Modular Manual

A primer on prefabricated construction processes for co-op housing in Canada.

Client:
Co-operative Housing Federation of Canada

Date:
2026

Team:
Joseph Choy
Sam Eby
Toby Evans
Michael Piper
Irina Rouby Apelbaum

What is Modular Construction?

This manual is designed as an accessible, high-level guide for anyone looking to understand Canada's prefabrication industry without needing a background in design or construction.

To build this foundation, we combined industry and academic research with case studies and manufacturer data. We also interviewed experts across design, manufacturing, and construction, cross-referencing their on-the-ground insights with published literature to ensure an accurate and reliable overview.

The guide starts with a brief introduction to prefab before diving into the three most common systems used in Canada: volumetric modular, panelized, and mass timber. For each approach, we explain the mechanics, weigh the pros and cons, and share a real-world case study. We wrap up by comparing the systems side-by-side, mapping manufacturer locations nationwide, and highlighting key factors to consider when choosing the right prefab strategy.

You can access the manual in English here and in French here.

Volumetric Modular

Volumetric modular construction involves building fully finished, three-dimensional units in a factory complete with walls, floors, ceilings, and often even the plumbing and electrical systems. Because so much of the hard work happens before the modules ever reach the site, final assembly is incredibly fast compared to other methods. However, moving these large, finished "boxes" requires careful handling to prevent damage, alongside meticulous planning for transport routes and crane logistics. This approach hits its sweet spot for cost-effectiveness when you're working with small, simple, and highly repetitive designs like studio apartments, though you can certainly achieve more customized layouts if your budget allows for it.

Panelized

Taking a 2D approach, panelized construction uses flat wall and floor panels that are built in a factory and assembled on-site. While these panels can be used with various structural frames, we focused on load-bearing systems where the panels themselves hold the building up. Unlike volumetric modules, these panels usually arrive "bare" without interior or exterior finishes, meaning you will spend a bit more time finishing the building on-site. The major upside is design freedom as you get much more flexibility with your floor plans and exterior look. Plus, flat panels are significantly easier to transport, require less staging room, and can be lifted with smaller cranes, making them a perfect fit for tight or constrained lots.

Mass Timber Post & Beam

Mass timber utilizes large, engineered wood products to create robust, beautiful structural systems. Focusing specifically on post-and-beam construction, this method relies on vertical columns and horizontal beams to carry the building's weight, completely freeing you from the need for load-bearing walls. Because these strong wood beams can span long distances, designers get maximum flexibility to create larger open interior spaces. It is also an incredibly strong framework, making it the go-to choice if you are looking to build taller structures. The main trade-off to keep in mind is the price tag: due to the highly complex structural connections and premium materials, this tends to be the most expensive of the three approaches.

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