This presentation discusses strategies for smooth integration of modular construction on-site. Key points include identifying opportunities for modularization through cost savings analysis and risk reduction. The modularization strategy must be integrated throughout the project lifecycle from design through construction. Module detailing should involve collaboration between designers, fabricators and installers. Site work must be planned to align with modular delivery and interface connections. Efficient module installation and hook-up can significantly reduce construction costs and duration. Attention to interface tolerances and constructability is important for smooth on-site integration of modular components.

1. Smooth Integration
of Modules On-Site
6TH ANNUAL MODULAR CONSTRUCTION &
PREFABRICATION SUMMIT
PRESENTER: SCOTT COOMBES

2. Introduction
Project Manager, having been a Project
Engineer and involved in the Coal Seam Gas
industry for the last 7.5 yeas.
Involved in a range of
projects (over the full
life-cycle):
• Large gas compression
and processing plants,
• Gas and water
gathering networks
including wellhead
surface facilities.
• Exploration pilots and
dam construction.
• Water treatment and
water / brine injection
test facilities.

3. Agenda
A. Introduction
B. Why modularise / pre-fabricate
C. Identification of opportunities and cost savings
D. Integration of modularisation strategy within project
E. Identifying whether detailing developed is in collaboration with the
design team, general contractor, fabricator and installer.
F. Designing the project so that work structured for what is done on-site
matches what has been manufactured in the factory
G. Efficient flow of site assembly works.
H. Hook-up / connection onsite
I. Closing summary

4. I believe the principals behind
successful modularisation apply
across all sectors.
I will also provide some specific
examples of what worked. This will
be based on process plants.
For the purpose of this
presentation:
• Pre-fabrication,
• Equipment skidding,
• Equipment modularisation
Can all be take as “modularisation”;
the principal discussed generally
apply to all of the above.

5. Why modularise / pre-
fabricate?
The drivers behind your modularisation strategy should be clear:
• What do you hope to achieve in taking this approach?
• What are the trade offs that have been made?
• What are the risk associated with the strategy being taken?
Delving deeper than a presumed and schedule saving or quality
improvement.
Being clear of the objectives and this feeding into each stage of work
and work planning is key.
Integration (or planning) of your modularisation strategy over the whole
of project lifecycle is key to the best results (or success as verse failure
in some cases).
This especially the case is this is different to you (as a company / team).

6. Benefits
Cost:
• Access to lower labour rates,
• Access to lower / no labour overheads,
• Improved labour efficiency,
Schedule:
• Early commencement long lead scope.
• Design interfaces (can be a decrease in
complexity or an increase in complexity).
• Elimination of trades / work sequences on
critical path site works.
• May be the only effective method for
concurrent work.
De-risking project
• Work outside of weather issues or site
access considerations.
• May be more able to remove scope poor
performing fabricators as vs site works.
• Typically shop or yard fabrication is able to
be executed in a manner lending itself to
safer methods as well as better / more
efficient QA / QC process.
Project Management:
• Typically a structured / effective
method for separation of scope and
packages to various parties (with
options for more competitive
bidding).
• Can simplify site installation scope,
and provide clear boundaries
between scopes.
• Fabrication management is typically
less intensive than site management
(onshore fabrication).
• Reduced site scope / time with the
associated stakeholder benefits.
• Decongested worksites / reduced site
manning pressures.
• Ability for extensive offsite testing
and control optimisation.

7. Identification of opportunities
and cost savings.
Suggestions for identification and
prioritisation:
• Break the project down and target the
high cost area’s first.
• Quantify the cost difference between
on and off site work (including
efficiency).
• Identify the associated benefits from
modularisation, benchmark and cost
these.
• Review what others are doing, out of
your sector / industry (good for idea’s
and contacts).
• Look at what’s putting the highest risk
and or management burden into your
project.
$-
$50.00
$100.00
$150.00
$200.00
$250.00
Brisbane Remote
Rate Comparison - Supervisor (2014)
($/h)
Base Rate (to client) Accomidation
Vehicle Costs Travel on and off shift costs
Daily paid travel time Remote site productivity impact

8. Why Modularise - A specific case on
specialised labour.
Equipment, plant and system complexity generally increasing over
time.
This leads to increased requirements for specialist labour onsite,
especially during start up and commissioning.
The overhead, lead time and resource utilisation on site is lower than
in most fabrication workshops or yards.
One example. Mobilisation of a specific PLC programmer from
Adelaide to central Queensland.
• 2+ days of induction,
• 1 week lead time, 2 days mobilisation and demobilisation each way.
• Increased rates,
• Decreased productivity onsite.
For less than a weeks work onsite. Do it before the equipment arrives
onsite.

