Waco Modular doubles factory capacity to meet surging demand for modular buildings
Waco Modular, an industry leader in modular construction solutions, has completed a major expansion of its manufacturing operations, adding a new 660m2 undercover assembly area to its Jet Park factory in Boksburg, effectively doubling its output capacity.
This strategic investment comes at a time of unprecedented demand for modular construction across various South African sectors, ensuring the company can deliver faster and more resilient solutions to clients under mounting project pressures.
“Market demand has accelerated significantly, particularly in education and mining. Historically, the education sector places enormous pressure on production toward year-end to meet school deadlines. In 2025, this was compounded by surging demand from mining projects. Our expansion ensures we can deliver on both fronts without compromise,” says Andries Stander, Factory Director at Waco Modular’s Johannesburg branch.
Faster delivery, greater certainty
The expansion has reduced Waco Modular’s standard manufacturing lead times from 4-6 weeks to as little as 1-3 weeks, depending on project scope. For clients, this translates into greater certainty that critical mobilisation deadlines can be met, helping avoid costly penalties and delays.
“Our clients no longer need to worry about whether units will arrive on time. We can now dispatch modular buildings within days, enabling projects to progress faster and more profitably,” Stander explains.
Appointed to the role of dedicated Factory Director, Andries Stander will oversee operations, delivering immediate and measurable benefits. Faster production cycles, improved quality standards, and higher staff morale have all contributed to the doubling of output capacity.
Stander says that daily leadership presence on the factory floor ensures tighter alignment between engineering, procurement, and executive teams, reinforcing Waco Modular’s culture of accountability and excellence.
Technology and semi-automation
The expansion has also introduced new technologies and semi-automation, including a modernised stores management system that enhances workflow efficiency, stock control, and operational visibility. Purpose-specific equipment and tooling have been deployed across production stages, while semi-automated assembly processes reduce reliance on tedious manual tasks. Together, these innovations have streamlined production flow and strengthened resilience.
Despite increased volumes, Waco Modular maintains its commitment to international manufacturing standards. Enhanced on-floor supervision and continuous staff training have improved product quality, while safety remains paramount. The company’s facilities are equipped with lifelines for safe working at heights and has surpassed one million man-hours without a lost‑time injury, which is a strong testament to its safety culture.
“Safety is non-negotiable and a standard that we will never compromise. Our people are our greatest asset, and their wellbeing underpins everything we do,” Stander emphasises.
Tangible impact across sectors
The benefits of expanded capacity are already being realised across multiple industries. In mining, early delivery of modular units has expedited operations dependent on timely infrastructure. In education, schools preparing for the 2026 academic year have gained certainty that facilities will be ready on schedule. Commercial and public infrastructure projects are also benefitting from faster turnaround times and scalable solutions.
Looking ahead, Waco Modular remains committed to continuous improvement. Three new product lines were successfully launched in 2025, with another in development for 2026.
A partnership with Waco Engineering Services (WES) also provides seamless collaboration between design, engineering, and manufacturing, while dedicated supplier agreements are paving the way for a just‑in‑time supply chain model.
“Our goal is to deliver smarter, faster, and more resilient solutions. By investing in people, processes, and technology, we are ensuring that Waco Modular remains the partner of choice for industries that cannot afford delays,” Stander concludes.
