Modular Construction

Modular Construction provides an alternative way of approaching the logistical challenges associated with traditional site-built construction projects, creating construction solutions that can be applied in a wide range of situations.


A pre-fabricated  modular penthouse  component. 

A prefabricated industrial module being transported to the jobsite. 

As a driver for value creation, PCL Agile is focused on creating the best environment for off-site manufactured building solutions, bringing together DFMA (design for manufacture and assembly), self-perform work, and strategic procurement/purchasing.
By using industry-leading virtual construction technology, PCL Agile is able to identify elements of a construction project that can be prefabricated as modules of various sizes and complexity in a controlled factory environment. By doing this, PCL is able to significantly improve the productivity and efficiency of the construction process, while reducing the time that would have been required to build these components onsite. Our team includes BIM (Revit), project management, and production staff, supplemented by in-house specialists, supporting the integration of the appropriate solution into projects.
Utilizing its Greater Toronto Area-based 65,000 square-foot off-site production facility and own forces work crews, PCL Agile designs, engineers, manufactures and assembles offsite modular building solutions at every scale and for a full range of applications, from simple building components such as washroom pods, corridors, stairwells and penthouses, to foundation systems such as helical piles, to fully fitted-out data centres.​


Modularization of heavy industrial construction reduces costs and increases schedule certainty, and allows the project team to push ahead with engineering work while other activities proceed concurrently at the construction site. PCL’s heavy industrial modular work is performed in a controlled environment, employing lean manufacturing principles and the latest welding technologies.
The combined capacity (on 115 acres) of PCL’s three Canadian module assembly facilities, each located adjacent to Alberta’s high-load transportation corridor, is among the highest in Canada. Right next door, PCL operates one of Canada’s largest and most technologically advanced pipe fabrication facilities on a 13.3-acre site in Nisku, offering a total of 125,000 square feet of indoor work space.
In the United States, PCL’s 25-acre fabrication and module assembly yard is a leading facility of its type in California. The fully fenced and secured yard contains two 12,500-square-foot covered fabrication bays. Its design accommodates heavy-haul transporter traffic.


DFMA is a versatile component of PCL’s broad offering of construction services with many benefits. We are able to draw on in-house resources, and those of our trade and consultant partners, to integrate offsite solutions seamlessly into project deliveries.
Engineering, module assembly, and site work can proceed concurrently when modular construction techniques are employed, significantly reducing overall cycle time. Improved site access, reduced congestion and trade stacking, and less need for scaffolding all enhance productivity and safety.
Modularization allows workers to perform a constant scope of work closer to the ground and in accordance with consistent standards, procedures, and policies. 
This approach is also inherently more “green,” as it generates less waste and reduces vehicle traffic to and from the main jobsite.
Because so much construction is performed offsite, modularization greatly reduces workforce requirements including camp and transportation costs, making it a sustainable choice.
PCL is able to work with project stakeholders to determine the most appropriate construction solution, and with easy access to road, rail, and ship, PCL is able to serve the prefabrication needs of clients across North America. 
This reinforces our century-long track record as a construction company dedicated to providing construction services that are focused on meeting each client’s unique needs.

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