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Modular versus Stick Built Plants
For decades plants have been stick-built one piece at a time. This is slow. It’s also expensive. This can turn into a logistics nightmare taking a lot of resources.
Now, let’s look at the alternative: Modular Plants. Using proven engineering/design tools and manufacturing techniques, Modular Plants have proven over and over to save time and money.
No one likes surprises or last minutes changes
Stick-builders admit that time and time again many details of “the plan” end up not working as anticipated in the field. That’s because the person who draws the plans is not a builder and vice-versa. The design world collides with the practical world!
Often with the Modular Plants, the process and methods are well established before construction begins. STC’s engineers and designers working with SMC’s manufacturing leads have a proven record of producing such modular plants that meet, and in many cases, exceed customer expectations in terms of safety, operability, and maintainability. All at a very good overall value.
Advantages of Modular vs Stick Built Plants
| Modular Build | Stick Build |
|---|---|
| Climate Controlled Facility | At the mercy of the elements |
| Non-union Labor | Union workforce |
| Steady, predictable labor force | Transient labor force |
| Minimum end-user involvement | Constant end-user involvement |
| Manufacturing off-site | Manufacturing on your site |
| Minimum rental equipment | Maximum rental equipment |
| Shop labor rates | Field labor rates |
| No site-specific training | Costly site-specific training |
| Clean shop manufacturing | Dirty manufacturing area |
| Integrated machining, fabrication, and assembly | Potential need for multiple sources |
| Utilities readily available | Utilities have to be brought in |
| Engineering & design resources available, as needed | Additional contractor required |
| Buying power of an OEM shop | Project-specific purchasing |
| Prep and paint in a clean room | Prep and paint in the open |
| Minimum disruption to site during fabrication | Disruption to site through all phases of the project |
| Single and complete set of employees under one roof | Potential multiple subcontractors on-site at once |
| Insurance in place | End-user/Multiple Contractors must handle insurance |
| No permits required during manufacturing | Numerous permits required for field manufacturing |
| Multiple shifts available without special arrangements | Multiple shifts require special arrangements |
| No mobile field offices and supporting buildings required | Field offices, safety equipment, etc must be provided on-site |
| No mobilization costs | Mobilization/demobilization costs |