Pre-Fabrication & Modularisation Handbook

PRE-FABRICATION & MODULARISATION HANDBOOK

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THE



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CONTENTS

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PRE-FABRICATION AND MODULARISATION OVERVIEW

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WHY CHOOSE MODULAR CONSTRUCTION?

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OVERCOMING THE 3 BIGGEST CHALLENGES IN MODULAR CONSTRUCTION

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WORDS FROM THE MASTER: INTERVIEW WITH THE INVENTOR OF 3RD GENERATION MODULARISATION

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THE IMPORTANCE OF BUILDING INFORMATION MODELLING

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QUICK SELECTION CRITERIA FOR MODULARISATION

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ABOUT PRE-FABRICATION CHINA 2016


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PRE-FABRICATION & MODULARISATION OVERVIEW Whilst pre-fabrication and modularisation construction techniques have been around for years, its popularity is now booming as technologies such as building information modelling (BIM), have enabled the better planning and integration of prefabricated / modular components. Furthermore, the drive towards greener, larger and more remote construction projects, particularly for the oil and gas sector, has made the advantages pre-fabrication and modularisation more favourable when deciding construction methods. But there are benefits across sectors too, notably in China’s housing sector, where the rapid pace of urbanisation has created the need to improve efficiency and meet energy and environmental goals. A survey conducted by McGraw-Hill found that of 800 architecture, engineering and contracting (AEC) professionals using prefabrication and modularisation: • 66% report that project schedules are decreased - 35% by four weeks or more. • 65% report that project budgets are decreased - 41% by 6% or more. • 77% report that construction site waste is decreased - 44% by 5% or more.1 The benefits of pre-fabrication and modularisation are significant, but to leverage these benefits, it is first necessary to carefully understand the challenges and changes necessary in your project planning, transport and construction processes. To help, this eBook will provide you with the insights you need to tackle the associated challenges pre-fabrication and modularisation.

SIMULTANEOUS TRANSLATION

B 2 S ook a sa epte nd ve m p up be ay b to r 20 efo US 15 re D$ an 12 d 50

Main Conference: 25 - 26 November 2015 u Location: Shanghai, China Pre-Conference Workshops: 24 November 2015 u Post-Conference Site Visit: 27 November 2015

Driving Efficiency, Effectiveness and Sustainability with Cutting-edge Strategies in Prefabrication & Modularisation

EXPERT SPEAKER FACULTY INCLUDES: r g eu g g nt an an t irit ite , fen f W tor, re Hu ua gji en Fe ff-s on ) un r o or m ec ua anh cts on sid ring Sa Dir sho ring ien r, O ucti AMS g J cto lu sh je ff tr m to g g H e Pre inee an ire , F Jo r, W Pro -O inee Da irec ons ms ( an W ty D ring to r g gin C te ec la Zh Vic En na etro Eng ee pu s gD r o Dir odu Ma P De ngin ry rin odula r Sy M C tu M E la en fac du nu Mo Ma tic lan At

2015 HIGHLIGHTS: 15+ experts from successful regional & local companies: ADCO will present their pro-active approach of implementing an effective quality management system throughout the modular project’s life cycle Bechtel will reveal the key aspects in addressing supplier quality surveillance, with specific case studies on how the quality assurance tactics were implemented Kearns International will share their winning strategies for mitigating financial risk by conducting feasibility studies to identify cost saving opportunities for modular projects Fluor will elaborate on accurately planning the modular projects through effective designing, scheduling, forecasting and creating contingency plans PETRONAS will showcase their best practices and continuous improvement initiatives for modular projects, aiming to achieve and sustain asset integrity, and reduce operational risks Media Partners: Research & developed by:

World ils

Plus, we’ve got 3 hands-on workshops to walk you through the ins and outs of modular construction! Join our workshops to learn more about the basics of modular construction, risk mitigation, and best practices in crossfunctional project management!

This eBook was created in preparation for the 6th Annual Prefabrication & Modular Construction China 2015, which will run 24 - 27 November, 2015 Shanghai, China. Don’t miss the chance to meet the experts in prefabrication a modular construction from companies including Petronas, Larsen and Toubro Limited-Integrated Engineering Services, Abu Dhabi Company for Onshore Oil Operations (ADCO), Atlantic Modular Systems (AMS) and many more.

A site visit to the fabrication yard at Shanghai Matsuo Steel Structure! Take a step ahead of the competition, let’s unlock the benefits of 3D Laser Scanning (3DLS)!

