Why the supply format matters
A modular building can be supplied as factory-complete units or as flat-pack sets. Factory-complete modules reduce site work, while flat-pack supply uses shipping volume more efficiently and can simplify delivery to projects with restricted access. The correct choice depends on programme, labour availability, transport route, local lifting capacity and the level of factory completion required.
Flat-pack should not be treated as a shipping decision alone. Structural connections, panel sequence, MEP interfaces, waterproofing and installation documentation must all be developed around the selected supply method.
Typical loading capacity
For a standard module approximately 2.40 m wide and 5.95–6.00 m long, a 40-foot high-cube container can typically carry up to eight basic flat-pack sets when the units do not contain pre-installed bathrooms or kitchens. The exact quantity changes with wall-panel thickness, floor and roof build-up, loose accessories, doors, windows and the packing method.
Road transport may allow approximately 10–12 basic sets per truck on suitable routes, but vehicle dimensions, axle loads and national transport rules must be checked for every destination.
- Confirm the final packing list before booking transport.
- Separate fragile doors, glazing and sanitary items where required.
- Protect painted or galvanized surfaces against movement and moisture.
- Identify every package by building, floor, module and installation sequence.
What must be included in the package
A complete flat-pack package is more than the primary frame. It should identify roof and floor cassettes, columns, wall panels, flashings, gutters, connection plates, bolts, sealants, trims and all project-specific accessories. Electrical and plumbing components must be coordinated with the level of completion agreed in the commercial scope.
Numbered production drawings, a packing list and a clear installation manual reduce handling errors and help the site team build in the intended sequence.
Planning installation before dispatch
The installation team needs a level foundation, safe lifting equipment, weather protection for open packages and enough space to sort components. Assembly output varies with crew experience, access, building complexity and weather. Bathrooms, kitchens, corridors and multi-storey buildings require more coordination than open-plan accommodation or office units.
The most reliable programme is prepared after design approval, packing strategy and site responsibilities are confirmed. This prevents an optimistic factory schedule from becoming an unrealistic completion promise.
Information required for an accurate quotation
Provide the delivery country, module quantity, intended use, layout, insulation target, electrical standard, sanitary scope and required Incoterm. For remote projects, also identify port limitations, final road access, unloading equipment and whether an installation supervisor is required.