From Hurricane Sandy to Helene and Milton

Anthony Zarrilli, a premier modular home builder based in Brick, New Jersey, is no stranger to the challenges of natural disasters. Having successfully navigated the devastation of Hurricane Sandy, his company, Zarrilli Homes, emerged as a trusted leader in rebuilding efforts along the Jersey Shore. With a commitment to quality, innovation, and the resilience of modular construction, Zarrilli played a pivotal role in restoring homes and hope to countless families affected by the storm.

Anthony Zarrilli, President of Zarrilli Homes

In this interview, Anthony Zarrilli shares his journey from navigating the immediate aftermath of Sandy to rebuilding a stronger, more robust business in its wake. He delves into the lessons learned from one of the region’s most catastrophic events, including how his experience with modular construction allowed for faster, more efficient rebuilding processes while maintaining the highest safety and design standards. Zarrilli’s insights offer a roadmap for new home builders looking to incorporate modular techniques, particularly as coastal communities continue to grapple with extreme weather events.

As we explore Zarrilli’s approach to disaster recovery, we also look ahead to the future of modular home building. Anthony advises new builders on preparing for the unexpected and discusses the importance of embracing innovation to stay ahead in an evolving industry. His story of survival and growth offers invaluable takeaways for both seasoned professionals and newcomers to modular construction.

Gary Fleisher, Offsite Innovators:  After Hurricane Sandy, you faced the challenge of navigating a flood of new building codes across multiple states and municipalities. What were the most significant regulatory hurdles you encountered, and how did you manage to stay ahead of the constant changes?

Anthony Zarrilli, owner of Zarrilli Homes: After Sandy all government agencies stated they were going to “streamline” the process to help people get back in their homes most efficiently and as quickly as possible without red tape or bureaucracy.  I didn’t work in any area where this wasn’t inaccurate.  I am still building homes that customers and I continue to fight with insurance companies, townships, financing companies, state agencies, inspectors etc. to get their project underway or completed.  Truly so frustrating and lack of empathy.  

The first 1-4 years the flood zones, heights, building codes were changing daily and their was no uniformity or consistency.  After 12 years that has been mostly cleaned up but now more regulation is coming down the pike fast and aggressive and we will know shortly how this will crush the building industry throughout NJ, Florida and many other states. 

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Gary: With Hurricane Helene now leaving similar destruction in its wake, what innovations or improvements would you like to see in how building codes are created and implemented to avoid the confusion that builders and developers faced after Sandy?

Anthony: There needs to be more communication caross between regulatory agencies so that the codes are clear, precise and I as the builder know what we need to comply with and build to the proper standards.  I don’t see this happening for the government and other agencies involved cannot get out of their own way to accomplish this efficiently.  

Gary: From your perspective as Engineering Manager, what advice would you give to local and state officials to streamline the building code update process in the wake of disasters like Helene, so that builders can rebuild more quickly and efficiently?

Anthony: Every state regulated the builder licenses in their state.  Immediately following any changes to their codes should immediately be emailed out to all active builders in their state and also a website set up with full explanation/information to be reviewed by the builder so that they fully understand updated/new regulations.  Also a help/assistance line that has knowledgeable people on the other end who, if needed, can explain details or answer any/all questions from the builder.  This would mitigate most if not all mistakes made in the field due to a work force that is not properly informed. 

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Gary: How do you think modular construction could benefit from more standardized or flexible building codes in disaster recovery efforts, and what regulatory changes would best support innovation in this area?

Anthony: Modular construction should be used more widely throughout the building industry and more importantly when disaster hits.  Homes construction modifications to meet code changes can be adapted very quickly to delivery homes to these areas and get families back in their homes as quickly as possible.  Our industry is underutilized and overregulated for so many reasons when it is the best solution to so many problems (disasters, affordable housing, ADU, home efficiency, etc.) but in order to do so more people in the positions of authority are biased a lot of the times against this due ot lack of being educated on this superior construction method. 

Gary: Looking forward, what new strategies or technologies would you like to see incorporated into building codes to not only ensure safety and compliance but also foster more resilient and sustainable rebuilding practices after hurricanes like Helene?

Anthony: All municipalities handling the permit and inspection process should be all electronic from plans, submission, permits, etc.  This process in almost every town I build from NJ to FL are still using paperwork and have not moved to electronic submission.  Florida has made it easier electronically but here are some bugs that need to be worked out still that delays the process.  

Township inspectors can hold up a job and typically do with their schedule.  Being able to hire a third party agency (design professional – ie architect/engineer) is a game changer in building homes more efficiently, in a reasonable amount of time and most cost effective.  We use private inspections companies in Florda and project times to complete as compared to NJ typically are half or less due to the efficiency of the private inspectors. 

Zarrilli Homes – This Old House/Jersey Shore Rebuilds

Great Interview

Thank you, Anthony, for sharing your invaluable insights into the challenges and complexities of post-hurricane rebuilding. Your experience and expertise in navigating the aftermath of Hurricane Sandy, combined with your dedication to modular construction, offer a clear and inspiring path forward for builders facing similar challenges. Your advice on preparedness, resilience, and innovation will undoubtedly help others in the industry rise to the occasion when disaster strikes. We’re grateful for the time you’ve taken to provide such thoughtful perspectives.

A note from Anthony:

I could go on and on with answers to all of the above but trying to keep it short.  Let me know if I can help further. 

