The use of modular systems is increasing day by day both in industry and in the construction sector. In both cases, the aim can be summarized as creating the system with all its components in a factory environment, i.e. as a module outside the project site, completing all quality control inspections, including the necessary tests, and making it ready for assembly.
The difference of modular systems from conventional prefabricated systems can be explained as the completion of the project elements to be turned into modules in both industrial and construction projects by bringing together all engineering components and completing them ready for assembly. It is not only the structural elements that are in question here, but also the creation of the module as a whole with all its components, including mechanical electrical architectural elements. The main advantages of modular systems over conventional construction methods are as follows;
- Hızlı tamamlama (yaklaşık %50 daha hızlı),
- Daha düşük maliyet (yaklaşık %35),
- High quality,
- Reduced security risks,
- Reduced negative environmental impacts,
- Opportunity to do business in wider geographies,
- High added value.
Modular systems try to combine as many components as possible. The most important constraint here is the volumetric dimensions and weight of the module. While determining the size and weight limits, limitations related to transportation means (such as sea, road, rail, etc.) and loading-unloading facilities come to the fore.
MODULAR SYSTEMS IN INDUSTRY
Especially in the realization of industrial facilities that involve a large proportion of chemical processes, such as oil and gas refineries and petrochemical plants, higher quality manpower and technically equipped "contractor" companies are required compared to normal construction projects, from engineering to manufacturing and field work.
The number and quality of field staff varies greatly depending on the geography of the project. Today, many countries impose quotas on the number of employees who can come from abroad in line with their own manpower support policies, which necessitates restrictions on the number of employees whose quality you are sure of. On the other hand, constraints such as the environmental conditions of the region where the project will be carried out, regional working rules and conditions are also factors that directly affect the completion time, quality and cost of the project. For this reason, minimizing the field work and performing the work in the contractor's own geography as much as possible, realizing the desired quality and higher value-added production in a shorter time and at a lower cost, brings sustainable growth for the contractor. At this point, modular systems come to the fore.
Especially in oil refineries and petrochemical plants, both increasing energy efficiency and revamping of systems and equipment that become obsolete over time are frequently on the agenda. In order not to disrupt the production schedule of such works, it is aimed to complete these works within pre-planned shot-down periods. In the meantime, it is important to keep downtimes as short as possible in order to minimize possible production losses during downtime. Modular systems also provide great advantages in this type of work.
In the planning of new facilities, starting from preliminary engineering studies, modular solutions as much as possible will provide significant reductions in construction costs and durations, as well as reducing the costs of the maintenance-repair-renewal process during the operation of the facility.
Industrial plants;
- Pipe bridges,
- Heat exchanger and pump groups,
- Process units such as reactors and vessels
It is possible to build many units, especially modular units.
In these projects, modular systems generally consist of the following components;
- Steel load-bearing frame,
- Equipment (heat exchanger, pump, vessel, etc.)
- Piping and related fittings (flanges, valves, etc.)
- Control systems,
- Cable trays, etc.
Technology-intensive chemical process projects such as refineries and petrochemicals have much higher added value for the contractor than general construction projects.
Our country is in a very advantageous position in terms of getting a share from such projects with its geography and qualified manpower. It is especially important for Turkish contractors to be able to undertake such projects in order to achieve sustainable growth and competitiveness. For this, it is necessary to closely monitor and implement innovative technological developments. In this respect, modular systems stand out as an innovative technology that has become increasingly important in recent years.
Modular systems should be considered as an industrial investment in terms of both engineering and manufacturing. In this respect, the spread of modular system applications is also important in terms of increasing sustainable quality employment.
MODULAR SYSTEMS IN THE CONSTRUCTION INDUSTRY
In order to ensure sustainable productivity and growth in the construction sector, it is inevitable that the sector will evolve from its current conventional structure into a "Construction Industry" in order to apply new technologies. In this respect, the widespread use of modular systems in construction projects is an important opportunity for the industrialization of the sector.
The production of modular systems is carried out in a factory environment, independent of site and environmental conditions, using innovative industrial production techniques and qualified manpower. It is a much more controllable process to realize the system in accordance with the planning at every stage from engineering to production. This ensures that higher quality components are produced on schedule and at lower cost. In the creation of modules, it is aimed to go for standard solutions as much as possible. This provides significant advantages in both production, material supply and quality control processes. In this respect, it is important that initial planning and preliminary engineering studies are carried out for modular solutions.
Increasing the number of modular elements in the project as much as possible provides significant advantages in increasing productivity and reducing the completion time and cost of the project. In this context, projects with many repetitive units such as hotels, dormitories, schools, hospitals and social housing are very suitable for modular solutions.
However, in building projects that serve different functions other than the above-mentioned structures, it provides significant advantages in terms of both time and quality, especially in building projects that serve different functions, especially in wet areas such as bathrooms and toilets, where electrical-mechanical components are frequently included together with structural and architectural components, and which are manufactured modularly in the factory environment and sent to the project site after all tests and controls have been carried out and placed in place in a short time. It is possible to add even simpler single elements such as balconies and stair systems, which are manufactured by combining all structural and architectural components together.
Modular manufacturing paves the way for doing business in wider geographies as well as exporting higher value-added products to different parts of the world. The use of modular systems in the construction industry, as in industrial modular systems, requires multidisciplinary engineering work both in the design and manufacturing stages. It is much easier to ensure interdisciplinary coordination in modular system manufacturing compared to conventional construction techniques. At this point, BIM-centered innovative project approaches make it possible to achieve high productivity gains and high added value gains.
CONCLUSION
The use of modular systems in both industrial projects and the construction industry contributes significantly to better quality and faster production by minimizing the workforce and time to be spent at the project site. By shortening the time on the project site and minimizing the manufacturing to be carried out on site, possible negative environmental impacts and safety risks during the construction process are also minimized.
The spread and diversification of modular systems brings about sustainable growth with high added value for contractors and other stakeholders working on industrial and construction projects, and increases international competitiveness.
Source : TUCSA.ORG - Construction. Contract. Eng. Alparslan Güre