Modular Construction Services
Mammoet’s combination of expertise, creative engineering and equipment reduces modular construction schedules and delivers modules safely – cost-effectively bringing forward the uptime of plants.
Modular construction techniques bring an array of benefits to power plants, refineries, mines and civil construction projects. Building a facility in large modules and then transporting each component to the site has huge advantages in terms of construction efficiency. The balance to be found is always between the benefits of the construction approach and the challenges it creates for the project’s logistics. By working with a heavy lifting and transport specialist from the earliest stages of the project clients can make the most of the advantages of modular construction. Realizing lower costs and shorter schedules, while managing the logistical risks.
For example, when considering construction in extreme locations such as the Arctic Circle, operations are limited by several factors. Severe weather conditions are an obvious safety issue, and the expansion of the ice pack in the winter limits access for deliveries. The labor pool in remote northern locations is also limited, so workers have to be relocated to the site, with all the associated costs and safety considerations.
A modular construction approach solves many of these problems, and contributes further efficiencies. The facility owner can source modules from the best suppliers and obtain the lowest prices by going to the global market. The vast array of components required can be constructed in parallel, reducing the timeline. And they can be fabricated in locations with a large labor force and the skillsets required for the work. Construction of the components can be carried out in a controlled environment, which enhances safety, and where weather conditions are never a limiting factor. The project schedule using conventional stick building methods, can be significantly reduced however using modular construction techniques.
Planning and design
Working with a heavy lifting and transport specialist like Mammoet from the outset means that each module can be designed with various modes of transport and lifting requirements taken into account. Mammoet will survey all the logistical options, considering the routes that might be taken, infrastructural limitations, load restrictions and permits, gradients, weather conditions, modes of transport required and any bottlenecks that could possibly impact the project’s critical path. Through careful analysis, engineering plans can be drawn up that define the optimum dimensions and weights of the modules taking the capacity of the lifting and transport equipment into account.
In addition, our careful planning will account for the forces the modules are likely to encounter on their journey. Assessing these factors in advance ensures that fastening points are included in the construction so that modules can be secured in place, whatever the chosen methods are for transport and lifting. Detailed engineering also ensures that the modules are built with the right level of reinforcement in place, for instance to withstand journeys by sea. If further reinforcement is required, Mammoet can engineer this as part of the transport and lifting solution.
Prefabrication versus stick building
Major industrial facilities like petrochemical plants, offshore oil and gas facilities and mines are not the only beneficiaries of modular construction. In civil construction projects it offers a range of advantages. Infrastructure or building components can be built or assembled next to the construction site to allow simultaneous construction and demolition or preparation activities to take place. This approach can minimize disruption to the local area while improving safety and bringing forward deadlines.
The roof of a stadium, for instance, would require a great deal of work at height and months of construction time. However, if it is prefabricated in a designated area near the construction site, then moved and lifted into place when it’s ready, it can be built in parallel with the main stands – shortening the project’s timeline and ensuring the facility can go into use sooner. This approach also greatly enhances overall site safety.
Similarly, bridges and transport structures, vital to a city’s infrastructure, can be replaced in operations that take place overnight, or over a weekend. This realizes significant time savings compared to a demolition and reconstruction project, which would take months. New bridge sections can be built whole in areas near the transport route. When complete, the road or rail line carried by the bridge can be closed for a short period while the old bridge is moved aside for demolition using heavy lifting and transport equipment, and the new one is slotted into place.
Mammoet has extensive experience in crafting solutions for modular construction across a range of scenarios. We have worked with clients in the offshore, petrochemical, power, nuclear, civil construction and mining sectors and our professionals have an in-depth understanding of the requirements of each industry. Our approach to engineering and logistics often leads to significant savings in time and money, improving safety and cost effectiveness while minimizing environmental impacts and disruption to local businesses or communities.