Capsys
Client:    Concern for Independent Living, Medford, NY
Architect:    DeLaCour & Ferrara Architects, Brooklyn, NY
Project Description: 85 modules forming 65 studio apartments and the supporting public areas, stair towers and elevator shaft of five residential levels above a site-built first level.
Process: Fabrication begins with the welding of the structural frame. W10 wide-flange steel beam perimeter bands, W8 beams for floor joist, with 4” tube steel vertical supports.
Process: Floor assembly ready with removable forms to accept 3”concrete pour. Notice the steel reinforcement mesh and structural studs – integral components of our composite beam floor structure.
Process: A 4000 PSI lightweight concrete sub-floor is poured and finished
Completed structural chassis. Capsys modules are self-supporting for projects up to 12 stories.
Process: Plumbing stacks are assembled and bench tested prior to being installed. Plumbing, electrical and structural inspections are performed in our factory.
Process: Walls are mounted to the chassis with gypsum board and electrical boxes already installed. Mechanical and electrical rough-ins are installed early in the fabrication process.
Process: Modules taking shape side-by-side on our dual assembly lines. Capsys can assemble over 35,000 SF per month.
Process: The module’s ceiling is lifted onto the module as a single assembly pre-wired and with sprinkler piping already installed.
Process: Our fabrication facility encompasses over 75,000 SF.
Process: Gypsum walls are finished and receive a primer coat of paint. Ceramic tile for floors and wainscoting is factory installed and grouted.
Process: HVAC fan coil being installed above the ceiling of the foyer. Capsys technicians can install any mechanical systems required.
Process: As the module travels down the line, all electrical, sprinkler, HVAC, plumbing, and DWV installations are completed.
Process: Near the end of the assembly line: Windows and air infiltration barrier are installed.
Process: Exterior insulation, brick tie-backs and brick relief angles are factory installed making on site masonry installation much faster.
Process: Tile floor & walls, plumbing fixtures and bath accessories, even lights are all factory installed. Ceiling access hatches facilitate floor to floor plumbing interconnections during on-site finishing. Kitchen floor tile, solid-surface countertops, solid-wood cabinets, plumbing fixtures, and lighting are factory installed. Doors & hardware, sprinkler, HVAC, base, door and window trim are all factory installed.
Process: Completed modules are transported from the end of the assembly line to a storage location.
Process: Modules in storage wrapped in protective plastic, EDPM for weather protection prior to modular erection.
Process: An all-terrain mobile crane with 250 ton rating and a 230‘ hydraulic boom being set up. We will use this for modular erection.
Process: Day 1 – modular erection at the site. First module arrives.
Process: Day 1 – 1st module lifted from the transporter. The spreader bar below the crane hook allows all column points to be lifted vertically with no stress to the walls. 1st module being positioned.
Process: Day 2 – 1st floor rear being set. 1st modular level complete. Note the site-built steel podium and framing for site-built 1st level.
Process: 1st level corridor – The modules remain wrapped in protective materials until just prior to setting the next upper level.
Process: Day 3 – starting the 2nd level of modules. The welding of the structural inter-connections commences while setting is ongoing.
Process: Day 5 – 3rd level rear installed. Building is over 40% complete.
Process: Day 7 – 4th level rear. Module being lifted into position.
Process: Note the formed concrete floor slab and the plumbing stubbed under the floor ready to be interconnected with plumbing risers in the ceiling of the module below after erection is complete.
Process: Day 10 – 5th level nearing completion. 5th level front module being guided into final position.
Process: Day 11 – 90% complete
Process: The Capsys structural system assures perfect vertical alignment for multi-story buildings.
Process: Corner lounge area module with the elevator shaft opening in floor being positioned.
Process: Day 12 - Final module placed. 85 total modules erected in 12 Days.
Process: Exterior finishes, in this case brick, may begin be 1nstalled immediately after modular erection is complete.
Process: Parapet walls being capped after brick installation is complete.
Process: Chillers installed on roof. Notice the modular stair bulkhead in the rear.
Process: After erection, ¾” self-leveling concrete topping is poured throughout the corridor to fill all modular mate line seams. Final layer of gypsum board is installed in corridors after all the MEP connections are completed.
Process: Then corridor finish floor tile and the ceiling suspension are installed. Elevator installation is 100% on site. Master electric and building subpanels are site installed on site.
Process: A final coat of paint is applied to the apartment interior. Vinyl plank floors are installed in apartment interiors
Process: As a sustainability measure, a rooftop solar array is installed. This project qualified for the NYSERDA Multifamily Performance Program which requires a substantial reduction in operational energy consumption.
Process: A 4000 PSI lightweight concrete sub-floor is poured and finished
Project Complete: The Capsys modular tower was completed within 16 weeks of modular erection.
Multi-Family: Main Street Plaza, Ossining, NY
Multi-Family: Main Street Plaza, Ossining, NY
Multi-Family: Main Street Plaza, Ossining, NY
Multi-Family: Atlantic Center, Brooklyn, NY: 32 Three-family Homes
Multi-Family: Atlantic Center, Brooklyn, NY: 32 Three-family Homes
Hospitality: HarborFront Inn, Long Island
Hospitality: HarborFront Inn, Long Island
Hospitality: HarborFront Inn, Long Island
Assisted Living: NRNRC West End 2000, New Rochelle, NY: 102 Apartments
Assisted Living: NRNRC West End 2000, New Rochelle, NY: 102 Apartments
Assisted Living: NRNRC West End 2000, New Rochelle, NY: 102 Apartments
Assisted Living: Queen of Apostle’s Convent, Harriman, NY: 40 Apartments
Assisted Living: Queen of Apostle’s Convent, Harriman, NY: 40 Apartments
Multi-Family: Townhouse Multifamily, Edgemere II, Edgemere, NY: 112 One & Two-family Homes
Multi-Family: Townhouse Multifamily, Edgemere II, Edgemere, NY: 112 One & Two-family Homes
Multi-Family: Townhouse Multifamily, Edgemere II, Edgemere, NY: 112 One & Two-family Homes
Multi-Family: Townhouse Multifamily, Nehemiah Spring Creek, East New York, NY 117 One, Two, & Three-family Homes
Record-Setting Speed

