(Given that the article appeared before a press release was issued, I assume it was placed as an exclusive.)
Five years after announcing that it had “cracked the code” on modular building technology and would open a factory in Brooklyn to construct modules, the developer Forest City Ratner is getting out of the prefab construction business.Let's note that Forest City is surely taking a big loss. Also that Forest City didn't make all the modules; the partnership of Forest City and Skanska made the first significant batch.
The firm said on Wednesday that it would sell its factory at the Brooklyn Navy Yard along with the associated technology to a former Forest City executive, Roger Krulak.
The decision came as the developer completed construction of the tallest prefabricated steel structure in the world, a 32-story tower at 461 Dean Street in the Pacific Park complex in Brooklyn, which is weeks away from receiving its first tenants.
Forest City made the 930 modules that were used to build the tower at the Navy Yard. It had originally planned to use the factory to create the building blocks that could be outfitted with wiring, plumbing, bathrooms and kitchens for each of the 15 buildings planned for Pacific Park, originally known as Atlantic Yards.
While Bagli writes that "the tower was plagued by delays and later a bitter dispute" with Skanska, that ignores a state monitor's report of leaks, mold, and the need to gut apartments, as I reported.
Now conventional construction for the rest of the project does indeed disturb neighbors.
“The bumps we hit, with respect to Skanska, are typical of any start-up,” Forest City CEO MaryAnne Gilmartin told the Times. “The good news is that we’ve worked out a lot of the bugs and gotten through the growing pains of innovation.” Except the lawsuits between Forest City and Skanska remain unresolved.
The Times reports:
Mr. Krulak, who oversaw the work on the modular building for Forest City, and recently formed the company Full Stack Modular, said that he and Forest City had worked out the factory mishaps, technology kinks and disputes that turned what was supposed to be a quickly built tower into one of the longest-running construction projects in the city.But the disputes haven't been worked out: lawsuits are still pending between Forest City and Skanska. Except we don't really know how the mold monitoring really went.
The building, he said, is proof that the technology works.
(Update: Krulak told Fast.Co Design that Full Stack Modular has some contracts in the works for multi-family projects, but nothing as tall as 461 Dean: "Our sweet spot for modular in an urban environment is in the 10-to-18-story, 80,000-to-120,000-square-foot buildings.")
Note that the press release below calls Krulak an "award-winning inventor," but the Breakthrough Award he got from Popular Mechanics was bestowed with notably poor timing, given that the modular building in Brooklyn had stalled.
Update: The press release issued at 7 am today
Full Stack Modular LLC Purchases Core Assets of FC Modular, LLC from Forest City Ratner CompaniesUpdate: Krulak interview
Leading Member of FC Modular and Award-Winning Inventor of High-Rise Modular Technology Acquires Company's Core Assets, Launches Full Stack Modular
Full Stack Modular to Build on the Success of 461 Dean Street, The World's Tallest Modular Residential High Rise
BROOKLYN, N.Y., Oct. 6, 2016 /PRNewswire/ -- Full Stack Modular, LLC announced today that it has purchased the core assets of FC Modular from Forest City Ratner Companies (FCRC), a wholly owned subsidiary of Forest City Realty Trust, Inc., (NYSE: FCEA and FCEB). Full Stack Modular will offer turn-key modular solutions for developers of new multi-family buildings, hotels and dormitories and will continue to operate out of the 100,000+ square foot factory in the Brooklyn Navy Yard.
Full Stack Modular's CEO and founder, Roger Krulak, was formerly Senior Vice President of Modular Construction at FCRC where he was a leading member of the team that built the modular business that formed the foundation of FCRC's flagship project, 461 Dean Street, the tallest modular building in the world. 461 Dean is now leasing and will welcome its first tenants this fall to breathtaking views and amenities made possible by its modular construction.
The deal includes the long-term lease at the Brooklyn Navy Yard, all equipment and Intellectual Property, as well as the bespoke technology created for this manufacturing process. Full Stack Modular will also maintain the groundbreaking collective bargaining agreement with the Building and Construction Trades Council of New York and its members, and anticipates rehiring much of the original workforce responsible for 461 Dean Street.
