【In-depth Discussion on Modular Installation in HaiChuan】Great Article – Trends in Modular Construction for International EPC Projects

The origin of the modular construction concept The core of modular construction is to divide industrial facilities or building structures into multiple sub-modules; these are prefabricated and assembled in land-based factories before being transported to sea or another location for on-site installation, thereby reducing reliance on resources and minimizing construction risks. Modular construction enables the industrialization of the construction process, facilitates the efficient use of resources, and supports quality control and safety management. Due to its rationality and efficiency, an increasing number of developed countries have adopted this modular construction technology and methods; modular technology has become one of the key technologies in modern shipbuilding and offshore engineering. 　　The continuous development of modular technology has led to significant changes in design concepts, construction methods, and project management. Over the past decade or so, the construction of some coastal industrial projects that meet modular requirements has gradually adopted modular concepts. In addition to offshore modules, modular construction projects that are already fairly mature have also progressed from an exploratory stage to a more developed state in areas such as shipbuilding, desalination projects, LNG terminal projects, metallurgical projects, mining projects, energy projects, and infrastructure construction. The modularization of engineering projects is set to see rapid development in the booming international EPC project sector.

Prerequisites for adopting modular construction I. The construction site must be located along waters with good navigability. When adopting a modular construction approach for a project, it is necessary to consider the feasibility and cost-effectiveness of transporting the modules. Project sites that typically employ modular construction are located by the sea, on islands, along the coasts of the mainland, and alongside major rivers with good navigability; they must have public docks or the potential to build their own docks. 　　For inland projects, modular construction is not necessarily cost-effective. The construction site is more than 30 kilometers away from the water’s edge where large construction vessels can access it, and modular construction projects are generally not undertaken even in remote areas. A range of factors such as the construction of transportation roads, the removal of aerial obstacles, and the reinforcement of bridges will increase the project’s construction costs. 　　II. Experience in modular construction or prior research results. Whether a construction project will use modular construction methods depends on the feasibility of applying such methods to that project. Only those with experience in modular construction for similar projects, or those who were pioneers in researching modular construction for a certain type of project and have conducted in-depth studies on it, can accurately estimate costs and construction timelines, and thus minimize risks to keep project development under control. 　　In addition to offshore modules, other relatively mature modular construction projects are also gradually moving from the exploration stage to maturity in areas such as shipbuilding, desalination projects, LNG facility projects, energy projects, metallurgical projects, mining projects, and infrastructure construction.

　III. Collaboration with suppliers specializing in heavy logistics and lifting operations Modular construction technology encompasses various stages such as planning and design, factory fabrication, measurement and control, assembly, transportation, and on-site installation. It integrates advanced techniques such as BIM (Building Information Modeling), deformation control in the manufacturing of large-scale steel structures, precise measurement and positioning, remote transportation of large modules, and the lifting of heavy equipment and components. It is one of the most advanced engineering technologies in the world today. Modular construction of projects is a systematic process, with almost all its stages involving heavy-lift logistics and lifting suppliers. During the design and construction process, it is common for there to be a disconnect between aspects such as project feasibility studies and design work, and communication with logistics providers and lifting equipment suppliers; this leads to various problems during the project’s execution and increases costs. Finding an experienced and capable large-scale logistics and lifting supplier to be involved in the entire project is a crucial element for the smooth progress of modular construction projects. 　　Large-scale logistics and lifting suppliers conduct inspections of the unloading docks during the early stages of project research, and put forward technical requirements for renovation or construction ； Participated in the research on modular segmentation for design, determining the maximum module weight and size from the perspective of transport feasibility ； Put forward requirements for the module construction site and participate in its layout ； Participation in determining the lower structure of the module ； Participation in determining the technical requirements for module roll-on/roll-off, sea transport, and transshipment ； Participate in the relocation of small modules and provide accurate coordination for docking ； Propose a design scheme for specialized tooling ； Develop detailed plans for roll-on/roll-off transport, strapping and securing, sea shipping, and precise on-site positioning, and conduct analyses and evaluations of the feasibility and safety of these plans. During the project implementation phase, tasks such as lifting the modules onto vehicles, weighing them, transporting them, loading them onto ships via roll-on/roll-off method, securing them with straps, shipping them by sea, unloading them at the destination port, transporting them to the project site, positioning them accurately, and preparing and submitting the documents required by insurance experts are carried out.

Advantages of modular construction The emergence of modular approaches in construction projects and industrial installations represents a technological \"revolution\" in the installation industry; it **significantly improves project quality, progress, and safety； It also offers significant advantages over traditional construction methods in terms of energy conservation and environmental protection, cost reduction, and improving the working conditions for construction workers. 　　I. Shorten the construction period: While site grading, foundation pouring are carried out at the overseas construction site, and construction is done using a self-provided dock, module construction can take place domestically. Once the foundation construction is completed, the modules are also assembled at domestic offshore construction bases or docks. Large ocean-going ships are then used to transport these modules to the site for installation. By coordinating the entire project construction process, the project completion time can be **reduced**. 　　II. Reducing transportation costs The modules can be constructed simultaneously in different locations, which avoids interference between construction activities at various sites; this **improves construction efficiency, enables the simultaneous shipment of multiple modules, increases the loading capacity of ships, and ultimately reduces maritime transportation costs. 　　III. Enhancing safety measures 　　The modules are constructed at various offshore construction sites, shipyards, or dockyards, where there is ample space and a flat, solid surface that facilitates the use of various cranes. The favorable construction conditions improve efficiency, ensuring high quality in module construction as well as timely completion of projects. At the same time, this approach **improves the working conditions for workers and enhances construction safety. 　　IV. Avoiding legal risks International EPC project construction often encounters constraints such as local laws, resulting in numerous uncontrollable factors that make it difficult to carry out the project as planned. This leads to delays in completion and a sharp increase in construction costs. By adopting modular construction methods, it is possible to minimize the scope of work abroad and avoid as much as possible local regulations related to international labor standards, labor protection laws, customs procedures, quality inspection, and various other requirements. It enables maximum control over project construction.

V. Avoiding political, economic, and social risks Most of the international projects undertaken by Chinese engineering companies under the EPC model are located in Southeast Asia, Africa, the Middle East, and Latin America. These regions are not only poor but also suffer from political instability, significant economic fluctuations, and poor security conditions; as a result, there are many uncertainties and risks associated with carrying out construction projects in such places. Adopting a modular construction approach to minimize overseas work can reduce various risks. 　　VI. Reducing project costs International EPC projects employ modular construction, which minimizes reliance on local resources at the project site; meanwhile, domestic resources with advantages can be utilized in an intensive manner, thereby reducing risks and saving costs. The project adopts modular construction; although the amount of steel structure used increases by 30%–50%, comprehensive considerations such as export tax rebates, time savings, reduced labor costs, and a lower dependence on the resources of the country where the project is located show that modular construction **reduces the project’s construction costs compared to traditional construction methods. At the same time, it **improved project quality, progress, and safety, while avoiding risks related to politics, law, economics, and society as well. 　　(Author’s institution: China Foreign Transport Heavy Goods Logistics Co., Ltd.) 　　(The article is excerpted from the February 2015 issue of the magazine International Engineering and Labor Services)

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