John Wiley & Sons Modularization Cover Modularization A practical, hands-on guide to offsite preassembly, beginning with the project as ju.. Product #: 978-1-119-82471-8 Regular price: $65.33 $65.33 Auf Lager


The Fine Art of Offsite Preassembly for Capital Projects

Kluck, Michael / Choi, Jin Ouk


1. Auflage Februar 2023
256 Seiten, Hardcover

ISBN: 978-1-119-82471-8
John Wiley & Sons

Jetzt kaufen

Preis: 69,90 €

Preis inkl. MwSt, zzgl. Versand

Weitere Versionen



A practical, hands-on guide to offsite preassembly, beginning with the project as just a concept gleam in the CEO's eye and winding all the way through implementation at the construction site.

Modularization is a philosophy change! And along with that change, comes the need to understand the implementation requirements and project mindset adjustments that impact and influence all aspects of the modular project. To accomplish this, the book provides a complete (from beginning to end) identification and evaluation of the differences that make a modular project unique, starting with the very basics in terms of definitions and setting the groundwork of expectations by identifying benefits and challenges. Then, because the journey is as important as the destination, the reader is guided through the various project phases in a manner that reflects how they would be addressed in the workplace. From the very earliest identification of concepts, through early assessment and selection of the optimal choice to be finally carried into detailed design, the reader is acquainted with each phase of the development process, including explanations and relevant suggestions for many of the questions and issues that typically come up.

A perfect reference for professional and technical leaders when developing the early, critical planning phases of modular projects, this guide offers useful examples and details on the fundamentals required to get a modular project started correctly and keep it on track. And, for those whom this is not their first foray into modular project management, this guide includes suggestions, examples, and/or lessons learned to make the subsequent module projects easier to implement.

Recognized industry experts Michael Kluck and Dr. Jin Ouk Choi have authored this guide to modularization that is ideal for owners, contractors, project management, engineers, project controls, and procurement--in fact, anyone interested in improving current construction project management practices. In addition, its thought-provoking examples and project case studies provide the perfect platform for its instructional use in teaching modular concepts.

Written from the perspective of both the Client/Owner and the EPC Contractor, this guide provides useful information needed for initial project management setup and technical details useful to working functional groups within the project. As such, it is truly a universal guide that can provide personnel at all levels within the project with the information needed to make project implementation more seamless. This book is written in terms of the large-scale industrial modularization project, but the steps and process are equally applicable to small-scale projects and projects outside the industrial construction realm.

Some of the topics covered in this guide include:
* The basics (to set a basis for major topic presentations)
* Module configurations ("good, bad, and ugly")
* A deep dive into modularization business case
* Module team and project interactions
* Module execution planning and timing
* Success factors, pitfalls and avoidance
* A walk through the "module project"
* A modular project case exercise - tying it all together
* Standardization - the next step
* What the future holds




Chapter 1 - What is Modularization?