"I am very proud to own a company that will continue to build upon our original mission at Forest City, and further grow the valuable relationships with the community, the unions and the talented workers who help bring our vision to life," said Krulak. "Modular is the future of multifamily construction and Full Stack Modular will be at the forefront of innovation in our industry. Our systems are not only more efficient and cost effective than conventional building, but also more sustainable and community-friendly."
"We have always been firm believers in modular construction and we are incredibly proud of the breakthroughs we've made that will soon be seen at 461 Dean Street," said MaryAnne Gilmartin, President and CEO of Forest City Ratner Companies. "The sale allows us to put our focus on our core strengths – management of our assets and our incredible pipeline of development. We are thrilled that the high-rise residential modular industry we launched will continue its groundbreaking innovations in the skilled hands of Roger Krulak at Full Stack Modular. We know it will be a great success."
"We're pleased that Full Stack Modular will remain at its home in the Brooklyn Navy Yard and will maintain the agreement to employ highly skilled, unionized workers," said Gary LaBarbera, president of the 100,000 member Building and Construction Trades Council of Greater New York. "It's also good to hear that the company plans to hire from the community and anticipates rehiring much of the original workforce responsible for the project at 461 Dean Street. We look forward to working together in partnership with Roger Krulak and Full Stack Modular."
An internationally recognized expert in modular construction and innovation, Roger Kulak was the recipient of the 2014 Popular Mechanics 'Breakthrough Award' for his work on the creation of the high-rise modular process, has been appointed to the Building Innovation Panel for the Country of Singapore and regularly speaks all over the world.
About Full Stack Modular
Full Stack Modular provides turn-key modular solutions for developers of new multi-family buildings, hotels and dormitories. Full Stack Modular is dedicated to the innovation and creation of environmentally-conscious, cost-effective and labor-friendly development of multi-family housing. The company is located in New York City, in the Brooklyn Navy Yard. For more information, please visit www.fullstackmodular.com or email email@example.com.
Some excerpts from Multi-Housing News, 10/19/16. Roger Krulak Takes Modular Building to the Next Level, with emphasis added:
MHN: What details can you give us on the purchase of Forest City Ratner Companies’ core assets?
Roger Krulak: Full Stack Modular purchased all of the assets of FC Modular (from Forest City Ratner Cos.) including a lease for 100,000 square feet of space in the Brooklyn Navy Yard plus 85,000 square feet of storage. All of the infrastructure improvements valued at over $14 million, all of the equipment, the IP related to FC Modular High Rise modular system and a groundbreaking collective bargaining agreement with the joint building trades.
MHN: What are your plans for Full Stack Modular? Did you set out any short term and long term goals?
Krulak: We are focusing our efforts on multifamily developers in three market segments. Hotels, student housing and multifamily rentals because these are the ideal uses for our system. We are focused on the middle 70% of the market...
MHN: On your company’s website it is stated that modular construction is cost certain. What can you tell us about that and about cost benefits compared to traditional builds?
Krulak: Our process allows you to develop a project meeting your program at a cost certain price. If you include all development costs, carried interest, excess general conditions, early revenue recognition, reduced onsite safety requirements, the savings can be as much as 20 percent compared to traditional construction.
MHN: Tell us about Full Stack Modular’s up and coming projects.
We have several projects in the pipeline from additions to existing rental buildings to passive rental buildings and multiple hotels for major U.S. chains.
MHN: What is the strategy behind modular construction in general?
Krulak: From Full Stack Modular’s perspective, we are offering a turnkey solution to developers of multifamily both public and private. Give us the land you control and your desired program and we will do the rest. When we build off-site, we can benefit from of all the advantages of manufacturing: ergonomic work environment, tighter tolerances, safer working environment, less waste, better working conditions, faster completion, lower cost than in general conditions, less neighborhood disruption, tighter construction.