One Day Makes All the Difference in Modular Construction

It is time to step into the new millennium and shed old preconceived notions when it comes to modular construction in home building.

This week, Wohlfarth Construction will be building a new home in the Quail Run subdivision in Darnestown. New construction is not new to the Wohlfarth family, who has been building custom homes in the D.C. metropolitan area since the 1930s. What is new about this house is the mode of construction, namely that it is a factory-built modular home that will be “under roof” and assembled in one day.

George Wohlfarth of Wohlfarth Construction makes it clear that this custom built modular home is “not a mobile home. When you say modular home, people get concerned,” he said. “But it is definitely not what you think.”

Scheduled for delivery this week, Quail Run’s new home will arrive in eight boxes at the construction site at 15213 Buckeye Court.

Each of the eight boxes contains a fully-constructed module that will be assembled in sequence by a crane, almost like building blocks.

The modules are nearly completed rooms that are fully-insulated with primed drywalls and painted trim. Finished details are in place like electrical outlets, switch plates and recessed lighting. And, in many cases, vanities, tubs, appliances and cabinetry are already installed within the finished module.

This will be the first modular home that Wohlfarth has built. He had seen them go up in and around Bethesda and other locations, but was not sold on the idea of modular construction until, after two years of research, he came across Professional Building Systems in Middleburg, PA. They are largest home manufacturing facility on the East Coast.

Wohlfarth discovered that there are a number of advantages to modular construction. The modules are built in a factory under controlled conditions, thus they are never exposed to the elements and have a lower risk of mold, mildew and pest infestation.

Constructed on an assembly line in a short period of time, the modules are subject to constant scrutiny and inspection by factory, state and third party inspectors. A big advantage to this kind of construction is the amount of time that is saved.

"This house went through the assembly line in five days," said Wohlfarth.

In addition, more materials are used (30 percent more than in stick built homes) which makes for a sturdier construction. Wohlfarth noted that the modules, transported by truck from Pennsylvania, must be of “sound construction because they are designed to withstand the pressures of road travel.”

The Quail Run community has a long running standard of excellence in custom-built homes since its inception in 1968.

“My father took his carpenters on trips to Williamsburg to study the exteriors and trim work,” said Wohlfarth, “in order to recreate those details here in Darnestown.”

Inspired by the design, custom trim and exterior finish of homes in Colonial Williamsburg, Jay Wohlfarth, Wohlfarth’s father, began construction and development of Quail Run.

“Because of the traditional Williamsburg architecture, beautiful custom trim and Flemish bond brickwork,” said Wohlfarth, “this new home will fit right into the neighborhood.”

The modular home was scheduled to go up today, but the prospect of rain and flooding will postpone the construction until next week. Check back with Patch for coverage of the final construction.