I had a 2000 ft modular house put up in February 08 and am in the middle of a large lawsuit. Recently a state inspector came in and he said in general, modular homes are not as well built as stick. You see my modular is up to code, (especially after the roof had to be completely redone) but that does not mean good workmanship and I had a contract where I paid much more for the modular company to oversee the subcontractors. You have the manufacturing company usually in PA to deal with and the company in your state that does the setting and the buttoning up. The company in PA did poor bridging of my floors which were not level. Remember they precut the bridging and just pop it in so it may not as in my case be flush with the joists or have enough glue. So my tile is not level and my hardwood floors creak and squeak like mad but the modular company asserts that bouncy floors are not a structural defect. The bolts securing the main roof beam in the attic are crooked but that is acceptable because it still is up to code. Also the primary carrying jack stud under the ridge beam is completely broken but the modular company's warranty said it is not suppose to carry any appreciable load so it is not an issue. I have hairline cracks throughout the sheet rock in every room. The state inspector said that the problem with modulars is that they often slap sheet rock right over commercial grade lumber or green lumber and it takes a few seasons for the lumbar to dry out. Therefore in my case the sheet rock in about a year cracked in all the rooms. If the setting company is not a pro they will not set the units flush and as in my case I have a 4 inch corner sticking out upstairs, charming. The marriage wall was never insulated and many modular companies do not insulate so you have a 1-2 inch gap from basement to attic where you can feel a breeze coming through and heat is lost. The whole idea of putting all your money up front for this modular the day it arrives before you can ascertain any problems is faulty. Then few modular companies allow you to interview the contractors who are doing the setting and buttoning up and obtain references. Modular companies will hire the cheapest to get the most profit and it comes down to that.
I had clowns do my sheet rock, siding, gutters, porch roof and cement porch slab. There are humps where the units are joined, the porch roof has a dip, the siding has fallen off, my gutters all leak and the cement porch has shrinkage cracks but it is considered up to code. Lastly the in-state modular company had taken the plans off another modular company's internet plan, did not obtain the blue prints and although they tweaked the plans to make a few changes they completely forgot an overhang on the back of the house so the rain falls flush down on my kitchen windows. There is an overhang on the original plans but I did not know modular companies had no scruples about taking other copy written plans and claiming them as their own even putting their own stamp on them.
So in essence, you are using complete strangers to put up your house, using the cheapest local contractors, putting your money up front and the warranties are useless. Nevermind the hidden costs. You pay extra for installing shower doors, gas fireplaces, knobs on cabinets, painting, light bulbs, garage overhead doors, and seeding(grading) over the tile and hardwood floor expenses. Also when they show you the samples for counter tops, you can't see how they look. I opted for simulated granite that looked beautiful in the round samples and ended up with noticeable seams and straight cuts, not the rounded curves I expected. This simulated granite easily scratches. My modular was just as expensive as stick and remember on the average the company in PA is completing your modular in about 4 days so you are not getting quality. I checked out 3 other modular homes before deciding on this one and still was cursed. Never again. Ever.