As was pointed out in the opening column, change is required
for survival. In the construction world, one of those changes is
an increase in the use of modularization, which is the design or
production of something in separate sections. The use of accurate
3D models, the current shortage of skilled labor and owners’
increasing demands for zero incident jobsites in conjunction with
shorter schedules, has changed modularization from a luxury on
many large projects to a necessity. There are numerous benefits to
modularization for both the contractor and the end user, including:
- Improved safety
- Improved quality
- Shorter overall construction schedule
- Cost reduction
- Staffing benefits
IMPROVED SAFETY & QUALITY
Many owners and contractors demand incident free jobsites and
expend significant resources to achieve this goal. Modularization
can improve safety through the benefits of operating in a more
controlled environment. For small modular projects, this could
be the confines of a climate controlled fabrication facility. For
larger modular projects, it could be an off-site assembly yard, free
from hazards posed by other activity on the site. In either case,
construction sites are full of potential hazards, and work completed
off-site, in a controlled environment, has exposure to fewer hazards
– thereby reducing the potential for incidents and injuries.
Schedule
With today’s typical project lifecycles, projects are usually already
behind on the day notice-to-proceed is given. Technology has
increased the ability of A/E/C companies to provide shorter project
durations, thus increasing the expectations of most owners. Schedule
acceleration is another tremendous advantage of modularization.
Take a simple pipe rack module for example, which can be fully
assembled before the foundation work is ever completed. In this
simple example, the project could realize months of savings in the
event that soil stabilization or deep foundations are required.
Cost
Cost is usually a concern; modularization can be cost effective
and actually save money. In some cases, the money saved through
productivity increases and potentially lower wages in a given area
can more than offset the shipping cost for the modules. In other
cases, where the supporting structure is required to be substantially
increased, the cost of modularization can be a premium, but the
benefit to the schedule makes up for that premium through a
reduction in time to market.
Staffing
Modularization can also alleviate staffing issues, which are currently
plaguing nearly all contractors. The benefits of modularization with
regard to staffing are twofold. First, the number of workers required
is generally less due to the increase in productivity from working in
a controlled environment. Second, many areas of the country are
faced with more severe labor shortages than other areas. Utilizing
modules allows a significant portion of the work to be completed
away from the project site.
While modularization was once analogous with a pre-piped pump
skid, today it is much more. A little pre-planning and some out-ofthe-
box thinking have resulted in gargantuan modules assembled
and shipped by Robinson Construction and others. These
behemoths, like the ones featured below, no doubt create a sense
of awe from even the least mechanically-minded passerby who
happens to see one of them being transported.The time-lapse below
features construction of a few pipe rack modules and a 650,000 lb
process module that measured 56 ft x 54 ft x 45 ft tall. If you have a
project that you think might be a good fit for modularization, give
us a call! We are happy to answer any questions you may have.
This post first appeared in our quarterly publication, Robinson Report (Volume 15, Issue 4, 2017). View the full issue here.