Modularization: The Fine Art of Offsite Preassembly for Capital Projects

Cover
Title Page
Copyright Page
Contents
Preface
Acknowledgements
Introduction
	Chapter 1: What Is Modularization?
	Chapter 2: Advantages and Challenges of Modularization
	Chapter 3: Industry Status on Modularization
	Chapter 4: What Is a Module?
	Chapter 5: The Business Case for Modularization
	Chapter 6: The Module Team and Execution Plan Differences
	Chapter 7: Key Critical Success Factors for Modular Project Success
	Chapter 8: The Fabrication Yard
	Chapter 9: Module Considerations by Project Group
	Chapter 10: A Practical Module Development Process
	Chapter 11: Modularization Application Case Study Exercise
	Chapter 12: Standardization: The Holy Grail of Pre-Assembly
	Chapter 13: Innovative Technologies for Modularization
	Chapter 14: Moving Forward
	Chapter 15: Key Literature and Resources on Modularization
Chapter 1 What Is Modularization?
	1.1 Definitions
		1.1.1 Modularization
		1.1.2 Module
		1.1.3 Percentage Modularization
	1.2 “Planning for Modularization” as a Best Practice
	1.3 Current State of the Construction Industry
		1.3.1 How Did the Construction Industry End Up in Such a Sad State of Affairs?
		1.3.2 The Solution: Modularization
		1.3.3 Why Aren’t All Jobs Modular?
		1.3.4 Are Module Jobs More Expensive?
	1.4 Three Distinct Module Options (or Circumstances)
		1.4.1 Very Limited
		1.4.2 Selective Implementation
		1.4.3 Maximized Modularization
	1.5 What Modularization Is “Not”
		1.5.1 Panacea (a Solution for All Difficulties)
		1.5.2 Constant
		1.5.3 Easy
	1.6 Summary
	References
Chapter 2 Advantages and Challenges of Modularization
	2.1 Why Do Fabrication Yards Have an Advantage?
		2.1.1 Obvious Reasons
		2.1.2 Less Obvious Reasons
	2.2 Advantages of Modularization
		2.2.1 Reduced Capital Costs
		2.2.2 Improved Schedule Performance
		2.2.3 Increased Productivity
		2.2.4 Improved Predictability (Surety/Reliability) or Less Variability
		2.2.5 Increased Safety and Quality Performance
		2.2.6 Increased Sustainability Performance (Green Benefits)
		2.2.7 Site and Site Construction Team Benefits
	2.3 Challenges
		2.3.1 Critical Path (Reduction in Flexibility)
		2.3.2 Upfront Cost (and Pre-Commitment)
		2.3.3 Barriers to Engineering
		2.3.4 Acceleration of Procurement
		2.3.5 Owner and Contractor Capabilities
		2.3.6 Module Fabricator Skills and Capabilities
		2.3.7 Extensive Coordination
		2.3.8 Logistics (Module Transportation)
		2.3.9 Others
	2.4 Summary
	References
Chapter 3 Industry Status on Modularization
	3.1 Modular Projects Case Study
		3.1.1 Case Study Methodologies
		3.1.2 Sample Characteristics
	3.2 Results (Industry Status on Modularization)
		3.2.1 Advantages of Modularization
		3.2.2 Cost and Schedule Savings Compared to Stick-Built
		3.2.3 Recognized Project Difficulties and Impediments to Modularization Application
		3.2.4 Business Case Drivers for Modularization
		3.2.5 Types of Module Units
		3.2.6 Number, Size, and Weight of Modules
		3.2.7 Characteristics of Job Site and Module Fabrication/Assembly Shops
	3.3 Summary
	Acknowledgments
	References
Chapter 4 What Is a Module?
