Wood has emerged as one of the most promising materials, if not the most, for sustainable construction, owing to its renewable raw material characteristics. In Brazil, a tropical country where tree growth is rapid and land availability for reforestation is ample, the potential of wood as a construction material is immense. Traditionally used in construction, wood today meets the demands of industrialized and high-tech construction perfectly. The Brazilian engineered wood industry has adopted pine and eucalyptus as raw materials.

At Modular BV, the choice was made to use eucalyptus, a medium-density wood with excellent technical performance, which receives treatment that is more suitable for health and the environment, avoiding the use of autoclaving. The project was developed in partnership with Crosslam, a pioneering company in engineered wood production in Brazil, ensuring both quality and technical rigor. It is a housing construction system designed as an assembly process. The structure and enclosure were conceived in beams, columns, walls, and slabs made from reforested wood, produced in a factory and transported to the site for assembly.

Additionally, the system is based on the design of programmatic modules: Living Room, Kitchen, Bedroom, Studio, Balcony, etc., which can be freely grouped to create various house configurations. The plans for each module were developed with meticulous care and precision, resulting in internal dimensions of 5 x 5 meters, providing well-calculated space for bedrooms (with either a double bed or two single beds), spacious bathrooms, living rooms (allowing for various and comfortable arrangements), and dining areas that incorporate a fully equipped kitchen, designed with precision to facilitate practical kitchen activities.

With the project developed in independent programmatic modules, the system achieved significant adaptability potential for different program arrangements, built areas, geographical situations, topography, views, and sunlight exposure. Simultaneously, the system ensures technical precision, with remarkable speed and agility in both design and construction phases.

In the context of climate change, the impact of the construction industry on increasing atmospheric carbon is well known. Engineered wood presents itself as an alternative renewable construction matrix with low energy consumption for production. During its growth, wood contributes to carbon capture through photosynthesis, and this “sequestered” carbon would return to the atmosphere during the decomposition or burning of the wood.

Thus, using wood in construction is a way to delay this effect. Finally, the project was designed with autonomy concerning natural resource consumption—water collection, electricity generation via photovoltaic panels, disposal of gray and black water, and biodigesters. Modular BV was developed in two versions, Modular 5.5 and Modular 2A, to meet various implementation contexts.

Manufacturing and Machining of Wooden Components

The project utilized eucalyptus wood for the production of components, sourced from legally certified plantations in the South and Southeast regions of Brazil. For lamella bonding, an adhesive free of formaldehydes, certified for structural use and waterproof, is employed. To enhance resistance to deteriorating elements, the structure undergoes a surface protection application with fungicidal and insecticidal properties. Additionally, to prevent weathering (wood desaturation), a high-performance water-based stain is applied to all faces of the wood components. For industrialized pieces, eucalyptus is processed into glued laminated timber (GLT), both in Cross-Laminated Timber (CLT) and Glued Laminated Timber (GLT) formats. The technology has been crucial for developing new adhesives for lamella bonding, precise cutting of components using mechanical arms, and structural calculations.

3D Model (BIM) of Architecture and Infrastructure Systems

The project was developed on a BIM platform, allowing for the precise specification of the entire construction operation, starting with the production of wooden components: accurate cutting and machining. This decision in the design process enabled all infrastructure systems to be incorporated into the three-dimensional model, resolving potential conflicts between disciplines—concrete structure, topography, electrical installations, plumbing, air conditioning, and telecommunication. The innovation lies in using a material, wood, from the initial housing stages within a cutting-edge construction context, maximizing performance through computational design, with a focus on sustainability and design.

Construction Site and Low Environmental Impact

The construction site serves as an assembly area, where a small number of workers can quickly erect the house. Unlike conventional construction, it has proven highly suitable for both urban contexts and remote, difficult-to-access locations. The lightweight nature of the wood construction allows it to be built on a concrete slab (radier) or a shallow foundation with a suspended concrete slab (suitable for various ground slopes). The wooden structure consists of beams and columns in Glued Laminated Timber (GLT), including walls in Cross-Laminated Timber (CLT) and a roof panel also in CLT. The rapid construction and organized site operations ensure high execution quality with minimal construction waste (which is also associated with the absence of material loss during assembly). These conditions minimize the impact of the new construction on the site, with minimal earth movement, preservation of natural drainage lines, and native vegetation. The incorporation of solar panels for water heating, photovoltaic panels, rainwater collection tanks for reuse, and sewage treatment via a domestic biodigester makes the unit self-sufficient.

