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The off-site construction process is incredibly enlightening for anyone who visits our production facility. When you visit and see the process in person, you’ll know you’ve made the best homebuilding decision.
Even though there is a systematic process behind the building of your home, it is not lost on Virginia Building Solutions that behind every home, there is a family. That is why we treat every home we build as if it were our own.
building step by step
Floor systems are a modular home’s underpinning. All other parts of a home are dependent upon a well-built floor. Our floors are built at the same time as the walls and roof systems. Our floors are constructed on jigs, which ensures that wood members conform to exact standard floor widths.
The floor systems are then double-banded at the perimeter for extra strength and are constructed with 2-inch by 10-inch wood members 16 inches on center. Our floor decking is comprised of sturdy 3/4-inch tongue and groove OSB (Oriented Strand Board), which is glued and screwed to the floor joists.
Walls support a home’s roof system and dictate the framework of the floor plan. Exterior walls are made up of 2-inch by 6-inch studs, whereas 2-inch by 4-inch studs are used on the interior walls at 16 inches on center. Dry wall is adhered to the studs by a special foam seal adhesive. This technique allows for a smooth, flawless drywall finish with fewer nail pops. The walls are then lifted by a crane to the production line and set into place on the floor section. They are fastened directly to the floor system, perpendicularly, as prescribed by a nailing a schedule
Our roof systems are engineered to fold down flat and require an integral self-supporting rafter system.
A Microlamb® beam may be installed where there are larger, more open areas and to support heavy weight loads. This also is where front and rear overhangs are installed. The roof and ceiling system is then lifted by crane, set and then lag-bolted, fastened, and strapped to the perimeter top ceiling plate and its exterior wall.
Whatever home design you select, your home will have water supply lines, waste lines and venting stacks installed.
All lines are pressure-tested to the required 95 psi and 100 psi for water lines and 35 psi for waste lines to ensure against any leakage. Water supply lines and waste lines are installed in kitchens and bathrooms. Any second-story water and waste lines must then be connected on-site by your builder once the home is delivered and set. Your builder is responsible for connecting your well or public water to your homeYour home will be fully pre-wired at the production facility as prescribed by the NEC code and according to your home’s electrical plan.
Standard 12/2 wiring is used and “pulled” through the roof system then fed through drilled holes in the wall cavities throughout the home. Electrical wire is run to junction boxes where switches, smoke detectors, lights and outlets are located and electrical components are installed and connected.
Based on your home’s floor plan, the electrical panel with circuit breakers is later installed after your home arrives at the site.
During this stage of production, interior walls are finished.
Drywall is installed, glued and fastened to the studs. After that, tape and joint compound are applied to the joints or seams. Corner bead, which is a 45-degree angled thin piece of metal or curved bead, is affixed to all drywall corners. This provides for crisp, clean wall corners. In this stage and if the floor plan dictates, a fireplace is installed in a prescribed chase areaR-21 batt wall insulation and R38 ceiling insulation are installed in your home. <Read More>
All open areas in the wall cavities are insulated. The entire exterior of the home, including the marriage walls where the modular units will be joined together, is sheathed, glued, and fastened with OSB, and caulk is applied under the walls.
All of the modular units receive exterior air infiltration barrier, known as house wrap and exterior doors and windows.
Installing these components takes some preparation, and doing it correctly guards against external elements. Energy efficient windows are installed, leveled, glued and fastened into place. Door openings are prepared, and the door sills, thresholds and flashing are installed and caulked around the openings.
Vinyl siding is a top choice among homebuyers and is a low-maintenance standard feature in Virginia Building Solutions’ homes.
Cement board siding can also be installed at the manufacturing facility as well. Another option is having brick, masonry or stone treatments installed on-site.
Low-maintenance ventilated vinyl soffit and aluminum fascia are installed on overhangs, and decorative shutters are mounted if it’s included in your home’s plan.
The roof is comprised with 7/16-inch OSB sheathing that is nailed into place.
Next, drip edging is attached, ice and water shield is installed around all eaves, synthetic felt paper is installed over the entire roof and shingles are installed.
A flood of activity happens during the final finish of your home.
Finish line workers are accomplishing tasks simultaneously to get the modular units ready for the final stages of construction. Numerous varieties of base trims, window trims, and casings are installed, and walls are sanded.