Done on the Double

Efficiency and speed are critical to supportive housing projects. Using the Capsys system, a new project can be designed, built and occupied in half the time of a conventionally built job.

Simultaneous Construction

Our process sets records. A recent Building Design + Construction article describes one of our Brooklyn-based supportive housing projects: “While the site was being prepared and the foundations constructed, Capsys was simultaneously fabricating the modules. When the site was ready, so were the modules . . . . The erection process happened so quickly that all six stories were installed in just 12 days.”

Read the full article to learn more about why our process is being called “a model for New York housing.”

Controlled Process

Regulated and Rigorous

Thanks to our meticulous factory-built construction process, we’re proud to have earned the distinction of being New York City’s only Approved Modular Fabricator.

Using a rigorous, quality controlled building process means that we make efficient, high-quality buildings. We scrutinize every detail, from materials to environmental impact to the seal on every seam, and all plumbing, electrical, and structural inspections are performed in our factory.

Since the process is precise, project timelines and budgets are easier to predict and control.

Dependable Quality

Every Detail Counts

Inside the Capsys factory, our expert builders have the ideal environment, resources, and training to perfect every detail of your building. At every step of construction we run quality control tests to ensure best-practice craftsmanship.

Before it leaves our doors for on-site assembly, each unit gets the full treatment: We install tile floors and walls, plumbing fixtures and bath accessories, and even lights. Doors, hardware, sprinklers, HVAC and other mechanical systems are set in place. And that’s just the short list of features we test, assemble, and install in our secure, climate-controlled factory.

Save On Management Time

Focus on Key Decisions

Capsys’s modular construction process puts decision making up-front, which removes the need for multiple rounds of deliberation. When key decisions are made early, you encounter fewer problems and fewer hurdles. We streamline the process, so you can focus on other aspects of your project.

Everything According to Plan

Being New York City’s only approved modular fabricator makes the inspection process simple and streamlined. Our detailed knowledge of city and state regulations and various program requirements helps you save time and money.

Easy to Implement Your Program

Executing Your Vision

Tell us about your design goals, and we will engineer our modules to meet them. The Capsys system is flexible enough for a vast spectrum of sustainability standards, aesthetic styles, and layout requirements.

On Time and On Budget

With supportive housing projects, you can’t afford to have timelines creep, costs explode, and efficiency goals slip away. We deliver construction with a directed process, one that lets you make important decisions and follow through with your vision—on time and on budget.

The Best System for Supportive Housing

We are confident that the Capsys approach offers the best system for supportive housing. Curious to find out why?  We’re glad to tell you all about it. With 16 years of experience, Capsys is New York City’s modular expert.  We know the challenges of the city.  We know the challenges of construction.  And we’ve mastered each one.  Call us to get your supportive housing project off the ground. 

Call Tom O'Hara at (718) 403-0050 or email him at tohara@capsyscorp.com

Modular Supportive Housing by Capsys

Capsys is New York City’s leader in modular construction, and an experienced partner in supportive housing. Our off-site construction process offers an unparalled combination of speed, quality, and precision.

T  (718) 403-0050
F  (718) 643-4820
tohara@capsyscorp.com

Do you have specific design goals? Are you aiming for LEED certification or other sustainability benchmarks? Our system is extremely flexible and we can help you bring your vision to fruition.

We know the city, we know construction, and we know supportive housing. Call us to get your project off the ground.