Breakbulk Americas 2011: Modularization Adds Complexity

While modularization is not new, the size of modules has grown significantly, panelists at Breakbulk Americas 2011 session on the impact of increased modularization agreed. Modules have gone from small over-sized truckloads to mega-modules measuring 45 feet tall and weighing hundreds of tons. Added size brings more complexity to shipping these huge pieces.

The panel was moderated by Grant Wattman, director of logistics and expediting at CH2M HILL. Wattman was joined by Richard Knoll, owner of Drexel Logistics, Danny Fahringer, strategic sourcing manager for North American products at Air Products and Chemicals, Guus Stigter, director of Mammoet USA South, and Jim Cook, logistics manager for WorleyParsons.

The advantages of modules include faster startup, shorter construction time, smaller job site footprints, better quality control, standardization, economies of fabrication scale and reduced costs by avoiding field construction labor.

Modularization demands a lot of planning time. “Engineers believe modularization simplifies transportation,” Richard Knoll said. “That is simply not the case.”

Megamodules present challenges to shippers. Many are first-of-a-kind jobs, so there is no transportation blueprint. Further, the push for low cost country sourcing in places such as India and China makes transportation much more challenging.

The key to success in transporting these huge pieces is early involvement between design engineers and logistics providers. Engineering, construction and procurement firms need specific information from logistics providers such as crane availability and capacity, ship deck space and what protection is needed for boxing multimodal shipments. Logistics providers need useful engineering drawings and accurate weights and dimensions from the engineers.

To develop an effective transportation plan, Knoll recommends starting with the date the plant will go into service and then working backwards. The owner must set forth a chart of responsibilities including probable benchmarks and watershed goals for the project itself and all parties involved.

The complexity of today’s megamodules was illustrated by a case study presented by Jim Cook. "Offshore modularization is a necessity, not a choice," he said. “We are building something just short of a small city.”

Unlike houses which are framed and then are equipped with electricity and plumbing, each level or deck must be completely installed with its systems before the next deck can be added.