Modularity and Finishing Flexibility

The system offers several facade finishing options for ventilated facades (CLT wall coverings): corrugated metal panels (in various colors), natural wood slats, or stained black or other colors. It also provides options for flooring, countertops, sanitary fixtures, and fittings, allowing customization while maintaining the goal of delivering a ready-to-use construction. Another important element for flexibility is the lighting system, organized through an electrical channel running through the entire house, from which all fixtures can be mounted and powered. The fixtures feature adjustable angle diffusers, allowing direct or indirect light, upward or downward, depending on the use of each space or situation. Wood serves as the finish for the walls and ceilings in most rooms. However, the exterior walls are covered with shingles or wood decking, creating a ventilated facade, with the finish being a choice for each future resident. The system also includes options for facade and interior finishes.

Modular 5.5

The Modular 5.5 features wide eaves that accommodate large window frames, optimizing conditions for natural light and ventilation while ensuring views of the exterior. The front eave, with nearly 2 meters of projection over the windows, allows for large openings with controlled sunlight. The side and rear eaves, where the roof approaches the ground, are smaller and correspond to facades with fewer openings. The windows are arranged in two planes and at two heights: the first, floor-to-ceiling, enhances views and integration between indoor and outdoor spaces; and the second, a linear and higher plane, allows for cross-ventilation even when the house is closed. Cross-ventilation flows through high, screened windows on opposite faces, creating a complete relationship between indoor and outdoor environments.

Modular 2A

The 2A system is a derivative of the 5.5 system, allowing for new implementation possibilities and vertical expansion into two floors. With a structure in Glued Laminated Timber (GLT) and floors and walls in Cross-Laminated Timber (CLT), always using eucalyptus as the base, the system offers natural wood as a finish for interior areas. The Modular 2A does not feature the extensive eaves of the Modular 5.5 but can be fitted with awnings or pergolas to create balconies and shaded areas, which can be added where needed. Without large eaves, the Modular 2A adapts better to smaller or heavily wooded sites with limited space for house installation. Furthermore, despite having the same plans as Modular 5.5, the Modular 2A was designed using smaller components (GLT and CLT), which can be transported in smaller trucks, making it feasible to access and assemble in more challenging topographic conditions or denser arboreal areas.

Visual, Thermal, and Acoustic Comfort

The system provides excellent thermal, acoustic, and visual performance for interior spaces. The walls and roof, sealed with 8 cm thick CLT panels, not only facilitate assembly but also act as high-inertia thermal insulators, resulting in an excellent finish for indoor environments. Engineered wood also prevents fungi and pests, offering great maintenance conditions. The use of ventilated facades, such as wooden slats and Tyvek membranes, protects the wall panels and contributes to thermal efficiency and airtightness. Thus, the interiors remain well-lit and ventilated, which are crucial for healthful residential construction. In contrast to the large windows, the medium-toned eucalyptus wood walls and ceilings provide a balanced light atmosphere, free from glare and dark spots. The compact kitchen, integrated with the living area, includes appliances such as a refrigerator/freezer, stove, extractor fan, microwave, water filter, garbage disposal, and built-in trash can—along with countertops and cabinets, meeting all ergonomic requirements. A horizontal window above the countertop and a specific lighting design ensure optimal lighting quality for this workspace.

Innovation

The innovation of the Modular BV system includes aspects related to material use, construction site operations, adaptability concerning the program, its distribution, and the method of implementing the new construction while respecting geographical characteristics, along with the high degree of customization the system offers. Unlike modular systems that present a concept of a compact capsule delivered ready from the factory but with significant limitations in flexibility and potentially costly transportation, the Modular BV construction system addresses the programming equation, room dimensions, ease of transport, and access in remote or challenging sites.