CLICK HERE TO LEARN MORE

www.prefabmodconstruction.com

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http://www.modular.org/htmlPage.aspx?name=McGrawHill_Prefabrication


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WHY CHOOSE MODULAR CONSTRUCTION? BENEFITS • Improved safety • Schedule compressed (civil work while pre-assembling) • Shorter onsite duration • Less field labour required (lower work density) • Cost of housing the field labour at site is reduced • Higher shop productivity • Weather related delays are minimized • Benefit from cheaper labour in low wage area or country • Lower overall project costs • Quality is improved (controlled work area) • Permitting advantages • Reduce plant footprint • Simplified foundation requirements • Decreased site risks

IMPEDIMENTS • Additional front-end planning • Early decision whether to modularise or not • Additional engineering & design considerations • Additional transportation logistic considerations and costs • Additional interface considerations • Less flexibility for design changes • Increased structural steel required • Estimating & cost control are much more complex • Insurance costs more than conventional • Layout of plant critical for access • Rejection to take work outside the country


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OVERCOMING THE 3 BIGGEST CHALLENGES IN MODULAR CONSTRUCTION Whilst a million different things can go wrong in any project, the biggest concerns in modular construction projects almost always revolve around logistics, hook-up and sequencing. This section looks at each aspect and provides the key considerations needed to overcome the challenges at each stage. Logistics In considering logistics, it is important to define fabrication location and transport & logistics constraints. In a paper released by Foster Wheeler written by Richard Brookfield and Jeremy Cooke about modularization, it was argued that “important for every modular project is the maximum module size that can be fabricated, shipped and transported. “Onshore modules typically range up to 5,000 tons, although the maximum practicable size and weight will vary from project to project dependent on the physical limitations of transportation routes and the availability of heavy-lift and transportation equipment,” it said. The key things to note include: • Identifying alternative fabrication centres both local and overseas • Survey site constraints in terms of labour availability/skills, rates, productivity, IR, local content laws, weather, environmental issues, permits, safety issues • Site access, elevations, laydown areas, heavy lift footprint • Survey all transport routes for physical constraints: power lines, bridges, roads, turning circles, etc. • Look at available public Wharfs (structural strength) or alternative • Material loading/off -loading facilities • Identify tidal movements/depth and dredging potential at offloading port • Identify vessel/barge/tug limitations: speed, draft, deck capacity, ability to discharge and acceleration characteristics • Identify land transport axle limitations • Define transport envelopes maximum & optimum) – these dictate maximum module sizes for each route

Hook-up Hook-up and commissioning is a critical phase in the successful development of a modular construction project. Good planning and control is therefore essential. In a paper entitled, The Planning and Control of Offshore Hook-up and Commissioning, the challenges involved in offshore hook-up and commissioning were detailed out: The availability of beds offshore strictly limits the size of workforce which can be employed on hook-up work and, therefore, imposes a major constraint on the schedule. Hotel- ships can be used to supplement the number of permanent platform beds but will substantially increase the manpower cost. In addition to bed limitations, manning levels are restricted by safety regulations and operating practice. The early commissioning of safety systems and equipment, such as the lifeboats, will be an important factor influencing the rate at which labour can be mobilized in the early stages.


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Sequencing With proper work schedule and sequencing, modules can allow for shorter durations of large cranes and other equipment in the field. Proper sequencing for construction minimises the handling of equipment and modules. Several of the technical considerations in preassembly that covers sequencing and other considerations: • Modularize around equipment not around structural steel and considering installation sequence • Modularize only where economic (i.e., do not ship air) • Maximize personnel access by including flooring, handrail, electrical access for cable installation, and complete access towers • Sub-stations & control rooms and transformer kiosks (c/w distribution panels) to be fitted out as transportable units • Consider alignment issues • Consider construction sequencing and module placement • Consider crane movement and laydown areas • Temporary steel should be part of the structure as much as possible • Adopt standard connection details, lifting points/lugs

Tackling Modularisation Challenges The ever increasing demand for cost-efficiency and safety in heavy engineering construction, prefabrication and modularisation is fast becoming the preferred mode of construction. Given the challenges mentioned above, in addition to coordination, planning and project management challenges, gaining a deeper understanding of these issues and learning from experts who had dealt with these issues first hand is crucial for the success of your project.