1.1 Definitions

1.1.1 Modularization

1.1.2 Module

1.1.3 % Modularization

1.2 "Planning for Modularization" as a Best Practice

1.3 Current State of the Construction Industry

1.3.1 How Did the Construction Industry End Up in Such a Sad State of Affairs?

1.3.2 The Solution - Modularization

1.3.3 Why Aren't All Jobs Modular?

1.3.4 Module Jobs More Expensive?

1.4 Three Distinct Module Options (or Circumstances)

1.4.1 Very Limited

1.4.2 Selective Implementation

1.4.3 Maximized Modularization

1.5 What Modularization is "Not"

1.5.1 Panacea (A Solution for All Difficulties)

1.5.2 Constant

1.5.3 Easy

1.6 Summary

1.7 References

Chapter 2 - Advantages and Challenges of Modularization

2.1 Why do Fabrication Yards have an Advantage?

2.1.1 Obvious

2.1.2 Less Obvious

2.2 Advantages of Modularization

2.2.1 Reduced Capital Costs

2.2.2 Improved Schedule Performance

2.2.3 Increased Productivity

2.2.4 Improved Predictability (Surety / Reliability) or Less Variability

2.2.5 Increased Safety and Quality Performance

2.2.6 Increased Sustainability Performance (Green Benefits)

2.2.7 Site and Site Construction Team Benefits

2.3 Challenges

2.3.1 Critical Path (Reduction in Flexibility)

2.3.2 Upfront Cost (and Pre-commitment)

2.3.3 Engineering

2.3.4 Acceleration of Procurement

2.3.5 Owner & Contractor Capabilities

2.3.6 Module Fabricator Skills and Capabilities

2.3.7 Extensive Coordination

2.3.8 Logistics (Module Transportation)

2.3.9 Others

2.4 Summary

2.5 References

Chapter 3 - Industry Status on Modularization

3.1 Modular Projects Case Study

3.1.1 Case Study Methodologies

3.1.2 Sample Characteristics

3.2 Results (Industry Status on Modularization)

3.2.1 Advantages of Modularization

3.2.2 Cost and Schedule Savings Compared to Stick-Built

3.2.3 Recognized Project Difficulties and Impediments for Modularization Application

3.2.4 Business Case Drivers for Modularization

3.2.5 Types of Module Units

3.2.6 Number, Size, and Weight of Modules

3.2.7 Characteristics of Jobsite and Module Fabrication/Assembly Shops

3.3 Summary

3.4 Acknowledgments

3.5 References

Chapter 4 - What is a Module?

4.1 Common Terminologies

4.1.1 Pre-Assembled Pipe Rack or Pre-Assembled Rack (PAR)

4.1.2 Pre-Assembled Units (PAU)

4.1.3 Skid Mounted Unit (SMU) or Vendor Package Unit (VPU)

4.1.4 Vendor Assembled Unit (VAU)

4.1.5 Pre-Assembled Structure (PAS)

4.2 Other Terminologies:

4.2.1 Small PAU / Medium PAU / Large PAU / Super PAU / Mega (or Small / Medium / Large / Very Large / Mega Equipment Modules)

