Modular construction overview

Delivering plants efficiently, cost effectively, and safely.

We’ve grown since first modularizing propane economizer systems more than 60 years ago. Today, Jacobs consults, engineers, designs, fabricates, installs, and commissions modules for a wide range of process business lines.

Our turnkey delivery takes a project from the feasibility and concept phases through facility start-up. Jacobs provides custom, conventional solutions that align with industry best practices and take advantage of process replication. We provide our clients innovative, often award-winning projects, which accelerate schedule, decrease costs and deliver client value.

Jacobs has the capacity to build up to 75 barge-sized modules or 130 truck-sized modules simultaneously in a controlled environment under roof. This allows clients to eliminate weather impacts on schedule and move high-elevation work to an at-grade level in our inherently safer environment.

 

Benefits

Minimizing and controlling risk during construction.

Modular construction breaks the process plant down into “stand-alone” or horizontal, vertical, single-level or stacked modules. The units contain support structures, equipment, piping, tracing, insulation, electrical and instrumentation systems, HVAC, siding, special coatings, fire protection and ladders. 

Using this method of construction, clients can accelerate their project schedule and reduce costs while taking advantage of improved quality and safety.

Flint Hills, LSG Low Sulfur Gas, Corpus Christi, TX, USA
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
KPE, SRU Sulfur Recovery Unit, Europoort, Netherlands
Flint Hills, LSG Low Sulfur Gas, Corpus Christi, TX, USA
Genentech, ECP-1, Tuas, Singapore
Motiva, Motiva CEP, Port Arthur, TX, USA
Flint Hills, LSG Low Sulfur Gas, Corpus Christi, TX, USA
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
Charleston, SC, USA
Genentech, ECP-1, Tuas, Singapore
Motiva, Motiva CEP, Port Arthur, TX, USA
Flint Hills, LSG Low Sulfur Gas, Corpus Christi, TX, USA
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
Genentech, ECP-1, Tuas, Singapore
Motiva, Motiva CEP, Port Arthur, TX, USA
Charleston Facility, Charleston Facility, Charleston, SC, USA

Clients rely on Jacobs to execute innovative projects that exceed industry performance benchmarks. Incorporating modular construction can help compress a project schedule by up to 22 %. By using modular construction in parallel with site-based construction, modules can be built at the same time as work in the field is completed, thereby accelerating project delivery times.

With nearly 460,000 square feet under roof, weather is not a factor, nor is permitting since modular construction can continue independent of environmental or regulatory licenses – factors that can positively affect a project's schedule.

Modular construction can help create better solutions for Jacobs' clients and their capital investments by taking advantage of manufacturing efficiencies as our stable craft force builds duplicate units in a controlled work environment. The cost of capital decreases as the time between major construction work and production start-up diminishes, which results in less schedule and cost variability from original base line estimates.

In addition to the reduced costs, our clients on average can generate revenue, on average, 8 months earlier on a typical 36-month project schedule.

Jacobs employs AWS certified inspectors, many with more than 15 years of modular construction experience, as our quality control supervisors. We also retain a reliable workforce with a proven history of performance in a controlled shop environment – both of which contribute to a higher quality work product

Consistent material control methods such as receiving, inspection, and warehousing of tools and procedures also eliminates quality chain risks and provides the opportunity for any degree of testing and checkout prior to the modules being shipped to site. This can include client inspection and advance training for operations personnel before the facility is erected on site.

Jacobs continuously trains its construction professionals to help reduce risk. Most of our work is performed at or near grade from the ground, ladders, or man lifts. We separate modules on the shop floor to minimize the need for craft to work “on top” of one another and also safely work on all “faces” of a module in parallel.

Performing work indoors reduces the potential of slips and falls on wet and/or icy surfaces and shifting labor hours from site to our shop environment minimizes the potential of spills, fires, and vehicle accidents – in addition to helping avoid unnecessary congestion on site.