	4.1 Common Terms
		4.1.1 Pre-Assembled Pipe Rack or Pre-Assembled Rack (PAR)
		4.1.2 Pre-Assembled Units (PAU)
		4.1.3 Skid Mounted Unit (SMU) or Vendor Package Unit (VPU)
		4.1.4 Vendor Assembled Unit (VAU)
		4.1.5 Pre-Assembled Structure (PAS)
	4.2 Other Terms
		4.2.1 Small PAU/Medium PAU/Large PAU/Super PAU/Mega (or Small/Medium/Large/Very Large/Mega Equipment Modules)
		4.2.2 Small PAR/Medium PAR/Large/Very Large PAR (or Small/Medium/Large/Very Large Pipe Rack Modules)
	4.3 Module Considerations
		4.3.1 Plot Plan Development
		4.3.2 What Does Such an Exercise Look Like?
		4.3.3 Why Analyze the Process?
		4.3.4 Steps in Maximizing Module Efficiency
		4.3.5 Additional Module Considerations
	4.4 Summary
	References
Chapter 5 The Business Case for Modularization
	5.1 Fundamentals of the Business Case
		5.1.1 What Makes a “Good” Module Candidate?
		5.1.2 Every Project Has Some Amount of Modularization
		5.1.3 Three Distinct Levels of Involvement
		5.1.4 Advantages and Challenges
	5.2 Important Factors to Consider
		5.2.1 Universal Key Project Drivers
		5.2.2 Additional Project-Specific Factors
	5.3 The Business Case Process
	5.4 The Business Case Model
		Project Analysis
		The 13-Step Business Case Flowchart
	5.5 The 13-Step Business Case Flowchart
		Step 1 Modularization Technical Feasibility
		Step 2 Identify Module Drivers
		Step 3 Analyze Module Potential
		Step 4 Perform Options Analysis
		Step 5 Develop Module Scope, and Step 6 Develop Module Size
		Step 7 Produce Module Definition and Index
		Step 8 Develop Execution Strategy and Execution Plan
		Step 9 Produce a Definitive Cost Estimate
		Step 10 Produce a Definitive Schedule
		Step 11 Check Module Viability
		Step 12 Proceed with Modularization to the Next Project Phase
		Step 13 Fall Back to Stick-Built
	5.6 How Often Should the Business Case Flowchart Be Utilized?
	5.7 Summary
	References
Chapter 6 The Module Team and Execution Plan Differences
	6.1 The Module Team
		6.1.1 A Module-Savvy Leader
		6.1.2 The Module Team Members
		6.1.3 Critical Team Members
		6.1.4 Integration into Project Management
		6.1.5 Module Team Growth
	6.2 Execution Plan Differences (EPDs)
		6.2.1 Guiding Principles
		6.2.2 Topics of Execution Plan Differences
		6.2.3 Detailed List of Execution Plan Differences
		6.2.4 Timing of Execution Plan Differences
	6.3 Summary
	References
Chapter 7 Key Critical Success Factors for Modular Project Success
	7.1 Modularization Critical Success Factors (CSFs)
		7.1.1 CSF Labels and Descriptions
		7.1.2 Frequent Module Job Mistakes
		7.1.3 Responsibility and Timing of CSFs
		7.1.4 Most Delayed CSFs in Terms of Accomplishment Timing
	7.2 Association between Modularization CSF and Project Performance
	7.3 Training Exercise
		7.3.1 Instructions for the Training Exercise
	References
Chapter 8 The Fabrication Yard
	8.1 Basic Benefits of the Fab Yard
	8.2 Manufacturing and Construction Mixture
	8.3 AWP and Module Fabrication
	8.4 Selecting a Fabrication Yard
		8.4.1 Project Size
		8.4.2 Number of Yards Utilized
		8.4.3 Location of the Yard
		8.4.4 Complexity
	8.5 Contracting Strategy
		8.5.1 Type of Contract
		8.5.2 The Best Type of Subcontract
	8.6 Division of Responsibility
	8.7 Summary
	Reference
Chapter 9 Module Considerations by Project Group
	9.1 Engineering Considerations
		9.1.1 Module Evolution
		9.1.2 Operations and Maintenance Input
		9.1.3 Structural Engineering Is King
	9.2 Scheduling Considerations
	9.3 Procurement Considerations
		9.3.1 Fabrication Yard Interfacing
	9.4 Sub-Contract Considerations
		9.4.1 Heavy Haul (HH)
		9.4.2 Vessel Transport
		9.4.3 Module Offloading Facility (MOF)
		9.4.4 Heavy Lift (HL)
		9.4.5 Pipe Spools and Galvanized Structural Steel Fabrication
	9.5 Fabrication Considerations
		9.5.1 Bolted vs. Welded
		9.5.2 Structural Shapes
	9.6 Completion/Testing/Prep Considerations
		9.6.1 Shipping Incomplete
		9.6.2 Ship Loose
	9.7 Load-out Considerations
		9.7.1 Land Load-out and Self-Propelled Modular Transporters (SPMTs)
		9.7.2 Marine Onloading and Offloading
		9.7.3 Capacity of the Wharf or Quay
	9.8 Module Movement Considerations
	9.9 Module Responsibility Matrix
	9.10 Shipping Considerations
		9.10.1 Tying or Fastening the Module
		9.10.2 Movement to Site and Hook-Up
	9.11 Construction Considerations
		9.11.1 Understand the Schedule
		9.11.2 Understand the Modules
	9.12 Summary
	References
Chapter 10 A Practical Module Development Process