4.2.2 Small PAR / Medium PAR / Large / Very Large PAR (or Small / Medium / Large / Very Large Pipe Rack Modules)

4.3 Module Considerations

4.3.1 Plot Plan Development

4.3.2 What Does Such an Exercise Look Like?

4.3.3 Why Analyze the Process?

4.3.4 Steps in Maximizing Module Efficiency

4.3.5 Additional Module Considerations

4.4 Summary

4.5 References

Chapter 5 - The Business Case for Modularization

5.1 Fundamentals of the Business Case

5.1.1 What Makes a "Good" Module Candidate?

5.1.2 Every Project has Some Amount of Modularization

5.1.3 Three Distinct Levels of Involvement

5.1.4 Advantages and Challenges

5.2 Important Factors to Consider

5.2.1 Universal Key Project Drivers

5.2.2 Additional Project Specific Factors

5.3 The Business Case Process

5.4 The Business Case Model

The 13-Step Business Case Flowchart

Step 1. Modularization Technical Feasibility

Step 2. Identify Module Drivers

Step 3. Analyze Module Potential

Step 4. Perform Option Analysis

Step 5. Develop Module Scope, and Step 6. Develop Module Size

Step 7. Produce Module Definition and Index

Step 8. Develop Module Execution Strategy and Execution Plan

Step 9. Produce a Definitive Cost Estimate

Step 10. Produce a Definitive Schedule

Step 11. Check Module Viability

Step 12. Proceed with Modularization to the Next Project Phase

Step 13. Fall Back to Stick-built

5.5 How Often Should the Business Case Flowchart be Utilized?

5.6 Summary

5.7 References

Chapter 6 - The Module Team and Execution Plan Differences

6.1 The Module Team

6.1.1 Module Savvy Leader

6.1.2 The Module Team Members

6.1.3 Critical Team Members

6.1.4 Integration into Project Management

6.1.5 Module Team Growth

6.2 Execution Plan Differences (EPDs)

6.2.1 Guiding Principles

6.2.2 Topics of Execution Plan Differences

6.2.3 Detailed List of Execution Plan Differences

6.2.4 Timing of Execution Plan Differences

6.3 Summary

6.4 References

Chapter 7 - Key Critical Success Factors for Modular Project Success

7.1 Modularization Critical Success Factors (CSFs)

7.1.1 CSF Labels and Descriptions

7.1.2 Frequent Module Job Mistakes

7.1.3 Responsibility and Timing of CSFs

7.1.4 Most Delayed CSFs in Terms of Accomplishment Timing

7.2 Association between Modularization CSF and Project Performance

7.3 Training Exercise

7.4 References

Chapter 8 - The Fabrication Yard

8.1 Basic Benefits of Fab Yard

8.2 Manufacturing & Construction Mixture

8.3 Advanced Work Packaging (AWP) and Module Fabrication

8.4 Selecting Fabrication Yard

8.4.1 Project Size

8.4.2 Number of Yards Utilized

8.4.3 Location of Yard

8.4.4 Complexity

8.5 Contracting Strategy

8.5.1 Type of Contract

8.5.2 The Best Type of Subcontract

8.6 Division of Responsibility

8.7 Summary

8.8 References

Chapter 9 - Module Considerations by Project Group

9.1 Engineering Considerations

9.1.1 Module Evolution

9.1.2 Operations and Maintenance Input

9.1.3 Structural Engineering is King

9.2 Scheduling Consideration

9.3 Procurement Consideration

9.3.1 Fabrication Yard Interfacing

9.4 Sub-Contract Considerations

9.4.1 Heavy Haul (HH)

9.4.2 Vessel Transport

9.4.3 Module Offloading Facility (MOF)

9.4.4 Heavy Lift

9.4.5 Pipe Spools and Galvanized Structural Steel Fabrication

9.5 Fabrication Considerations

9.5.1 Bolted vs. Welded

9.5.2 Structural Shapes

9.6 Completion / Testing / Prep Considerations:

9.6.1 Shipping Incomplete

9.6.2 Ship Loose

9.7 Loadout Considerations:

9.7.1 Land Loadout and Self-Propelled Modular Transporter (SPMT)

9.7.2 Marine Onloading and Offloading

9.7.3 Capacity of the Wharf or Quay

9.8 Module Movement Considerations:

9.9 Module Responsibility Matrix:

9.9.1 Equipment

9.9.2 Module Movement

9.9.3 Module Loadout

9.9.4 Module Tie-down

9.9.5 Transportation

9.9.6 Offloading and Trip to the Site

9.9.7 Module Set at the Site

9.10 Shipping Considerations

9.10.1 Tying / Fastening the Module

9.10.2 Movement to Site and Hook Up

9.11 Construction Considerations

9.11.1 Understand the Schedule

9.11.2 Understand the Modules

9.12 Summary

9.13 References

Chapter 10 - A Practical Module Development Process

10.1 Introduction

10.2 Initial Project Analysis

10.3 Early Discussions

10.4 Module Tenets

10.4.1 Definitions

10.4.2 Boundaries / Limitations

10.4.3 Cost

10.4.4 Impacts

10.4.5 Experience

10.4.6 Commitment

10.5 Project Drivers

10.5.1 Cost versus Schedule

10.5.2 Other Drivers

10.5.3 Owner Furnished Equipment

10.5.4 Module Team

10.5.5 How Many and How Big

10.6 The 5-Step Module Development Process

10.6.1 Step #1 The stick-built versus Module Comparison

10.6.2 Step #2 The Module Layout

10.6.3 Step #3 Expand & Accept

10.6.4 Step #4 Schedule

10.6.5 Step #5 Cost

10.6.6 Other Activities

10.7 Concerns To Watch Out For (Lessons Learned)

10.7.1 Structural Members and Connections (otherwise known as bolted versus welded modules)

