While the stick-built approach remains the conventional method in construction, the costs associated with executing work on site is undeniably high. Module yards offer the same project execution tools as a construction site in a more controlled environment. Projects benefit from reduced on-site construction time, enhanced worker safety, scheduling efficiency, and lower capital costs.
At Hatch, we apply to modularization the same fundamentals as those applied to construction management and procurement: early planning and robust digital solutions. We look at each project on a case-by-case basis to determine the right approach and, unlike many of our competitors, we don’t only adhere to a stick-built approach. We apply creativity with intelligent solutions that consider cost, schedule, and risk. Then we use our industry-leading digital tools to ensure each module meets stringent safety and efficiency standards—a digital integration that allows for unparalleled precision, risk mitigation, and enhanced coordination across engineering, procurement, and construction teams. As a result, we’re shaping the way projects are assembled and delivered.
With modularization, if you’re trying to do it in FEL4, you’ve already missed the boat. When modularization strategies are considered in FEL2, or even earlier, the projects benefit the most. Thoughtful consideration can be given to site layouts, to design of project components, and to the project schedule. But the biggest challenge is identifying what to modularize. It requires particular expertise from those who know what’s possible. They have a fundamental understanding of the projects to begin with so the insights they lend, the ideas they bring, result in good solutions. By doing this early, we get the team aligned on the best project approach.
On large projects, each module can have thousands of components that all require a unique identifier. Traditionally, this process is labor-intensive and time-consuming, but digital environments like SmartPlant, which feature the automated assignment of module numbers to bulks, use intelligent algorithms to assign tags to components using predefined rules assigned to module subtype. This allows for module display sets to be generated, which are used in client, engineering, and construction reviews.
Transportation safety and efficiency hinge on the accurate calculation and management of each module’s center of gravity (COG). Digital tools provide real-time visualization of the COG within each module. As various disciplines add components to the module, the COG indicator adjusts dynamically, allowing designers to immediately identify and address any imbalances. This visual tool is crucial for ensuring that modules remain stable and safe during transport.
Accurate weight estimation is essential for the safe transportation of modules, especially when using road-truckable units with strict weight limits. In response to this, automated reporting systems are integrated with design models. Current weight estimates are within half a percent of the actual weights, significantly reducing the risk of transportation issues.
The choice of module yards, whether domestic or international, impacts logistics, cost, and schedule. While international yards offer cost advantages, the cross-ocean transportation can lead to schedule overruns and increased costs. Our experts use our digital systems to conduct a thorough analysis of these trade-offs early in the project development process, and by doing so, make informed decisions that optimize both cost and schedule.
To do this, standard quantitative modularization tradeoff study methodologies help determine the best fit for modularization strategy. The evaluation considers cost, schedule, and risk, while other site-specific trade attributes are considered on a holistic, case-by-case basis; assembly, shipping, and installation inform an all-in delivered cost and allow for a sound, full-picture decision to be made.
From automated tagging and real-time COG visualization to precise weight estimation and seamless integration with procurement, our digital tools ensure that modularization projects are executed with unparalleled precision and efficiency. This forward-thinking approach is driving the future of construction, where digital systems are integral components of a successful modularization strategy and workers feel at ease and at home where they work. As the global modularization market continues to grow, the tools that hold it together are strengthening, and as leaders in the industry, it’s our duty to keep up.
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