	10.1 Introduction
	10.2 Initial Project Analysis
		10.2.1 Reality Check Questions
	10.3 Early Discussions
	10.4 Module Tenets
		10.4.1 Definitions
		10.4.2 Boundaries and Limitations
		10.4.3 Cost
		10.4.4 Impacts
		10.4.5 Experience
		10.4.6 Commitment
	10.5 Project Drivers
		10.5.1 Cost versus Schedule
		10.5.2 Other Drivers
		10.5.3 Owner-Furnished Equipment
		10.5.4 The Module Team
		10.5.5 How Many and How Big?
	10.6 The Five-Step Module Development Process
		10.6.1 Step #1 The Stick-Built versus Module Comparison
		10.6.2 Step #2 The Module Layout
		10.6.3 Step #3 Expand and Accept
		10.6.4 Step #4 Schedule
		10.6.5 Step #5 Cost
		10.6.6 Other Activities
	10.7 Concerns to Watch Out For (Lessons Learned)
	10.8 The Inevitable Question
		10.8.1 The Late Requested Module Study
		10.8.2 Less Ambitious Options
	10.9 A Couple of Observations from Experience
		10.9.1 Underestimation
		10.9.2 Under-Collaboration
	10.10 Conclusion
Chapter 11 Modularization Application Case Study Exercise
	11.1 Oil and Gas (Downstream) LNG Modularization Project Scenario1
	11.2 General Project Description and Background
	11.3 Additional Project Site/Existing Facilities Information
		11.3.1 General Information
		11.3.2 Potential African Supply Bases
		11.3.3 Opportunity Island
		11.3.4 Asian Fabrication Yards
		11.3.5 The Houston Engineering Offices
		11.3.6 Project Scope
		11.3.7 Project Characteristics
		11.3.8 Project Stakeholders
		11.3.9 Modularization
	11.4 In-Class Exercise
		Opportunity Framing (FEL-0)
		11.4.1 Suggested Student Development Activities
		11.4.2 Suggested Student Development Activities
		11.4.3 Suggested Student Development Activities
		11.4.4 Suggested Student Development Activities
		11.4.5 Suggested Student Development Activities
Chapter 12 Standardization
	12.1 Why the Interest?
		12.1.1 Design Benefits
		12.1.2 Learning Curve Benefits
		12.1.3 Procurement Benefits
		12.1.4 Cost and Schedule Benefits
		12.1.5 Overall Value Captured
	12.2 How Might It Impact You?
		Example
	12.3 How to Implement Modularization with Standardization?
		12.3.1 The Two Methods of Combining Modularization and Standardization
		12.3.2 Ten Factors to Determine Potential for Standardization
		12.3.3 Suggested Standardization Study Sequence
	12.4 The Standardization Work Process
		12.4.1 The First Unit (or Prototype)
		12.4.2 All Subsequent Units
		12.4.3 Owner/Client Accountability
	12.5 The Standardized Approach: Critical Success Factors for Standardization
		12.5.1 Continuity
		12.5.2 Alignment
		12.5.3 Discipline
	12.6 Conclusion: You’re on Your Own
	Acknowledgments
	References
Chapter 13 Innovative Technologies for Modularization
	13.1 Introduction
	13.2 Current List of Innovative Technologies for Modularization
	13.3 Technologies of Interest
		13.3.1 Visualization, Information Modeling, and Simulation
		13.3.2 Sensing and Data Analytics for Construction
		13.3.3 Robotics and Automation
	References
Chapter 14 Moving Forward
	14.1 What’s Next?
	14.2 So, What Did We Get Out of This?
	14.3 What Did You Get Out of This?
	14.4 Suggested Future Actions: Our Seven Industrial Modularization Accelerators
		14.4.1 Applied Knowledge
		14.4.2 A Different Academic Teaching Approach
		14.4.3 Identify, Acknowledge, and Incorporate Required Paradigm Shifts
		14.4.4 Friendly Contracting
		14.4.5 Industry Re-branding (or Making the Industry Sexy, Again)
		14.4.6 More Alliances and Research
		14.4.7 Planning Techniques and Their Combinations
	14.5 The End or the Beginning?
	References
Chapter 15 Key Literature and Resources on Modularization
	15.1 Key Literature from Construction Industry Institute (CII) and Dr. Choi
		15.1.1 The Constructability Task Force 83-3
		15.1.2 Research Team 29
		15.1.3 Research Team 171
		15.1.4 Research Teams 232 and 255
		15.1.5 Research Team 283
		15.1.6 Dr. Choi’s Dissertation and the Follow-up Research
		15.1.7 CII Modularization Community for Business Advancement (MCBA) Toolkit
		15.1.8 (Ongoing) Research Team 396
	15.2 Key Research Articles on Modularization and Standardization by Dr. Choi
		15.2.1 New Technologies and Approaches for Modularization
		15.2.2 Modular Construction in the Building Sector
		15.2.3 Modular Construction for Post-Disaster Reconstruction
		15.2.4 Education for Modularization
		15.2.5 Accelerated Bridge Construction
		15.2.6 Facility Standardization
Abbreviations
Contributors
Index
EULA