AIIR Products CEO, Trevor Schick, warns the full promise of modular construction will not be realised if HVAC continues to be overlooked.
Modular construction has earned a reputation for solving some of the building industry’s toughest challenges. Faster project timelines, reduced waste, improved quality control, and greater predictability have made it an increasingly attractive option across residential, hospitality, healthcare, and education sectors. Yet one critical obstacle continues to undermine many projects: HVAC.
While HVAC is rarely the headline issue in modular construction discussions, it is often one of the most complex coordination challenges behind the scenes. The irony is that modular construction is designed to simplify project delivery, but HVAC systems frequently introduce layers of coordination, integration, and commissioning requirements that can quickly erode those efficiencies.
The challenge stems from the fact that HVAC sits at the intersection of nearly every building discipline. Mechanical systems must coordinate with structural elements, electrical infrastructure, controls, plumbing, architectural layouts, and increasingly stringent energy performance requirements.
In a traditional construction environment, many of these issues can be resolved during installation. In a modular environment, mistakes are often manufactured into the building itself. Once modules leave the factory, design changes become significantly more difficult and expensive to address. Industry experts consistently identify coordination failures between factory-built and site-built scopes as one of the leading causes of modular project delays and cost overruns.
HVAC introduces a unique layer of complexity because systems frequently cross module boundaries. Ductwork, refrigerant lines, ventilation systems, controls, and condensate management all require seamless integration between individual modules once they arrive on site. Even small dimensional discrepancies can create installation challenges that ripple through project schedules. As modular adoption grows, the importance of early-stage mechanical coordination continues to increase.
Fortunately, the industry is beginning to address these challenges through a combination of smarter system design and improved digital coordination.
One emerging strategy is the use of more modular-style HVAC architectures and form factors. Rather than relying on large centralised systems that require extensive field integration, designers are increasingly exploring distributed approaches that align more naturally with modular building methods. Factory-installed HVAC components can be tested before shipment, reducing commissioning time and minimizing uncertainty during installation.
Digital modelling is also playing a growing role. Improved BIM workflows and multidisciplinary coordination tools allow mechanical, electrical, plumbing, and structural teams to identify conflicts earlier in the design process. This is particularly important in modular projects, where resolving a clash digitally is far less costly than correcting it after fabrication has begun.
At the same time, advances in controls technology are creating new opportunities. Intelligently designed HVAC systems can simplify deployment by adapting to real-world occupancy patterns and environmental conditions after installation, reducing the need for extensive field tuning. Rather than treating commissioning as a one-time event, these systems can continuously optimize performance throughout the building’s lifecycle.
Modular construction will continue gaining momentum as the industry searches for ways to address labour shortages, sustainability goals, and project delivery pressures. However, achieving the full promise of modular construction requires greater attention to one of its most overlooked challenges.
HVAC may not be the most visible component of a modular project, but when coordination is done right, it becomes one of the key enablers of modular’s speed, efficiency, and long-term performance. As modular construction continues to evolve, HVAC systems must evolve alongside it. The future of building is increasingly factory-built, and the future of HVAC is increasingly intelligent, connected, and adaptive.
By combining modular-friendly system designs with AI-powered variable-speed technologies capable of reducing energy consumption by up to 40 percent, project teams can unlock not only faster delivery and simpler coordination, but also meaningful long-term operational savings for building owners.
About the Author
With a background steeped in technology and building expertise, Trevor brings over 30 years of operating experience across multiple industries to his role as CEO of AIIR Holdings. Most recently Trevor served as the COO of Real Estate Operations for Amherst Holdings, where he led all Operations, Technology, and Marketing for the Single-Family Rental and Bungalo Direct to Consumer platforms. This role included significantly growing the platform while creating operating leverage across the acquisitions, construction, leasing, and sales teams. Prior to Amherst, Trevor held senior-level supply chain roles at large global organizations such as Hewlett Packard Enterprise, Motorola Mobility, EMC, and Apple.