separated spaces. With these additions, LG’s Smart Cottage range now includes six different types — available in both one- and two-story configurations and sizes of 8, 14, and 16 pyeong.

Robotic Modular Factories Planned Across UAE, Europe, and US by Mulk Marses Robotics

Automated wall panel and pod production set for global rollout

Mulk International — the global arm of UAE-based Mulk Holdings International — has joined forces with Marses to launch Mulk Marses Robotics, a new venture aimed at fast-tracking the adoption of automated modular construction worldwide.

Expanding modular automation

The company intends to set up fully automated modular factories in the UAE, Europe, and the United States. These facilities will employ advanced robotic systems to mass-produce wall panels, bathroom pods, and modular building elements. By embracing industrialized methods, the joint venture aims to cut costs, shorten project delivery times, and ensure consistent quality.

Understanding Shape Imperfections in Modular Construction

When buildings are made the old-fashioned way, small mistakes in size or shape (like a wall leaning slightly or a column not being perfectly straight) are expected. Engineers know how to calculate these errors when checking if the building is safe.

But in Modular Integrated Construction (MiC), buildings are made from factory-built modules. These modules are very precise, but they still aren’t perfect. Even tiny factory errors, plus bumps during transportation and installation, can make modules slightly bent, tilted, or misaligned. These little mistakes are called initial geometric imperfections.

The problem is, old building design methods don’t work well for MiC because they focus on single pieces (like just one column), not on the whole module. If engineers ignore how these small errors add up across a module, they could design a structure that doesn’t behave as expected.

So, this study created mathematical models to connect small factory errors with the overall module shape problems. They tested these models using computer simulations (Monte Carlo simulations) to predict how much a module might be “off” in real life. With this, engineers can:

• Know how precise factories need to be when making modules.

• Reduce wasted time and rework from mistakes.

• Design safer, more efficient modular buildings.

Fire impact on the structural safety of modular buildings

This research looks at how modular buildings (buildings made from factory-built “boxes” that are put together on-site) behave in a fire.

Scientists wanted to see:

• How long these buildings can survive in a fire,

• What parts of the building fail first,

• And what happens when fire spreads from one room to another.

They tested this using computer models and math simulations instead of burning a real full-size building (which would be way too expensive).

Key things they found

1. The strong columns help a lot 

The buildings use special columns called CFST columns (concrete-filled steel tubes).

• The steel tube on the outside heats up,

• But the concrete inside slows down the heat and keeps it strong.

• This makes the building more fire-resistant than normal steel columns.

2. Where the fire starts matters

• Corner fires are more dangerous because there are fewer other parts of the building to help carry the load.

• Lower floor fires are also worse because those floors are holding up all the weight above them.

Modular Advantage Magazine - September/October 2025

Every two months, Modular Advantage magazine takes a deep dive into a key topic in modular construction, offering interviews and expert perspectives, industry news, case studies, and updates from the Modular Building Institute and its members. This trade publication serves as an essential guide for professionals and anyone interested in the global market for commercial modular and relocatable buildings.

Highlighted features and insights include:

Homes as Essential Infrastructure – a look at government programs in Canada designed to deliver affordable housing quickly.

Building the Future, Offsite – an exploration of how the U.K. is advancing modular construction through public-private collaboration and innovative financing.

POJI and MOKO – examples from Stockholm where modular industrialization is shaping lively, mixed-use neighborhoods.

Boutique Modern – demonstrating efficient, cost-effective modular housing solutions in the U.K.

BoulderMOD – emphasizing workforce training and affordable housing initiatives in Colorado.

Guerdon – showcasing multi-project pipelines in Idaho as scalable modular strategies take shape.

Other articles tackle technical and strategic themes, from waterproofing solutions and accelerating multi-family construction timelines to developer communication strategies and New York City housing challenges.

https://www.modular.org/modular-advantage/

Modular Advantage Magazine - September/October 2025 Issue - Read Here

Casa da Mata - Sustainable Modular Home Made of Wooden Modules, Brazil

Floor Plans
About Kika Camasmie Arquitetura

Project	Casa da Mata
Architects	Kika Camasmie Arquitetura
Builder	MAN Marcenaria, Paraju Construtora
Interior Design	KikaCamasmie + Arq, Studio Sall
Area	32 m² (345 ft²) one module
Photography	Oka Fotografia
Location	Brazil
Year	2023

Sustainability at every step. This project was conceived with a focus on full-circle sustainability. The concept centers on prefabricated wooden modules built by local craftsmen, leveraging their skills and techniques to save both time and cost. By relying on a single material—wood—the construction remains clean, efficient, and quick to assemble, as each component arrives pre-made for easy on-site installation.

Drop Pod - Prefab Home by Inspiral Architecture and Design Studios, Indonesia

Nestled in the lush hills of West Nusa Tenggara, Indonesia, sits a structure that could be mistaken for a prop from a sci-fi blockbuster. The Drop Pod by Inspiral Architecture and Design Studios is anything but a conventional prefab box. With its sculpted curves and purposeful lines, this futuristic dwelling shows how form and function can work hand in hand. Completed in 2025, the Drop Pod takes on one of today’s biggest challenges: creating housing that can be built quickly, works in different environments, and stands up to harsh weather.

One of its most striking features is how it’s positioned. Elevated 60 centimeters on a riverstone base, the home appears to hover above the ground—a smart choice in flood-prone Indonesia. This raised platform not only shields the living space from water damage but also provides a shaded area beneath and allows the structure to sit comfortably on uneven terrain. It transforms a potential weakness into a key design advantage.

Integrated Modular Builders See Stronger Profits

A McKinsey & Company report finds that modular construction firms handling both manufacturing and on-site assembly achieve better profitability than those offering only one service.

By controlling the entire process—from factory production to installation—these integrated offsite construction companies gain greater oversight of quality, scheduling, and efficiency. Because their teams are trained across the full modular system, they can manage larger project scopes internally and rely less on subcontractors, which improves margins.

Profitability is especially strong in specialized sectors such as hospitality and healthcare facilities. Higher construction costs per square meter in these markets increase the benefits of factory-built methods, and competition is often less intense compared with residential construction.

At the same time, advances in technology and tailored solutions are helping modular construction scale up, delivering higher-quality projects and a broader range of building types. Emerging digital platforms also make it easier for companies to link customers with suppliers, while optimizing and customizing designs to suit specific sites.