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Modular Building Project Spotlight: JTED @ S.T.A.R. Academic Center

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New Modular Building for JTED Construction Program

On March 7th, Pima County JTED will have its ribbon cutting ceremony for its new modular building, which you'd never was factory-built.  Located next to the S.T.A.R. Academic Center in Sunnyside Unified School District, this premier new facility houses JTED's Construction program.  Construction education is so important to mitigate the current shortage of skilled trade labor.  That we were able to complete the building in record time to get these students a place to work was a major advantage for students, instructor Jim Luckow, and for Dr. Alan storm and his talented team at Pima County JTED.  The cost savings were a huge factor in making this a possibility, too.

New Pima JTED Construction Program at S.T.A.R. Academic Center

This is a minute and a half long video about the program, which already has more than 60 students signed up:

JTED @ STAR Campus modular building appears in one morning

This video shows the installation of the building sections - an innovative and efficient building process to save time and cost.

Key benefits of ESB Design+Build modular building construction:

  • Lower cost
  • Shorter construction timeline
  • More design control and more seamless design process
  • Faster design approval through the State of Arizona
  • Greener building process that reduces waste and increases overall project sustainability
  • Greater structural strength since buildings are engineered to withstand transport
  • Increased building quality due to indoor, assembly-line-like construction
  • Reduced campus disruption for less distraction and greater productivity
  • Support the local economy by building with local contractors
  • Meet diversity goals by building with a woman-owned small business

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Article: New Yuma Clinic

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CEO: New health center fills need in north Yuma County

Rachel Twoguns (@RTwoguns) wrote a lovely Yuma Sun article about the medical need being served by a new Yuma clinic building ESB Design+Build completed at the beginning of this year: http://www.yumasun.com/news/ceo-new-health-center-fills-need-in-north-yuma-county/article_7e76ab70-9328-11e6-8fa6-5b6176ac09b9.html

A few highlights from the article about the new Yuma clinic building:

“Since our grand opening in April of 2016, Sunset providers have provided primary and preventive medical care services to approximately 2,890 patients,” said SCHC CEO David Rogers. “Unfortunately, area residents suffer economic, social, cultural, linguistic, educational, and transportation barriers in access to care. Overall poor health outcomes are reported due to lack of access to health care.” “The new Sunset Yuma North Clinic is approximately 10,000 square feet with 16 exam rooms giving the north area of Yuma a better access to primary and preventive health services,” Rogers said.
"Construction on the building first began in the middle of September of 2015, and ended around February of this year."
“After building construction began, the first hurdle SCHC encountered was realizing the location they had originally chosen for the building was not ideal, and it would be better to move it to the other side of the project site,” said CEO and co-owner of ESB Design+Build, Lois Morey. “Because the majority of the building is built in a factory, ESB was able to accommodate this change more readily than site-built contractors, and we even took it one step further and provided a mirror image of the original plan at no additional charge to SCHC. Sunset Community Health Center personnel were really great people to work with, and everyone at ESB is delighted to have been part of this community health care expansion.”
"In addition to the 16 exam rooms, the Avenue B location of SCHC contains two triage rooms, two provider suites, an entry, waiting and reception area, two labs and additional space for LabCorp, two sets of restrooms, two open-concept nurses’ stations and several other rooms for office, gathering and utility space." Click the link above to read the whole article!

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MBI’s Permanent Modular Construction Report 2016

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Favorite excerpts showcasing cost effectiveness and technical innovation and sustainability of permanent modular construction:

"Permanent Modular Construction (PMC) – PMC is an innovative, sustainable construction delivery method utilizing offsite, lean manufacturing techniques to prefabricate single or multi-story whole building solutions in deliverable module sections. PMC buildings are manufactured in a safe, controlled setting and can be constructed of wood, steel or concrete. PMC modules can be integrated into site built projects or stand alone as a turn-key solution, and can be delivered with MEP, fixtures and interior finishes in less time, with less waste and higher quality control compared to projects utilizing only traditional site construction." "In order to get the replacement clinic operational as quickly as possible, Coney Island Hospital chose offsite construction as the solution. The “offsite” construction process ensured shorter site installation time as all the modules had been built together to ensure precision fit and finish at the plant before being deconstructed for transport." "Building this facility in a controlled environment and away from the site helped reduce time and costs in project management and general conditions." "Growing population demands brought expanded services to Southern Coos Hospital by this medical clinic addition, making the timeline for completion of the facility aggressive and imperative. Creating a fully turnkey facility in such a short timeline is a feat that could only be completed by modular construction." "Offsite construction simultaneously completed with on-site earth work and creation of a stem wall foundation allowed for a quick occupancy of the facility. Profitable use of the clinic was achieved quickly through a shorter timeline for construction."