Jacobs' Charleston, South Carolina, U.S. facility maintains OSHA STAR VPP status, which means our injury and illness rates are well below National Bureau of Labor statistic averages and we implement effective safety and health management systems.

 

Our clients

Increasing your start of production.

Our clients rely on us to identify project specific opportunities that capitalize on the benefits modular construction provides. We listen to our clients’ needs, understand their goals and deliver modules via truck, rail, or barge to complete their projects – often quicker than standard stick-built construction.

We have supplied more than 2,000 modules to clients in a variety of markets. Working together, our projects have received numerous industry awards for their contributions to innovative, leading-edge performance from associations and trade publications such as the International Society of Pharmaceutical Engineers, the Construction Users Roundtable, and Engineering News-Record. Read more about our projects. Highlighted case studies include:

"The turnkey approach, using the three facets of Jacobs – engineering, modular construction and field construction – was probably the only way we could have a plant that was operational given our timeline." — Dennis Grieve, Project Manager, PCS Phosphate

Project types:

  • Process-intensive development facilities
  • Laboratories
  • Pilot plants
  • Large-scale manufacturing
Flint Hills, LSG Low Sulfur Gas, Corpus Christie, TX, USA
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
Genentech, ECP-1, Tuas, Singapore
Motiva, Motiva CEP, Port Arthur, TX, USA
Flint Hills, LSG Low Sulfur Gas, Corpus Christie, TX, USA
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
Genentech, ECP-1, Tuas, Singapore
Motiva, Motiva CEP, Port Arthur, TX, USA
Flint Hills, LSG Low Sulfur Gas, Corpus Christie, TX, USA
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
Genentech, ECP-1, Tuas, Singapore
Motiva, Motiva CEP, Port Arthur, TX, USA
Flint Hills, LSG Low Sulfur Gas, Corpus Christie, TX, USA
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
Genentech, ECP-1, Tuas, Singapore
Bristol Myers Squibb, BMS Formulation Skid, Manatí, Puerto Rico
Genentech, ECP-1, Tuas, Singapore
 

Our facilities

Ability to respond to the most aggressive schedules.

With indoor space to build process skids, pipe racks, truck ship, standard, large and very large modules, in excess of 1,000 tons, Jacobs' two modular manufacturing facilities provide an alternative to on-site fabrication for clients in a variety of industries and locations across the globe. Our teams can provide engineering, material management, structural frame assembly, pipe fabrication, blast and paint capabilities, and clean room facilities.

Charleston, South Carolina, USA
Charleston is Jacobs' largest modular fabrication facility. Its location on the Cooper River, only 12 miles from the Port of Charleston, allows us to ship modules via truck, rail, or barge. With more than 400,000 square feet under roof on 96 acres, this location includes high purity pipe fabrication with full traceability and validation documentation. If clients require more space under roof, an additional 100,000 square feet is available for construction projects.

Edmonton, Alberta, Canada
Jacobs' Edmonton facility operates as a module assembly yard, but also includes more than 25,000 square feet under roof on 10 acres. An overhead crane inside this location provides lift capacity up to 25 tons. A construction services warehouse also offers supplementary space for client projects.

"During the project planning phase, we evaluated several risk mitigation options. Using modules mitigated significant risks without sacrificing rigid design and quality standards. The quality of the modules was excellent, and overall, the use of modules was a great success. We anticipate wider use of modules in the future." — Brad Breuer, Project Manager, Flint Hills Resources
Edmonton, Alberta, Canada
Charleston, SC, USA
Edmonton, Alberta, Canada
Charleston, SC, USA
Edmonton, Alberta, Canada
Charleston, SC, USA
Edmonton, Alberta, Canada
Charleston, SC, USA
Charleston, SC, USA
Charleston, SC, USA
Charleston, SC, USA
Charleston, SC, USA
Charleston, SC, USA
Charleston, SC, USA
Modular construction