Would you like Anthony to answer more questions about rebuilding not only homes but your business after a Hurricane as well as working with code and inspection officials? 

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Over the past decade, we’ve witnessed some of the most devastating hurricanes in recent memory, including Hurricanes Sandy, Katrina, Helene, and Milton. While no hurricane is ever good, the aftermath of these disasters has highlighted the urgent need for more innovative and efficient approaches to disaster recovery. In this first of a three-part series, we will explore forward-thinking strategies to meet the challenges of future disasters.

Hurricane Sandy

To kick things off, I spoke with three key figures in the modular construction industry: a modular factory General Manager, an Engineering Manager, and a prominent modular builder in New Jersey. They generously shared their experiences from the rebuilding efforts after Hurricane Sandy and offered valuable insights on how we can improve recovery efforts today.

Aaron Trometter, Engineering Manager

Aaron Trometter, the Engineering Manager for Champion’s Excel Homes Group in Liverpool, PA, brings two decades of experience in modular construction. Throughout his career, he has faced the evolving challenges of building codes and regulations, especially in the wake of natural disasters. Having worked closely with builders to rebuild homes after such events, he has seen firsthand the need for new solutions. 

Hurricane Sandy

That’s why I asked him to share his thoughts on how builders, developers, and state code enforcement teams can better navigate the rebuilding process after Hurricane Helene. There must be a more effective way to restore cities, towns, and rural areas than simply relying on the practices used in normal times.

Gary Fleisher: After Hurricane Sandy, Excel Homes became a hub for rebuilding efforts, but you faced an overwhelming influx of requests from both established builders and newcomers looking for quick profits. What were the biggest challenges you faced in managing this surge, and how did it impact your company’s operations?

Aaron Trometter: The biggest challenge was mixing the rebuild effort with your core business while trying to keep everyone happy. While you want to go out of your way to help hurricane victims start the next chapter of their lives with a new house, you still need to build houses for builders and homeowners in your other territories. It might be helpful to set aside a few slots in your production schedule after a disaster hits.

Hurricane Helene

Gary: With so many opportunistic builders entering the modular industry after Sandy, what advice would you give to state and local officials in terms of vetting builders and ensuring that only qualified, reputable companies are involved in recovery efforts after Hurricane Helene?

Aaron: We were aware of these new “builders” popping up and trying to get rich after the natural disaster, so we made sure to take care of the established builders we already had in the area. They came first. Also, when a new builder appears, the factory needs to do some background checking (license, credit check, insurance, previous customer reviews). If needed, ask around and see what other builders or tradesmen think of the new “builder.” The last thing you want is a builder to buy the house, set it, and leave it unfinished. Seeing an unfinished modular house sitting on a foundation for months after being set just gives the whole industry a bad name.

Gary: Hurricane relief programs were launched in every affected state after Sandy, but many builders found it difficult to navigate the various regulations and funding opportunities. What improvements would you suggest to streamline these relief programs and make them more accessible to builders and homeowners in Helene’s aftermath?

Aaron: Not to create favoritism, but permit offices need to have a separate line/review process for these victims. If homeowners have their insurance money and permit sets and are eager to get back “home,” the local offices need to speed up their process. This also applies to site inspections. Many times a builder is sitting idle, waiting for an inspection before moving on to the next step. I know that after Sandy, local officials started conducting more thorough inspections of the foundation strapping to the house. Waiting for this inspection can prevent decks and porches from being built, which holds up the siding installation.

Hurricane Helene

Gary: How did the demands placed on your factory and builder network by site builders and developers unfamiliar with modular construction affect your ability to deliver quality homes after Sandy, and what lessons can be applied to manage similar situations during Helene’s recovery?

Aaron: Getting the required materials in time was one of the biggest hurdles. While you are doing your best to get hurricane victims back into a house, you still need to build it to the required codes. Whether it’s getting engineered braced wall calculations from an engineer, the necessary strapping, or special doors and windows needed for wind speed and exposure categories, there is always that bump in the road that causes a delay. There could be such high demand for windows with a higher DP rating that window manufacturers are unable to keep up, causing the modular manufacturer to face shortages.

Hurricane Helene

Gary: Looking ahead, what steps should modular builders and housing officials take now to better prepare for future disasters like Helene, ensuring a more coordinated and efficient recovery process for both builders and homeowners?

Aaron: Create a guidebook for these potential disasters, outlining a response/recovery process. This way, housing officials are more prepared for an influx of plan reviews and inspections at job sites. In areas prone to hurricanes, local builders, building organizations, and government officials should develop a support network for each other. Government officials should clearly outline exactly what they need for builders and homeowners to move from one step in the process to the next, avoiding unnecessary hurdles. A plan, partnership, and communication are key.

Hurricane Helene

In this first of three-part series, I explored innovative ways to improve disaster recovery efforts, particularly focusing on the role of modular construction in rebuilding after devastating hurricanes like Sandy, Katrina, Helene, and Milton. Through this insightful interview with Aaron Trometter, the Engineering Manager of Excel Homes, we delved into his experiences and the lessons he learned from Hurricane Sandy’s aftermath. His valuable perspectives shed light on how builders, developers, and state officials can better prepare for future disasters and navigate the complexities of rebuilding in the face of strict codes and regulations.

A special thank you to Aaron Trometter, Engineering Manager for Champion’s Excel Homes Group, for sharing his two decades of expertise. His forward-thinking suggestions highlight the importance of developing more efficient strategies for rebuilding in disaster-prone areas. 

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