Link to the August 2016 issue of Modular Advantage: http://www.modular.org/documents/Modular_Advantage/ModularAdvantage_Pub_3-Q_DIGITAL.pdf

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Ribbon cutting for new modular building | Santa Rosa de Lima Mission in Tucson

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Johanna Willett of the Arizona Daily Star did a fabulous job reporting on the Pascua Yaqui traditions that took place on Sunday, August 28th, 2016.  ESB Design+Build was honored to have been invited to attend the beautiful ceremonies.  We couldn't take too many pictures at the modular building dedication because it isn't allowed to photograph or video the cultural traditions, but ESB's Facebook page has a few initial photos of the exterior of Santa Rosa's new building prior to any landscape work. We are happy this opened in time for parishioners to celebrate the festivals of Santa Rosa and San Ignacio, which began with traditional Pascua Yaqui ceremonies, continued with a 9:30 A.M. Catholic mass, and finished with an all-day fiesta filled with delicious food and camaraderie.  We anticipate getting more photos of the new modular building and creating a Project Showcase page soon. Here is a link to her article: http://tucson.com/lifestyles/faith-and-values/pascua-yaqui-church-celebrates-new-hall-old-traditions/article_20a7b74e-2956-5060-8e48-5d585b2d9212.html 

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New Recycling Program | Modular builder goes even greener

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In addition to the information we just posted in the Sustainability 2016 article about the green benefits inherently associated with being a modular builder, ESB Design+Build is proud to have implemented a new recycling program to make our already green operations even greener.  In partnership with Republic Services, CFS Metals Recycling, and Pima County, ESB is able to responsibly recycle and dispose of all materials used in the factory for fabrication of our prefab buildings. In rolling out this program, I realized it is easy for small or local businesses to put green initiatives on the back burner for a lot of reasons, including lack of time, misconception that it may be expensive to implement or maintain, concerns for lack of conformance to the new policy, and general low prioritization.  Given our experience, ESB Design+Build is committed to look for ways to help fellow Tucson and Arizona small businesses understand what it takes to be as green as they can be.  We are actually saving money compared to what we were spending on trash services before, and we are coming together as a team to encourage compliance by our workforce. Stay tuned to this modular builder on the news site for a post about questions to ask and language to make sure you have in your agreement when you're signing up for a new recycling and waste contract.

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Performance of Modular Prefabricated Architecture | Sustainability 2016

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At a sustainability series event I attended in Tucson, AZ, I was questioned about the sustainability differences between ESB's construction methodology (technically categorized under the definition of modular (3D) prefabricated) and typical site-built construction.  I found this article by Edmond Boafo, et. al. online at MDPI, an open-access publishing site.  It addresses many of the lesser-known advantages and challenges of the prefabricated building industry, which includes modular construction methods like those ESB Design+Build uses.

Full Text: Performance of Modular Prefabricated Architecture: Case Study-Based Review and Future Pathways

Abstract:

"Even though tightened building energy efficiency standards are implemented periodically in many countries, existing buildings continually consume a momentous quota of the total primary energy. Energy efficiency solutions range from material components to bulk systems. A technique of building construction, referred to as prefabricated architecture (prefab), is increasing in reputation. Prefab encompasses the offsite fabrication of building components to a greater degree of finish as bulk building structures and systems, and their assembly on-site. In this context, prefab improves the speed of construction, quality of architecture, efficiency of materials, and worker safety, while limiting environmental impacts of construction, as compared to conventional site-built construction practices. Quite recently, a 57 story skyscraper was built in 19 days using prefabricated modules. From the building physics point of view, the bulk systems and tighter integration method of prefab minimizes thermal bridges. This study seeks to clearly characterize the levels of prefab and to investigate the performance of modular prefab; considering acoustic constrain, seismic resistance, thermal behavior, energy consumption, and life cycle analysis of existing prefab cases and, thus, provides a dynamic case study-based review. Generally, prefab can be categorized into components, panels (2D), modules (3D), hybrids, and unitized whole buildings. On average, greenhouse gas emissions from conventional construction were higher than for modular construction, not discounting some individual discrepancies. Few studies have focused on monitored data on prefab and occupants’ comfort but additional studies are required to understand the public’s perception of the technology. The scope of the work examined will be of interest to building engineers, manufacturers, and energy experts, as well as serve as a foundational reference for future study."

