Modularization That Turns Complexity Into Control

Modularization is a construction strategy in which a facility is divided into prefabricated sub-units. These sub-units are fabricated in specialized yards and transported to the project site, where they are assembled and interconnected.

Engineering through modular design, construction, and installation enables shorter project schedules by allowing parallel activities. Project costs are reduced through economies of scale, optimized material usage, and competitive labor rates. Modular execution improves overall quality, lowers environmental impact, enhances safety performance, and provides single-source responsibility.

KRAFT possesses comprehensive expertise across the full modularization lifecycle, from early design development through fabrication and seamless on-site integration. Our dedicated team supports clients in developing project-specific modularization strategies, drawing on extensive experience with fabrication yards and optimized design approaches that reduce construction risk. In addition, KRAFT has developed numerical methodologies for integrated, plantwide modularization planning.

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Advantages

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• Modules are fabricated in a controlled production environment, resulting in higher quality and reduced sensitivity to clashes. Traditional stick-built construction often leads to rework, inefficiencies, and higher rejection rates.
• Modules are manufactured in dedicated yards using established procedures and familiar work practices. In contrast, stick-built construction is typically executed by multiple contracted parties that must adapt to client-specific and local regulatory requirements.
• Module yards employ skilled, permanent workforces, whereas stick-built plants are often constructed by multiple subcontractors covering civil, structural, mechanical and piping, and electrical and instrumentation scopes.
• Fabrication yards offer an extended portfolio of capabilities, including in-house pressure vessel manufacturing. This facilitates the integration of critical equipment and enables stress-free alignment.
• Modules can undergo string testing without load and allow for an increased level of testing and pre-commissioning prior to delivery.
• Module yards operate independently of site-specific labor laws and special labor agreements that can impact on-site construction. This results in a more stable and motivated workforce and reduces the risk of labor-related disruptions.
• The number of critical lifts on site is minimized by using self-propelled modular transporters and tandem mobile crane lifts instead of extended crawler crane operations.
• Modular execution reduces the impact on local infrastructure and significantly lowers health, safety, and environmental exposure during site activities.

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Cost Comparison

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• Modularization enables the use of low-cost manufacturing locations worldwide while accessing specialized skill sets.
• Global sourcing of steel and labor allows cost advantages to be realized while avoiding destination-country taxation on individual components.
• This approach can reduce on-site construction activities by up to 70 percent compared to traditional stick-built execution, resulting in potential reductions of more than 50 percent in equivalent manpower costs.
• Overall, modularization can deliver total project cost reductions of approximately 30 percent.