Craftsmen install cabinets in the kitchen and bathrooms by screwing them into studs and blocking behind walls. After making careful measurements, countertops are installed.
In this stage, electrical outlets, switches and switch plate covers are installed.
All overhead lighting fixtures are installed and connected to the various junction boxes. The range hood in the kitchen is connected and other appliances that were ordered for the home are installed.
As each of the home’s individual modules look more like the interior of a home, almost all the details have come together.
Final touches to kitchen and bath plumbing are completed, sinks are installed, and faucets are connected to supply and drain lines.
Entering this stage, each modular unit is given a thorough, top to bottom cleaning.
Windows are washed, mirrors are polished and floors are mopped. All loose ends are completed so your home is as clean as it can be before it hits the road.
With off-site production complete, attention now turns to protecting the modular units during transport to the home site, where the final assembly takes place.
Each unit is wrapped with a weather-resistant membrane that is stretched around the entire exterior of the unit structure. The units are then carefully lifted, placed and secured onto a specially designed transporter for shipment to the home site.
delivery and installation
Logistical planning and preparation takes place before your home ever leaves the production facility. Routes are traced and permits are applied for to ensure legal transportation through the states and localities that your home will be traveling through.
The manufacturer’s transportation coordinator is in close contact with Virginia Building Solutions to establish the best route and to schedule the escort car service, the crane to set the units and the set crew. The coordinator also monitors upcoming weather conditions to ensure the home set goes smoothly.
On installation day, the builder’s install crew of usually 6 to 8 people help set the home.
Depending on the home’s number of units, temporary staging may take place first. Staging is when modular units are temporarily located nearby before being delivered to a home site.
Once the crane is in place, materials covering the units are removed and, one-by-one, the modular units are strategically and gently lifted by the crane and set onto the home’s foundation. For two-story homes, electrical, plumbing and waste lines are connected before the units are fully set.
Next, the roof is raised by the crane, and hinged knee walls that support the roof are put into place, secured and fastened. Gable end walls are installed. If the home has dormers or porch gabled roofs, they are installed with the crane as well. Finished roofing is completed, along with the installation of the ridge vent so the home stays weather-tight. Your home is then secured and affixed to the foundation sill plate and per a nailing schedule.
Depending on the complexity of your home, it is delivered to your home site approximately 70-80% complete. While there is still work to be done on-site, moving in can happen within 90 to 120 days after installation. More time may be required depending on the scope and complexity of the project. t and after the home is set. Multiple factors may be involved before certificate of occupancy is granted by the local building authority. Please consult your VBS project manager for more information.
Your home is comprised of modular units that come together to form its floor plan. Where one unit meets another, a marriage or mating wall is created. At these transition points, there is approximately an area of 2 feet between the marriage walls that must be completed on-site. In these areas, drywall, case openings and flooring are installed and finished to blend these areas seamlessly.
Paint touch-ups and repair of drywall cracks, which are typical will take place during this time. As required, your builder may install baseboard and other molding finishing touches in the home. If your home has carpeting, it will be installed on-site along with any other custom flooring treatments.
Following the set, there is a host important things that VBS must complete before you can move in. <Read More>
Your builder must finish the small areas of siding between your home’s foundation sill plate and your home as well as the areas between a home’s first and second story.
Exterior trim features are completed, along with the installation of rake boards on gable overhangs, corner boards and perimeter trim boards. Brick or stone accents are also completed on-site.
Virginia Building Solutions will also be responsible for the connection of all plumbing, waste lines, and electrical services of your home. This includes connection to the main panel and installation of all mechanical equipment, such as your home’s furnace, HVAC or air conditioning.
Virginia Building Solutions will perform a final walk-through of your home with you so you will have the opportunity to point out any things that may need attention. After all follow up work is finished, VBS will obtain the certificate of occupancy for you from the local building department. Welcome to your new home!
*All other work done on-site, such as garages, desks and porches, is agreed upon by VBS and the customer prior to sale.
Request a physical version of the brochure by clicking on the link below and filling out the contact form to learn how VBS can build you the home of your dreams.
Model Center Hours:
Mon – Fri: 10am to 5pm
Saturday: 10am to 4pm
Appointment recommended
Sunday: Closed
After Hours By Appointment
Model Center Hours:
Mon – Fri: 10am to 5pm
Saturday: 10am to 4pm
Appointment recommended
Sunday: Closed
After Hours By Appointment
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