Keywords:

prefabricated architecture (prefab); modular; energy; thermal behavior; acoustic constraints; seismic resistance; life cycle analysis

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Family business polishes modular construction’s old image

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Article Link: Marana business polishes modular construction's old image

Patty Machelor did a phenomenal job captivating what we do at ESB Design+Build with her article, "Marana business polishes modular construction's old image," in the Arizona Daily Star. Here is a snippet:

  A family-owned business in Marana has done more than move beyond simple modular construction: It’s done away with the term altogether. ESB Design + Build — formerly ESB Modular Manufacturing — offers custom-built commercial structures ranging from single classrooms to three-story medical facilities and specialized military buildings. The decades-old business includes three generations of women and several members of their extended family. “The way that modulars have evolved, it’s not just a portable little building anymore,” said Alan Johnson, an ESB foreman who has been with company since 1991. “These are all permanent buildings. We’re able to create a really nice product for people at a decent price." ...
With an annual growth rate of about 7 percent, ESB uses its 44,000-square-foot facility at 11280 W. Adonis Road to construct buildings that are then moved on-site. At any given time, 32 to 50 people work full time for the company, including inmates from a nearby minimum-security prison.
A recent ratings report for the General Services Administration gave ESB a top rating for nonresidential construction and included a survey of 19 customers who all gave positive feedback for order accuracy, delivery and timeliness and product quality.

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ESB Performance & Recommendations

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ESB Design+Build Letters of Praise

The image above is a Wordle that increases the size of a word based on its frequency of use in a body of text. The text I used to generate this graphic included the bodies of all letters of recommendation our customers have written over the past decade.

ESB Independent Performance Report - TOP QUINTILE!

In addition, a recent Open Ratings report, an independent report of a firm's performance based on customer feedback directly to a third party, ranked ESB Design+Build's performance in the top quintile against our peers for nonresidential construction (SIC 1542). Our 19 customers independently surveyed gave us 100% positive feedback for order accuracy, delivery/timeliness, quality, and responsiveness. ESB Design+Build received absolutely no negative feedback from all independent surveys ever completed on our behalf. The industries from which the independent feedback for ESB was obtained include:
  • Religious organizations
  • Community colleges
  • Head Start centers
  • Executive offices, local government
  • Individual and family services
  • Presbyterian churches
  • General medical and surgical offices
  • Mayor's offices
  • Facilities support services
  • Preschool centers
  • Regulation, administration of transportation, local government
  • Catholic churches
  • City and town manager's offices

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Business changing perceptions – Inside Tucson Business

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Brad Allis' article from last week's feature in Marana News was published today in Inside Tucson Business with a brand new family photo. Take a look! http://www.insidetucsonbusiness.com/news/business-changing-perceptions/article_ce28033a-9f8b-11e5-b971-a74fd464c9f4.html Here is a little preview:

Lois Morey is the CEO and co-owner of ESB along with her mother, Patricia See, and her brother, Paul See, and she runs the company her parents founded in 1984. Cecil and Patricia See came to Arizona on a vacation in 1984 and decided to stay. They initially went into business as residential contractors, repairing and remodeling manufactured homes. Paul joined his mother and father in 1985 and was a key contributor to ESB’s growth. Soon at the behest of their clients and vendors they began offering a wider array of services including site preparation, utility work and installations.

In 1991, they became licensed as a manufacturer of modular and prefabricated buildings and opened their first shop. In 1994, they moved to Marana and began work on the 28,000-square-foot factory they occupy to this day.

As Marana has grown, so has ESB.

“It was just bare ground, and we built everything up,” said Morey.  “We were here before all the houses were here.”

ESB Design+Build is a general contractor that plans, designs and constructs buildings using hybrid on and offsite techniques. This allows ESB to cut down on construction time and get buildings built in a more efficient and cost effective manner.

They are also able to serve as a one-stop shop. They can both design and construct a project, taking a project from the idea stage to the finished building. 

“It’s more of a seamless process,” said Erica Morey. “We are the construction manager, and we also have the resources and long-term relationships with other contractors, so we can reduce the project’s timeline.”

The main website for Inside Tucson Business is http://www.insidetucsonbusiness.com

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Family owned business changing perceptions – Marana News

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Brad Allis of Tucson Public Media wrote a compelling article about ESB Design+Build entitled "Family owned business changing perceptions," which was published in Marana News on December 2, 2015. The article is quoted directly below, or you can visit the following link to view the story on the Marana News website, http://www.tucsonlocalmedia.com/marana/article_dae9b402-9864-11e5-be8d-b7e1242b5adf.html. Posted: Wednesday, December 2, 2015 4:00 am

ESB full factory upper level

Photo courtesy of ESB Design+Build

ESB Design+Build

Through the years, Marana business ESB Design+Build has grown by offering high-quality prefabricated buildings at a good price. The buildings can be assembled quickly but are well built and designed to last.