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WORDS FROM THE MASTER: INTERVIEW WITH THE INVENTOR OF 3RD GENERATION MODULARISATION Fred Haney Executive Director, Design Engineering Fluor Corporation

Whilst pre-fabrication and modularisation construction techniques have been around for years, its popularity is now booming due to competition, price sensitivity and growing maturity of the construction process itself. To learn more, we speak with Fred Haney, Executive Director, Design Engineering at Fluor Corporation and the inventor of 3rd Gen Modular Execution, who outlines the decision factors behind going modular and the trends affecting the construction industry. What role is modularisation playing in the major oil and gas projects you’re involved in? Modularisation itself on a global basis is growing quite extensively. Where projects used to be stick built around the world but now they are being considered to be constructed using a modular execution mode. I’m currently engaged in several projects in Asia, Europe, Australia, North America and we’re now looking at projects in South America as well for the oil and gas industry.

Why are major construction projects choosing to go modular? It’s largely due to the lack of quality labour in locations where it used to be available. Furthermore, the cost of labour is going up and of course this is increased further depending how remote the site is. Also weather conditions will also have a bearing on these issues as well as on productivity, whether it be in the north type conditions or being in hot climate conditions.

What lessons can we learn for onshore modularisation from the offshore modular construction world? Fluor has developed a methodology called 3rd gen modular execution, it’s a methodology that has pulled some of the best aspects of offshore designs and put it into an onshore design facility. With this methodology we can increase the per cent of modularisation that can be achieved on construction projects, which is a key element when you are talking about remote locations and maximising the movement of effort offsite.


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To execute this 3rd gen modular methodology effectively will require a change. Companies need to design new guidelines and practices as well as moving towards standardisation and replicated designs, particularly for oil and gas projects. This is the future of the industry and is due to the drivers to reduce the capital outlays on these projects, because some of them are so capital intensive. By implementing modularisation and standardisation you can see significant reduction in capital outlay and which can be the deciding factor as to whether a project goes ahead.

What are the key considerations that your company as an EPC and your client as an operator have to take into account when deciding whether to modularise or not? The first element of any modular project is understanding the transportation envelope of the modules you can ship. For example, if a project is landlocked, what will the infrastructure allow you to transport on road or on rail? This is crucial because it will have an impact on the type of design that can be achieved in regards to the modular facility. If you have water access then that’s a different story. It provides an easier design method to modularise your facility. The old saying of “bigger is better” applies to modular design. It’s much easier to design big modules than smaller ones, meaning that good analysis upfront is essential on any project on what are the exact limits on the module and the size, dimensions and weight that can be transported. Understanding these aspects and constraints is the first aspect of any modular project. Next, when you execute a modular project you have to do more work upfront in order to define the modular design. Because you are moving a tremendous amount of work offsite, you have an execution curve that is actually two curves, a construction and a fabrication curve, which will drive engineering to do more work earlier. Furthermore, long lead equipment list will be larger and you will need to procure these components earlier than you would with a traditional stick build design. Once you’ve tackled that aspect you need to at the end of FEED to have a very complete design so you can proceed without changes. When you are talking about modular design, it’s not as change-friendly as a stick built design and that is a challenge for some owners and EPC companies.

Do you see any other upcoming trends affecting modularisation? Standardisation and replication, or templating of design, these are strategies many owners are looking at now. There is a great desire from owners for having one typical design for a facility and replicating that around the world. Modular designs accommodate this extremely well because it really tackles your above ground facility which can then be easily templated and installed in global locations. So you have a combination of modularisation, standardisation and replicating or templating. This all facilitates and really enhances the overall costs of these facilities and improves productivity and puts us in the framework of what the manufacturing business is doing, so we’re moving

Photo Credit: http://imgarcade.com/1/sakhalin-island-exxon/


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THE IMPORTANCE OF BUILDING INFORMATION MODELING

Prefabrication and modular construction projects place an extensive demand on pre-project planning and coordination between cross-interdisciplinary professionals. This can cause unexpected issues can arise during prefabrication and construction, subsequently impacting project timelines. To address this issue, new technologies and processes such as Building Information Modeling (BIM) seek to streamline the coordination between project stakeholders. This software platform not only displays the project design, like with computer-aided design (CAD), but also acts as a shared knowledge resource for all information about a structure, forming a reliable basis for decisions during its life-cycle. For example, BIM can also provide information such as spatial relationships, light analysis, geographic information and the properties of building components such as the manufacturers’ details.

