- 809m² accommodation space across nine apartments and three floors.
- 21 modules installed in just four days.
- Roof terraces: 100m² of external space.
- Green roof area: 20m² integrated into first-floor module.
- Factory completion: 90% of works finished off-site.
- Largest modules: 15m long, weighing over 20 tonnes.
- Transport logistics: Over half of loads escorted due to size.
Off-Site Innovation at Knaphill Apartment Complex
Reds10 successfully delivered a 809m² modular apartment complex in Surrey, showcasing the power of Modern Methods of Construction (MMC) in residential development. Spread across three floors, the nine apartments feature roof terraces, bolt-on balconies, and a green roof area, combining functionality with sustainability. Built from original traditional design drawings and adapted using BIM Level 2-compliant Revit Architecture, the project achieved 90% completion in factory conditions, ensuring exceptional quality and speed.
Delivering a High-Quality Living Space
The modular units provide 809m² of accommodation space, arranged across nine apartments over three floors. Each apartment was designed to maximise comfort and functionality, with the top-floor apartments featuring roof terraces that offer 100m² of external space. These terraces were integrated into the first-floor modules during manufacturing. To further enhance outdoor living, bolt-on balconies were included, providing additional external space for residents. An extra green roof area of 20m² was also incorporated into the first-floor module roof, contributing to sustainability and visual appeal.
Advanced Modular Design and BIM Integration
The bin and bike stores were constructed with factory-fitted concrete floors, ensuring durability and precision. The modular design was developed from original drawings intended for traditional construction and adapted by Reds10’s in-house design team using both traditional 2D CAD and BIM Level 2-compliant Revit Architecture. Thanks to the large size of the production facility, each floor could be laid out in full, maximising factory content and efficiency. This allowed the workforce to work simultaneously on all floors, achieving high levels of factory finishing, with 90% of works completed under controlled factory conditions.
Large-Scale Modules and Precision Handling
One of the unique advantages of Reds10’s premises is the scale of the facility. With over 50,000 square feet of clear-span space in each of the two production facilities, modules can be loaded using cranes. This capability enables the handling of very large modules—up to 18 metres long, 5 metres wide, and 4.2 metres tall—with minimal stress, reducing the risk of damage during transit. For the Surrey Apartment Complex, the largest modules measured 15 metres in length and weighed over 20 tonnes.
Overcoming Site Constraints with Careful Planning
As with most residential infill projects, the site was highly constrained and required meticulous planning, coordination, and timing to minimise disruption to residents and local facility users. More than half of the transport loads were escorted to the site due to their size. Installation was carried out using a 350-tonne crane with Super Lift and 140 tonnes of ballast. Despite these challenges, the 21 modules were installed in just four days, delivering a total of 809m² of accommodation across nine apartments and three floors.