The story of ESB Design+Build is a story of family. Well, family and adaptability. Family is at the core of what ESB Design+Build is all about. The company was founded and is still operated by the same family. In fact, walk into their office in Marana and you are bound to see three generations hard at work.

Lois Morey is the CEO and co-owner of ESB along with her mother, Patricia See, and her brother, Paul See, and she runs the company her parents founded in 1984. Cecil and Patricia See came to Arizona on a vacation in 1984 and decided to stay. They initially went into business as residential contractors, repairing and remodeling manufactured homes. Paul joined his mother and father in 1985 and was a key contributor to ESB’s growth. Soon at the behest of their clients and vendors they began offering a wider array of services including site preparation, utility work and installations.

In 1991, they became licensed as a manufacturer of modular and prefabricated buildings and opened their first shop. In 1994, they moved to Marana and began work on the 28,000-square-foot factory they occupy to this day.

As Marana has grown, so has ESB.

“It was just bare ground, and we built everything up,” said Morey.  “We were here before all the houses were here.”

ESB Design+Build is a general contractor that plans, designs and constructs buildings using hybrid on and offsite techniques. This allows ESB to cut down on construction time and get buildings built in a more efficient and cost effective manner. They are also able to serve as a one-stop shop. They can both design and construct a project, taking a project from the idea stage to the finished building. 

“It’s more of a seamless process,” said Erica Morey. “We are the construction manager, and we also have the resources and long-term relationships with other contractors, so we can reduce the project’s timeline.”

Today, the company employs between 30-45 employees, most of whom have been with the company a long time. Every member of the leadership team has been there for at least 13 years, with some being there over 30. Their newest foreman will soon celebrate his10th anniversary with the company. All of that is by design.

“They get treated well, so they treat us very well. They are a mainstay of our business,” said Lois Morey. “We could not operate without them.”

Recently, Lois’ daughter Erica joined the team. Following her earning her masters degree from the Eller College of Management at the University of Arizona, she joined the business to aid in marketing and new business development. Prior to her arrival, all business was generated via competitive bidding and recommendations of past customers.

The company re-branded themselves ESB Design+Build to emphasize both of their strengths. 

Although general contracting, site development, modular manufacturing and installation is what they do, their ability to design the building from scratch and deliver a turnkey project is a key component of what they provide.

Many have a preconceived notion of what modular buildings look like and what they can be used for. ESB is trying to change that.

“We want to build buildings that you cannot tell were ever built piece-wise,” said Erica Morey. “That’s why we feel we are a strong competitor to site built construction. It is not like it’s a box on wheels that looks like a prefabrication, it’s a real building that was just more efficiently constructed.”

The company recently received its third contract from Mohave Educational Services Cooperative, Inc. The contract simplifies and accelerates new building procurement for Arizona schools and government agencies. This is the 11th year that ESB Design+Build, a woman-owned small business based in Marana, has been a contracted vendor for Mohave.

Among the many projects that ESB has completed for Mohave members are nine new JTED Buildings, including a culinary arts building at Santa Rita High School.

ESB Design+Build most recently completed a 7,750 square-foot classroom building at Marana High School. They have done several projects for Marana Unified School District.

While most of their projects tend to be in the 8,000-10,000 square foot variety, they have done some on a larger scale, including a three-story medical office building in Tuba City. 

ESB recently finished the third phase of a four-phase project for Diné College in Northern Arizona. 

Their experience with Diné College illustrates how they attract a lot of their business. For its first project, the college had a sudden need for administrative space. ESB was able to complete the project quickly and with a high level of quality that impressed the school administration.

 “Many of our customers come to us with a new building project because they have a very short time frame and an immediate need for help,” Lois said. “Since our company provides both design and build services for new projects, we have complete control over the process and can expedite construction. Once we begin to work with new customers, our dedication to their project and our willingness to jump through hoops to provide a beautiful, high quality building gets their attention. Oftentimes, once we provide our first project, the customer will return over and over again because of our proven quality, dedication to their project, and response time.”

Their skill and ability to adapt over time and to their customers’ needs have established their business, but the added family touch is what sets them apart.

“Working with family is completely different than working elsewhere,” said Erica Morey. “We have a very close family, and we trust each other. This trust, mutual respect and the alignment of our values makes our doing business together exceptionally functional.

“I enjoy being able to give my mother and grandmother a hug every day,” she added. “Plus, seeing them every day makes it easier to coordinate family gatherings outside of work.”

For information about ESB Design+Build, visit their website at www.esbdesignbuild.com.

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