9. Integration of modularisation
strategy within a project
As the portion of scope that is modularised or the module complexity
increase’s this integration (or consideration of impacts) increasingly
critical.
Key considerations in early project planning / feasibility are:
Logistics Estimating and Planning Design
Transport / route module size
/ weight limits, can these be
changed?
What are the cost savings
(and what drives the
realisation of those costs).
Does the system / project
lend itself (or parts of it) to
modularisation or pre
fabrication.
Receiving site size / weight
limits.
What are the cost increases. Are there any major
departures in design
requirements to the norm?
Transport options lead-time,
duration and time
constraints.
What are the schedule
changes.
What’s the best module
stagey considering available
information.

10. Design and Delivery
Design Fabrication Contracting
Are new skills required? Complexity of scope and risk to project may
be different. Are you using the right
contract’s (from both a management and risk
mitigation perspective).
How is the layout / high level design done
considerate of modularisation. Factoring
access, lifting, module connection /
interfaces.
Depending on strategy, there may be an
increased volume of work tendered /
procured / expedited.
How do the modules interface efficiently. Are you fabricators experienced delivering to
the required standards (more QA / QC or
documentation scope may be associated with
the increased module scope).
What are the O&M requirements relating to
access, congestion or packaging.
How are transport constraints to be
managed? Are there any constraints local to
the fabricator?

11. Design and Delivery - continued
Construction Others
Does the construction work planning and
execution hinge on module deliveries?
Do you have to build out from modules?
Is there enough scope outside of the modules
(or enough work force flexibility) to cope with
changed module delivery dates?
Are there any stakeholder impacts e.g.
• Concerns over local content
• Impacts to the community due to module
transport (can be very visible).
Is a change in the workforce or plant
equipment required for efficient delivery.
Maximisation of offsite testing and plant
optimisation.
Is there a risk of damage to modules during
installation.
Are there any new major risks to the project,
what’s the mitigation plan or contingency.
Should you be adopting a just in time deliver
and place strategy or stockpile / stage and
install?
It becomes clear that these are not typically one dimensional problems.

12. Module detailing
Who’s best place to complete layout and detail design?
• In-house design team?
• Engineering consultants?
• Fabricator?
• Installation Contractor?
• Collaboration?
Collaboration, not the simple recipe for success;
• Stronger design leaders are required to coalesce options and idea’s into direction.
• Have found non design phase personnel can struggle finding good input and visualising both the
design and issues. Good technical leads are required to ask the right questions. Maybe
requiring mock-up’s, preliminary design details or prototypes to get the right input from
stakeholders and non design personnel.

13. Module detailing - Experience
Experience (with modular design) maters:
a) Good “normal approach” designers may not adapt to the changed requirements as well as
expected. Often resulting in missed opportunities.
b) There may be new design challenges, where the lack of experience becomes apparent (e.g.
design for transport size and loads, increased detailed consideration of O&M access,
complexity in module interfaces and layout details, new constructability issues).
c) Experience aligned with your modularisation objectives (or the key project lifecycle phases)
may be critical.
d) The rework / change complexity is typically higher with modularisation (mistakes and late
design evolution or changes cost more and take longer).

14. Module detailing -
Recommendations
Recommendations:
a) In early design stages look at what changes may have occurred. May need increased
stakeholder consultation in design / detailing (end users / operations and maintenance).
b) The right choice for detailing depends on your project, but likely uses either fabricators /
packagers or experienced engineering firms for the detailing for more extensive projects and
may uses your own for smaller or less complicated scopes.
c) Setting out the objectives, constraints (e.g. size) and specific requirements needs to be done
(or closely facilitated) by the project “owner”. This will also include making sure there is the
right representation from non design team disciplines for collaboration.
d) If your doing more extensive modularisation, this experience matters from the early project
stages such as layout.
e) It may be wise to allocate specific resources, deliverables and time to management and
maximisation of your modularisation outcomes (likely a experienced cross discipline
resources).

