Modularization is an industrial plant construction strategy that involves dividing a facility into prefabricated sub-units. These sub-units are constructed in specialized fabrication yards and then transported to remote construction sites, where they are assembled and interconnected.

We possess comprehensive expertise and proficiency encompassing every facet of modularization, spanning from initial design stages to seamless onsite integration.
Our dedicated team aids clients in crafting tailored strategies aligned with their project requirements, drawing upon our vast experience collaborating with yards, and employing optimized designs aimed at minimizing construction risks. Additionally, we have pioneered numerical methodologies for comprehensive plantwide modularization planning.

Advantages

• Modules are built in a process-controlled environment ensuring better quality and less clash sensitive. Stick-built execution will often result in rework, inefficiencies, and higher reject rates.
• Modules are built in own yards against own procedures, which personnel is familiarized with, whereas stick-built execution is often carried out by contracted personnel, who have to adopt / implement clients/local legislation.
• Module Yards have:
  • own skilled workers, whereas a “stick built” plant is often being constructed through various subcontractors (Civil, Structural, M&P and E&I);
  • extended portfolio range, and include own Pressure Vessels manufacturing, which eases the integration of critical equipment (stress free alignment);
  • the possibility to perform string test (no-load) and maximize the extent of testing and pre-commissioning.
• Module Yards are operating independently from the specific labour laws and special labour contracts that can affect on-site construction, module yards benefit from a cohesive work culture (more motivated and stable workforce,) reducing the risk of labour-related disruptions.
• The number of critical lifts will be reduced to a minimum. SPMT + Tandem Lifts (Mobile) in lieu of multiple Crawler Cranes for extended duration.
• Decrease on impact to local infrastructure.
• Reduce HSE exposure.

Cost comparison

• There is an opportunity to leverage low-cost manufacturing sites worldwide and tap into specialized skill sets.
• By sourcing steel and labour globally, we can capitalize on cost advantages while steering clear of destination taxation on individual components.
• Implementing this approach could slash on-site activities by 70% compared to traditional stick-built methods, leading to potentially over 50% reduction in equivalent manpower costs.
• Overall, this strategy could result in a total cost reduction of approximately 30%.