Heavy Industrial Modular Construction | PCL

Heavy Industrial Modular Construction

PCL’s module assembly facilities—primarily based in Nisku, Alberta—have recently reached a new milestone with the addition of 40 acres of land in northeast Edmonton, bringing the total to 115 acres.
Modules assembled at PCL’s facilities serve as the major building blocks for industrial facilities across western Canada.
Modules assembled at PCL’s facilities serve as the major building blocks for industrial facilities across western Canada.

EXPANDING CAPACITY

The modules assembled at PCL’s “Mod Yards” serve as the major building blocks for industrial facilities across western Canada. 
The combined capacity of PCL’s three module assembly facilities, each located adjacent to Alberta’s high-load transportation corridor, is among the largest in Canada. In addition, a new $10 million office at the main module yard in Nisku is scheduled to be completed by May 2013.
“Edmonton has become a center for modularization, with proven expertise, a large, skilled labor workforce, and sophisticated prefabrication and module assembly facilities,” said Gary Trigg, vice president, Fabrication, with PCL Industrial Constructors Inc. “PCL’s expanded facilities now give us an even greater capacity for work.”
PCL also operates one of Canada’s largest and most technologically advanced pipe fabrication facilities on a 13.3-acre site directly adjacent to the module assembly facilities in Nisku. The pipe fabrication facility offers a total of 125,000 square feet of indoor work space.

QUALITY BUILDING BLOCKS

PCL’s modular work is performed in a controlled environment, employing lean manufacturing principles and the latest welding technologies. Modularization allows for greater cost and schedule certainty, and the ability for the project team to push ahead with engineering work while allowing activities to proceed concurrently at the construction site.
“Lean manufacturing has led to great improvements for us,” said Trigg. “Implementation began in 2006 and is now quite mature, including shadow boards, 5S audit protocols, a supermarket, and a pull system to reduce production lead time. We now see a better alignment of production with schedule, and much less material on the shop floor.”

ENHANCING SAFETY WHILE REDUCING COSTS

Modularization allows workers to perform a constant scope of work closer to the ground and in accordance with consistent standards, procedures, and policies.
Because so much construction is performed off-site, modularization greatly reduces workforce requirements including camp and transportation costs.
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.
 

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