15. Site-work alignment for
modularisation
Extensive modularisation changes site work scope and also commercial /
contractual risks.
Module delivery to site may become key, with little ability to mitigate delays
by moving work fronts.
Clear scope for module installation and connection becomes increasingly
important.
Consider:
a) Align module design and fabrication sequence with site “areas”, packages or separable portions
where the site works can be done with a degree of independence from other areas. Align work
planning and scoping with this breakdown.
b) Fabricator / equipment package documentation is likely to be come more complex and extensive as
well as more critical for successful site works. Early identification and management of this with
fabricators and vendors is key. Leading into site work scoping and planning.
c) Module interfaces become important. Ensure that specific work planning is given to the interface
area’s and installation sequence.

16. Efficient flow of site assembly
works
Connection details:
• Constructability considered at design and installation planning.
• Adequately detailed.
• Interfaces (e.g. HD bolts) checked against as-con module dimensions (with sufficient
accuracy).
Module fit out / installation:
• Options to streamline fit out such as KOP’s issued with modules.
• Adequate installation details (manuals, assembly drawings etc.). Early enough for
construction estimating and planning.
Module delivery strategy
• Do you need to go with deliver and place or can you stage in local laydown?
• If there are a large number of modules, without major lifting or transport issues staging on
site gives some options during construction management.
• Avoid surprises on delivery or start up from transport damage (ensure specific thought is
given to transport and lifting loads as well as vibration and fatigue during design).

17. Efficient flow of site assembly
works
Safety and productivity – reduced working at heights.
Modules can be assembled at ground level and lifted into place.

18. Hook-up / connection onsite
I believe this is one of the key areas where a marked improvement in
savings and efficiencies from Modularisation and pre-fabrication can
come from.
True in all disciplines.
Biggest opportunities in structural, mechanical / piping, electrical and
concrete (pre-cast founding, landings and so forth).
Key points:
• Set metrics for design, which reflect your project objectives (e.g. number of
site connected pipes, number of modules) and drive these down.
• One of the biggest area’s where constructability reviews or input can benefit
• Be mindful of fabrication / foundation tolerances and the risks of damage
during placement.

19. Hook-up / connection onsite –
Mechanical alignment

20. Hook-up / connection onsite –
Instrument, Control and Electrical
Approach:
• ICE modularised
• Local PLC control for
each major processing
system
• Segregated process
control
• Balance of plant IO
and scope outside of
major packages
collected in separate
field IO cabinet
Specific example: Injection Trial Plant

21. Hook-up / connection onsite –
Instrument, Control and Electrical
Outcome:
• Simple integration and
interfaces (no
contractual issues RE
interfaces).
• Independent start of
each module
(concurrent work
fronts).
• Independent re-use of
each process system.
• Reduction in skilled
labour onsite as well as
reduction in hours.
0
50
100
150
200
250
300
350
400
Instruments Modularised
97% Reduction in
field terminations
Insturments
Number Modualrised
0
5
10
15
20
25
30
35
40
45
50
Aux. Skid connections within
packages
100% Reduction in
field terminations
Insturments Number plugged
0
20
40
60
80
100
120
140
160
Remote IO
93% Reduction in
field terminations
Incoming terminations
No. Field terminations

22. Hook-up / connection onsite –
Instrument, Control and Electrical
End use
Module “MCC”
Power Supply in and supply
to each system / area
Main Plant
Switchboard
Primary
Module A
On module
loads
Aux. Modules
Primary
Module B
On module
loads
Balance of
Plant Switch
board
Site lighting
Non
modularised
scope

23. Hook-up / connection onsite –
Instrument, Control and Electrical
Plugs can be a big benefit come site installation.

24. Hook-up / connection onsite –
Interface tolerances
Allow sufficient degree’s of freedom
for interface connection.
Length may be used to minimise
angular deflection.
Precision alignment between modules may not be viable, cost
effective, or necessary. Plan for this in your design.

25. Closing summary
Much of the above has talked about, design, integration thought all
stages of the project and clear objectives.
That’s because they by and large come to fruition as smooth integration
onsite and better project outcomes.
Hopefully the ideas and examples provided help drive your successful
modularisation and pre-fabrication.
For further advice, assistance or engineering and design:
Scott.Coombes@outlook.com
au.linkedin.com/in/ScottCoombesPM