Benefits of Building Information Modeling 1. Improved project visualisation amongst stakeholders 2. Improved productivity due to easy retrieval of information 3. Increased coordination of construction documents 4. Embedding and linking of vital information such as vendors for specific materials, location of details and quantities required for estimation and tendering 5. Increased speed of delivery and reduced costs

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http://www.prnewswire.com/news-releases/construction-industrys-commitment-to-bim-use-in-china-is-strong-300072461.html


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The Rapidly Growing Use of BIM in China According to a new study by Dodge Data & Analytics, an average of 24 per cent construction firms and 21 per cent of architects in China already use BIM.2 However the study predicts that the percentage of those using BIM on at least 30 per cent of their projects will significantly grow by 89 per cent among architects and 108 per cent among contractors over the next two years. The study goes on the reveal: • The number one business benefit reported by contractors both in China and globally is that using BIM enhances their organization’s image as industry leader. • The top three project benefits of using BIM for Chinese contractor are: - Reduced errors and omissions in construction documents - Better collaboration with other project team organizations - Reduced rework Whilst integrating BIM it into company processes requires training and change management, the study reveals that a rapidly growing proportion of companies in China’s construction industry are already yielding the benefits of this transformative design platform and process.

Photo Credit: “CustService 630X440” by Richard Binning - Own work. Licensed under Creative Commons Attribution-Share Alike 3.0 via Wikimedia Commons http://commons.wikimedia.org/wiki/File:CustService_630X440.jpg#mediaviewer/File:CustService_630X440.jpg


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QUICK SELECTION CRITERIA FOR MODULARISATION P P P P P P P P P P

Field labour productivity is much less than shop productivity Field labour costs are higher than shop labour costs Weather may affect the construction phase Plant process/system allow modularisation Local labour requirements do not restrict use of modular construction Transport envelope allows transportation of economical modules size / weight Site permits and regulatory approvals are not readily available Lifting and transportation available, economical Fabrication capacity is available Schedule is important or critical


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DISCOVER CUTTING-EDGE STRATEGIES TO DRIVE EFFICIENCY, EFFECTIVENESS AND SUSTAINABILITY AT: B 2 S ook a sa epte nd ve m p up be ay b to r 20 efo US 15 re D$ an 12 d 50

SIMULTANEOUS TRANSLATION

24 - 27 NOVEMBER, 2015 - SHANGHAI, CHINA

Main Conference: 25 - 26 November 2015 u Location: Shanghai, China Pre-Conference Workshops: 24 November 2015 u Post-Conference Site Visit: 27 November 2015

Efficiency, Effectiveness and Sustainability with Cutting-edge Don’tDriving miss the chance to arm yourself with the essential knowledge to Strategies in Prefabrication & Modularisation ensure your projects are delivery on time and within budget. EXPERT Featuring SPEAKER FACULTY INCLUDES:

modular construction experts including:

r g t eu g ng an or, rit -site n, un a i fen f W jia nt H t e u F Off tio S) un tor o or m irec hore g ng side ing ua anh ects J n a o c u h S l c n M r, g s ie u s H re eer j g D ff eri am cto nstr s (A P in an ire , F Jo or, W Pro ng W ty D ring D ire Co t ar gin tro-O gine ha Vice Eng m c a l e e D e Z u n t r du r n e e i a p s g a n E P o D o M y ul Sy De ngi rin M Cr tu Mod lar E en u fac d u n Mo Ma tic n a l At

2015 HIGHLIGHTS:

Junfeng Wang Mohamed Daoud 15+ experts from successful regional & local companies:

Project Manager Manager (Projects Quality Mgmt.), ADCO will present their pro-active approach of implementing Fluor China Engineering & Projects (E & P) an effective quality management system throughout the modular project’s life Abu Dhabi Company forcycle Onshore Oil Operations (ADCO) Bechtel will reveal the key aspects in addressing supplier quality surveillance, with specific case studies on how the quality assurance tactics were implemented

Kearns International will share their winning strategies for mitigating financial risk by conducting feasibility studies to identify cost saving opportunities for modular projects

Plus, we’ve got 3 hands-on workshops Damien Feiriteur to walkManufacturing you through Director, the ins andModular outs of Off-site Construction modular Atlanticconstruction! Modular Systems (AMS) Join our workshops to learn more about the basics of modular construction, risk mitigation, and best practices in crossfunctional project management!

CLICK HERE TO DOWNLOAD BROCHURE

Fluor will elaborate on accurately planning the modular projects through effective designing, scheduling, forecasting and creating contingency plans

PETRONAS will showcase their best practices and continuous improvement initiatives for modular projects, aiming to achieve and sustain asset integrity, and reduce operational risks Media Partners:

World ils

A site visit to the fabrication yard at Shanghai Matsuo Steel Structure! Take a step ahead of the competition, let’s unlock the benefits of 3D Laser Scanning

Pre-Fabrication & Modularisation Handbook

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