10.7.2 Module Yard Selection

10.7.3 Static and Dynamic Analyses

10.7.4 Grillage and Seafastening

10.7.5 Logistics and Transportation

10.7.6 Pre-commissioning / Commissioning

10.7.7 Setting and Hook up

10.8 The Inevitable Question

10.8.1 The Late Requested Module Study

10.8.2 Less Ambitious Options

10.9 A Couple of Observations from Experience

10.9.1 Underestimation:

10.9.2 Under Collaboration:

10.10 Conclusion

Chapter 11 - Modularization Application Case Study Exercise

11.1 Oil & Gas (Downstream) LNG Modularization Project Scenario

11.2 General Project Description and Background

11.3 Additional Project Site/Existing Facilities information

11.3.1 General Information

11.3.2 Potential African Supply Bases

11.3.3 Opportunity Island

11.3.4 Asian Fabrication Yards

11.3.5 The Houston Engineering Offices

11.3.6 Project Scope

11.3.7 Project Characteristics

11.3.8 Project Stakeholders

11.3.9 Modularization

11.4 In-Class Exercise

11.4.1 Opportunity Framing (FEL-0):

11.4.2 Suggested Student Development Activities

11.4.3 Assessment (FEL-1):

11.4.4 Suggested Student Development Activities

11.4.5 Selection / Pre-FEED (or FEL-2):

11.4.6 Suggested Student Development Activities

11.4.7 Basic Design (FEED) or (FEL-3)

11.4.8 Suggested Student Development Activities

11.4.9 EPC (Execution, Detailed Design, Procurement, and Construction):

11.4.10 Suggested Student Development Activities

Chapter 12 - Standardization: The Holy Grail of Pre-assembly

12.1 Why the Interest?

12.1.1 Design Benefits

12.1.2 Learning Curve benefits

12.1.3 Procurement Benefits

12.1.4 Cost and Schedule Benefits

12.1.5 Overall Value Captured

12.2 How Might It Impact You?

12.3 How to Implement Modularization with Standardization?

12.3.1 The 2 Methods of Combining Modularization and Standardization

12.3.2 10 Factors to Determine Potential for Standardization

12.3.3 Suggested Standardization Study Sequence

12.4 The Standardization Work Process

12.4.1 The First Unit (or Prototype)

12.4.2 All Subsequent Units

12.4.3 Owner / Client Accountability

12.5 The Standardized Approach: Critical Success Factors for Standardization

12.5.1 Continuity

12.5.2 Alignment

12.5.3 Discipline

12.6 Conclusion: You're on Your Own

12.7 Acknowledgments

12.8 References

Chapter 13 - Innovative Technologies for Modularization

13.1 Introduction

13.2 Current List of Innovative Technologies for Modularization

13.3 Technologies of Interest

13.3.1 Visualization, Information Modeling, and Simulation

13.3.2 Sensing and Data Analytics for Construction

13.3.3 Robotics and Automation

13.4 References

Chapter 14 - Moving Forward

14.1 What's Next?

14.2 So, What Did We Get Out of This?

14.3 What Did You Get Out of This?

14.4 Suggested Future Actions - Our 7 Industrial Modularization Accelerators

14.4.1 Applied Knowledge

14.4.2 Different Academic Teaching Approach

14.4.3 Identify, Acknowledge, and Incorporate Required Paradigm Shifts

14.4.4 Friendly Contracting

14.4.5 Industry Re-branding (or Making the Industry Sexy - Again)

14.4.6 More Alliances and Research

14.4.7 Planning Techniques and Their Combinations

14.5 End or Beginning?

14.6 References

Chapter 15 - Key Literature and Resources on Modularization

15.1 Key Literature from Construction Industry Institute (CII) and Dr. Choi

15.1.1 The Constructability Task Force 83-3

15.1.2 Research Team 29

15.1.3 Research Team 171

15.1.4 Research Teams 232 and 255

15.1.5 Research Teams 283

15.1.6 Dr. Choi's Dissertation and the Follow-up Research

15.1.7 CII Modularization Community for Business Advancement (MCBA) Toolkit

15.1.8 (On-going) Research Team 396

15.2 Key Research Articles on Modularization and Standardization by Dr. Choi

15.2.1 New Technologies and Approaches for Modularization

15.2.2 Modular Construction in Building Sector

15.2.3 Modular Construction for Post-Disaster Reconstruction

15.2.4 Education for Modularization

15.2.5 Accelerated Bridge Construction

15.2.6 Facility Standardization




MICHAEL KLUCK (Houston, TX) is a Senior Project Manager and modularization subject matter expert for KBR (Kellogg Brown & Root). With over 40 years in the industry, his equal time on both sides (Owner/Client and EPC contractor) of the modular project management fence has provided the basis for the unique perspective reflected in this guide.

JIN OUK CHOI, PH.D. (Las Vegas, NV) is an Associate Professor in the Department of Civil Engineering and Environmental and Construction at the University of Nevada, Las Vegas (UNLV). His extensive technical and academic work on the Modularization and Standardization research efforts dovetails nicely, providing both historic and state of the art information as well as linking the practical applications and efforts with documented technical research