Standardized designs, modular and hybrid build options are enabling car washes to go up in record time. 

New car wash locations are popping up everywhere. Over 60,000 locations currently exist and the U.S. Census Bureau estimates the sector is expanding at about 7% annually. Car wash operators who want to maintain their competitive position are looking for ways to build washes quickly to establish their presence before others enter the market. Fortunately, there are several building options to minimize the time from design to grand opening.

Use of a tested prototype design and careful evaluation of the building site are two ways to reduce construction time, said Ben Bruening, PE, SE, associate at structural engineering firm O'Donnell & Naccarato. “We typically begin with a well-tested prototype, then adjust as needed for site conditions, limitations of local jurisdictions and client-specific requests,” he said. “Our design team worked with one specific franchise to adapt their prototype for 100 car washes in 36 states over the past two years and updated it to reflect lessons learned in each build.” The design team considers factors such as seismic activity in the area or wind loading requirements, but timing of the site evaluation is critical. “It is important that homework on the site be done very early to identify potential pitfalls such as the need for remediation of contaminants or poor soil conditions to avoid a complicated, lengthy process to adjust the design or plan construction,” he said. 

“Our typical car wash client is a franchise that relies on a standard design,” Bruening said. Standardization, with adjustments for specific sites, not only shortens the design phase, but also sourcing materials, he added. Build time and cost are more predictable because you know exactly what materials are needed and can plan the construction schedule. “One structural material that is always obtained locally is concrete, so cost and delivery schedule for it may vary from location to location.”

Clear skies for the Gleam II modular build process.

Another way to minimize construction time is the use of modular construction. “A modular build is a building that’s built in a factory and it is a complete structure,” said Bruce Arnett, owner of Genesis Modular Carwash Building Systems. “People will talk about prefabricated, but modular is a combination of prefabricated items all built into assembled components. When we ship out a building, we actually have the floors, the electrical systems, the plumbing systems and interior finishes all complete in the building prior to shipment.”

Once the building arrives on-site, it is assembled like Lego blocks, Arnett said. “Entire sections are set down, and we can complete a building in a quarter of the time of traditional construction. We just completed a project that is a 120-foot tunnel, and it was completed in four weeks on-site,” he said. “There were several weeks of development inside the factory, but the on-site construction was brought down to just four weeks. When we do the design, it is all engineered upfront, which speeds up the process throughout the development cycle.”

One reason modular construction can be completed so quickly is the parallel construction – construction of the building takes place in a factory at the same time site development is occurring, said Shawn McGovern, CEO of Genesis. “Foundations, reclaim tanks and all the site utilities all have to be placed before the building itself typically goes vertical. With modular construction, we are doing the vertical construction off site in the factory while the ground and the site is being prepped.”

Traditional builds operate on a linear construction timeline, with site work occurring first, then construction of the building on-site taking place. “It takes just as long to fabricate the building and assemble it in the factory, but when the foundations are completed, the building itself is delivered on-site within a week,” McGovern said. “In fact, in most recent builds, due to constraints on things such as concrete, our building is waiting for the site to be ready as the contractors are working on scheduling the delivery of concrete for the site to finish the foundations. So our goal is to be ready with the building prior to the site being ready to accept it so that timeframe is minimized.”

An inside look at Gleam Car Wash, and their unique car wash build of over 17-foot tall ceilings and cafe.

First-Hand Experiences

When Emilie Baratta, founder and owner/operator of Gleam Car Wash, planned a second location in the Denver area, she selected modular construction because of the experience with her first wash. “Modular can offer several advantages relative to typical stick and brick construction. In theory, modular construction can be faster to market alongside a predictable price tag as modular units are built in a factory using salaried, skilled labor,” she said. “This enables the modular manufacturers to avoid weather and labor-shortage related delays that can plague conventional construction.”

There is also a benefit to obtaining state and local permits for modular construction. “If you are doing a very similar design over and over in the same state, it can shorten the entitlement process,” Baratta said. “Finally, a modular building is legally just a big washing machine, which offers significant depreciation benefits.”

Baratta refers to “theoretical decrease in construction time” because her second location did not go as quickly as planned due to issues unrelated to the construction. “I secured the land shortly after my first car wash opened seven years ago, but in my area, a car wash was a conditional use, so we had to take it through the entire entitlement process prior to even knowing whether we could build the project,” she said. Even with the unanticipated delays, some of the benefits of modular construction did help in the construction of the second location, Baratta said. 

Another option for some car wash operators who may want more customization to reflect their brand, location or site restrictions, is a hybrid approach that combines modular and on-site construction. Genesis used that approach on two of the car washes owned and operated by Genesis to test it before offering it to clients as an option. “We used ourselves as guinea pigs,” Arnett said, “and now have some people who are excited about this idea.”

“We actually built the equipment room as a modular unit, brought the equipment room to the site, set it, and then traditionally built the car wash around the equipment room. It was a fun project and it definitely worked out extremely well,” Arnett said. “We brought the completely-built equipment room in – backflow preventer, main distribution panel, control panel, all the chemistry, all the pumps, all the compressors, everything — then the car wash was built around it.” 

When looking for a way to launch a new car wash location quickly, there are several options to consider so Baratta suggested that owners consider their goals carefully. “Be honest with yourself about your design and your goals. If you have something straightforward, modular could be an excellent option. If you have something complicated, modular can still offer benefits, but it’s possible the benefits don’t outweigh working with a good, local team. And just like most things, if you’re doing modular for the first time, get someone on your team who is not doing it for the first time. Allow extra time, extra budget and be excited to learn.”

With Modulars, Preparations Are Key

One of the least exciting activities when planning a new car wash is the application for design approvals, building permits and zoning changes or exceptions that may be needed to begin construction. Modular construction also brings some specific challenges in approvals as well as inspections throughout the process.

Just as construction on the building and the site occur at the same time with modular buildings, so does the design approval and permitting process. “We handle everything in-house from design to getting the drawing sealed and stamped. So having everything in-house saves time and money,” said Charlie Zimmerman, national sales manager, Genesis Modular Carwash Building Systems. “Modular is all state stamped, either through the state or through a third party, and it usually supersedes local planning and zoning requirements. So, while the civil engineer is getting site drawings completed and sealed, we're doing the same thing for the building, which normally saves time.”

“In Colorado, the state – not the local municipality – handles approvals of all modular buildings through the Department of Housing, because housing was the first application for modular construction,” said Emilie Baratta, founder and owner/operator of Gleam Car Wash. “The modular manufacturer gets their buildings approved, but you will need a contractor and you will need to interact with your local municipality, so you must be prepared for frustrating conversations and discussions over scope.”  

“The most significant challenge of utilizing a modular building is that 98% of contractors and 90% of inspectors are unfamiliar with it,” Baratta said. Because a local contractor is needed on-site and local inspectors will be evaluating the project, it is important to make sure that someone on the team is familiar with modular construction and how it integrates into traditional builds and inspections, she said. 

Baratta worked with a consultant who served as the contractor for the modular construction of her first wash location and then acted as her representative on the second location. His role was to “translate” among the design team, contractors and modular engineers. 

“Modular permitting is normally through a state jurisdiction that is familiar with its construction type; however, the local inspectors or authority are rarely familiar,” said Elijah Williams of Williams Consulting, who worked on the second Gleam location. “Modular construction is viewed as an ‘appliance’ that has been certified and completed by an engineer, therefore the design review is different.”