MODLOGIQ & Becker & Frondorf Deliver Athens Medical Campus 1.5 Years Sooner with Real Progress Data and Modular Construction

MODLOGIQ, a leader in Smart Off-Site modular construction, and Becker & Frondorf (B&F), a project management and cost estimating consultant, were hired by Memorial Health Systems to construct the Athens Medical Campus, the largest permanent facility built using Smart Off-Site construction in North America. Once complete, the 4-story 100,000 square-foot campus will include a state-of-the-art Emergency Department, Outpatient Services, Specialty Care, Primary Care, Obstetrics, Gynecology, Ophthalmology, administrative offices, and an attached parking garage.

By choosing Smart Off-Site construction, Memorial Health Systems not only streamlined the construction process but also contributed to environmental sustainability by preventing 400 tons of greenhouse gas emissions and recycling 230 tons of construction materials. Furthermore, B&F’s recommendation of advanced progress tracking technology from OnsiteIQ enabled Memorial Health Systems to accelerate their construction timelines significantly, leveraging early detection and prevention of numerous potential schedule delays.

Modular construction offers distinct advantages over traditional construction, including accelerated schedules and cost certainty, as fabrication is predictable and can commence far in advance of breaking ground. However, modular construction plant facilities are typically located many hundreds of miles away from the permanent site location. And since project team members are also dispersed in different geographical regions, a siloed off-site construction process can create a situation with limited visibility into manufacturing progress.

Constructing a state-of-the-art, 100,000-square-foot facility in a prefabrication plant 1,000 miles from the actual construction site is daunting. Memorial Health Systems lacked visibility into construction progress. Furthermore, collaboration with owners representative B&F, who oversaw the entire project, was challenged in adequately monitoring progress since the bulk of construction occurred far from the final location. Quality control, normally conducted on-site, had to be managed within a manufacturing setting—a feasible task for MODLOGIQ but impractical for most others. In addition, shipping the build’s modular components and ensuring precise installation of those pre-fabricated components introduces it’s own set of unique complications. Consequently, MODLOGIQ and B&F sought a partner to bring these teams together and provide additional peace of mind with effective collaboration to mitigate on-site delays stemming from potential quality issues.

At the heart of solving for disparate project management and progress monitoring is a single-source of truth that centralizes actual progress at scale. To enhance collaboration between Memorial Health Systems and project stakeholders and to provide necessary visibility, transparency, and insights throughout the entire construction process, B&F strategically partnered with OnsiteIQ to support MODLOGIQ’s entire assembly process.

This collaboration brought several advantages. First, Memorial Health Systems and B&F gained instant remote visibility into construction progress through near real-time virtual walkthroughs, 360° photo documentation, and weekly progress reports. Additionally, B&F could now identify potential schedule delays by reviewing the quality of off-site construction, leading to highly productive team meetings empowered by a single source of truth—crucial for maintaining consistent alignment. Before shipping modular components, MODLOGIQ secured an irrefutable record of construction quality, a referenceable point in time to be leveraged for assembly, and also insurance against any potential damage incurred during transport. Finally, as the construction transitioned from offsite to onsite assembly, MODLOGIQ’s project management team maintained the same level of oversight as if they were still in their facility, despite the project being thousands of miles away.

While constructing the modular components of The Athens Medical Campus, Becker Frondorf identified several potential issues. Notably, water had infiltrated an area and got behind finished drywall, posing a serious risk. In a hospital setting, where there is zero tolerance for microbial activity, unchecked moisture could lead to mold growth, potentially causing significant delays in the onsite assembly due to necessary leak and mold remediation, as well as drywall rework. However, thanks to the use of OnsiteIQ, which provided an extra layer of assurance, this issue was flagged early on by B&F. MODLOGIQ was then able to promptly locate where the leak originated from and re-sealed that area to make it watertight. By catching this water infiltration issue up front, they avoided any need for extensive rework after the facility became operational.

In another instance, a large section of temporary exterior plastic sheeting blew loose while spray-on fireproofing of the structural steel columns and beams was curing. B&F flagged the sheeting issue while reviewing data from one of OnsiteIQ’s comprehensive walkthroughs that had been performed the day before. They were then able to quickly alert the MODLOGIQ team to secure and reinstall the plastic sheeting so the fireproofing could properly cure. Spray-on fireproofing material must be cured under strict temperature and humidity controls to ensure proper adherence to steel, and to maintain the desired non-combustible properties. Improperly cured and non-compliant fireproofing would require redoing the entire process, likely onsite and under time constraints.

OnsiteIQ’s Progress Tracking offers a sophisticated layer of analysis, setting it apart from traditional methods such as simple 360-degree capture or manual inspections. Leveraging OnsiteIQ, Becker & Frondorf and MODLOGIQ were able to flag construction activities that were behind schedule compared to OnsiteIQ provided percent (%) complete figures, provided through Progress Tracking, which is crucial for maintaining project timelines. For instance, they identified numerous tasks that superintendents planned to address at the permanent onsite location. By highlighting these tasks early on—tasks that would have delayed the schedule if performed onsite—they were completed during the prefabrication phase, thereby saving significant time.

A critical benefit of OnsiteIQ is its ability to provide a snapshot in time—far beyond what is achievable by taking occasional pictures and notes during site visits. With OnsiteIQ, project managers can virtually revisit specific moments or locations within the construction life cycle to visually verify if tasks were completed by certain dates, consistently providing definitive answers that would be otherwise extremely difficult to ascertain. Additionally, MODLOGIQ utilized OnsiteIQ’s reporting functions to deliver cohesive comprehensive updates to ownership, including progress reports and time-lapse documentation of the construction phases. The most substantial benefit, however, was in providing clients with a transparent view of progress during the prefabrication phase.

The MODLOGIQ and B&F Athens Medical Campus project showcases the power of modular construction, proactive project management, and innovative remote monitoring technologies partnering with OnsiteIQ. By delivering the project 1.5 years ahead of schedule, MODLOGIQ and B&F not only demonstrated the efficacy of Smart Off-Site construction but also set a benchmark for future healthcare facility projects.

The strategic partnership with OnsiteIQ enabled real-time insights and proactive issue resolution, which were critical in maintaining project momentum and adherence to high quality standards. The success of this project highlights how integrating advanced monitoring technologies can enhance construction processes, delivering faster, more efficient project delivery outcomes without compromising quality.