Modularisation (Modularization)

Modular means related module or constructed with standardised units (modules) that applies pre-engineered, factory fabricated structures between 80 to 95% are completed at the factory and then delivered to the site for final assembly.

Modular Construction is a construction technique in which all or a part of sections or facilities are prefabricated or assembled in one location and then transported to the site, placed in position, and connected. The modules are limited in size and weight only by handling capabilities such as fabrication yard, inland and ocean transportation, erection or installation capacity.

Modular Design is an engineering technique that is a module design of a complete unit or plant divide into smaller sections (system or subsystem) with tie-in provisions.

Modularisation (Modularization) is one of the construction methods that is applicable for difficulties in a skilled labour mobilisation at the site or remote areas and significantly disadvantages in economics for a traditional stick-built construction method which requires the large number of labours, construction equipment and supporting infrastructures. Modules are self contained and operated with essential utility supply. In general, a Modularisation project is shorter project schedule, but cost is dependent.  

Module Design and Engineering is slightly different form a normal engineering that is the reinforcement of structures for transportations and minimisation of ground spaces. The Modules are fabricated (pre-fabricated) or manufactured at the module shop yard, tested, pre-commissioned, preserved and transported to the site for the installation and connection (tie-ins) to other module or existing facility to complete a unit or plant. Modularisation plan is required in the beginning of the project, and to be performed a module design and engineering, procurement and construction.

Centre of Gravity (COG) is a weight control work process for module design and engineering for the transportation and installation at the site. A COG of a symmetrical body of a uniform material is in the geometric centre, in volume or area at which the facility or contents is in balance.

Pre-fabrication is the practice of assembling components of structures (steels or piping materials) in a factory or other manufacturing site, and transporting the complete assemblies or semi-assemblies to the construction site where the structure is to be located. The term is used to distinguish this process from the more conventional construction practice of transporting the basic materials to the construction site where all assembly is carried out. The Pre-fabrication is a volumetric application or based at component level, needs affection to the construction process. The benefits of using pre-fabrication include: higher quality products, improved productivity, and environmental benefits associated with its use. (Refer to the Piping Pre-fabrication)

Modularity is a degree of the modular application that depends on the project, especially the location of the construction site. 

Module is a set of separated parts from a complete unit or plant, or the self contained and operated with essential utility supply that is a transportable pre-assembly components of process plant designed to minimise site installation and commissioning activities, and labour costs.

Module Envelope Drawing is a modularisation plan drawing (module drawing index) with individual breakdown modules that is the basic technical data and performance requirements for the development or design selection of each module. The Module Envelope Drawing is extended detail drawings, specifications, or vendor item controls or source control drawings, etc.

Module Types are pre-assembled unit (PAU), pre-assembled rack (PAR), pre-assembled building (PAB), and vendor assembled unit (VAU).

Pre-Assembled Building (PAB) is one of the modular construction methods, especially buildings with building contents (e.g., Control Room, Substation, etc.).

Pre-Assembled Rack (PAR) is one of a modular construction method, especially Pipe Racks.

Pre-Assembled Unit (PAU) is the combination of the number of separate components into a partially or fully complete unit or system. Typical example includes a fully dressed vessel completed with the insulation, platform, ladder, walkway, piping, and instrument, etc.

Vendor Assembled Unit (VAU) or Skid Mounted Module is a number of separate items of equipment on a common base frame or skid that is a well established technique by a manufacturer as a package item. The method can be used in many applications to combine adjacent or connected items of equipment (e.g., combining rotating equipment with drivers and compressors with receivers, etc.)

Module Yard is a module manufacturing shop, or remote location of assembling and installation of components on or in a specific module.

Optimum Module Size and Inclusions are depending on the project economics, module handling capability as well as severity of project such as the project duration, quality, safety and environmental requirement. A Module handling capacity includes the module design and engineering experience; capacity of module fabrication shop; transportation ability for inland and ocean; accessibility to the site; module erection capacity (module installation equipment) at the site; equipment and material delivery schedule to the module fabrication shop; and skilled labour mobilisations, etc. 

Skid Mounted Construction is the assembling equipment and materials at point of manufacture on the permanent frame or structure that is a popular erection method and one of the most efficient and cost effective ways of construction. The Skid Mounted Equipment can then be easily and securely transported and used as a unit. Individual skids can contain complete process systems and multiple process skids can be combined to create larger process systems or entire portable plants. The Skid Mounted Construction can be advantaged including lower construction costs and shorter construction durations, improved site safety and quality, and single point manufacture and construction responsibility, etc.

Stick Built is a traditional construction method that is constructed and built entirely at the site. The Stick Built construction process is erected and installed the delivered equipment and materials piece by piece at the site as supplier's original manufacturing conditions with minor additional works, dress-up, spool prefabrication. (Opposite of the Modular Construction)

Modularization