Introductory Course on Modular

MEP Design and Prefabrication

F O R T I S C O N ST R U C T I O N

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Lecturer’s Profile

Company: Fortis Construction Pte Ltd

Designation: ELECT Construction Manager
Email: [email protected]
Mobl: (+65) 9658 5407

Mr. Stephen Michael Adams BEng (Mech)

With over 19 years of working experience in Singapore, Macau, Hong Kong, the
Middle East and the UK, Stephen has worked on a variety of Industrial,
Commercial, Utility, Process and Rail Projects for leading E&M / Main Contractors .
This included a Market leading Data Centre in Singapore where 70% of the MEP
services were prefabricated off-site, after setting up a manufacturing facility to
support the project. Most recently he is working on a Hyperscale Data Centre for
Fortis Construction that is using DfMA for large scale construction.

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Modular MEP Prefabrication

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Content

Session 1
• Introduction & Background
• Prefab Modular Design
• Types of Connections
• Factory Start-Up
• Equipment and Techniques
• Assembly of Module frames
• Production & Coordination

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Content

• Logistics, Deliveries & Planning

• Safety considerations in lifting, handling and delivery
• Methods of Installation and productivity metrics.
• Integration of Prefab MEP with other trades.
• Summary
• Q&A

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Introductions

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Prefabricated MEP Modules

What are Prefabricated Mechanical, Electrical, and Plumbing (MEP) systems?

A Modular system consisting of an assembly of MEP components and equipment that are
integrated into an off-site assembly and then installed on site.

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Prefabricated MEP Modules

MEP MODULAR TRADITIONAL INSTALLATION

• Fabricated in a control Environment • Reduced Labour on Site

• Mitigates Rework • Saving in site time.
• Quality
• Multi-tasking labour
• Health & Safety
• More productivity
• Sustainability
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 PRODUCT VS PROJECT

Measure Outcomes Measure Output

Ongoing Has a finish
Focus on Value Scope, time & Budget
An actual thing Task Management
Adaptive Predictive

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Product vs Project
The process and product life cycle have a linear relationship and although construction projects are
continuously being undertaken each one flow each one is unique.

Chemicals,
Continuous
Petroleum
flow

Cars, mobile
Mass phones
production

Process Heavy equipment

life Large batch
cycle
Project-based Construction,
Machine tools, architects, consultancy, IT,
Small bath medical defense, transport, telecoms,
instruments
NGOs, film-making, etc.
Aircraft, trains,
Unit airports,
software

One of a kind Low volume, low Multiple Few major products, High volume, high
standardisation products, low higher volume standardisation,
volume commodity products
Product life cycle

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Defining the Key Elements

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Prefab Modular Design

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Design Stage

Equipment
Skid
Corridors

Cat Walks Risers

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Identifying the Scope of Works
A typical Modular Assembly with several services combined onto the same
support frame system.

Service Responsible Pa rty

Trunking & Tray Trunking / Tray / Ladder Elec Subcontractor

Trunking (Sec / BMS / ELV) Elec / ELV Subcontractor

Cable Ladder

Trunking (Security)
Piping (P&S) P&S Subcontractor
Trunking (BMS / ELV

Chilled Water Pipe

Chilled Water piping ACMV Subcontractor
Piping (P&S)
Ductwork ACMV Subcontractor
Fire Sprinkler Pipe

Ductwork
Sprinkler Pipework Fire Subcontractor

Trunking (FA & PA) Fire Subcontractor

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Design Stage
General Arrangement Shop Drawings

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Design Stage

Structural Arrangements

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Demarcations & Responsibilities
Consideration for other Trades

Party Impact
- Crane Usage
- Logistics for storing
- Loading Platforms
Main Contractor - Sequence of Riser.
- Builders works openings
- Cast-in Anchors

- Builders Work Opening

Architectural Work - Sequencing wall construction
- Sequencing finishing works
- Openings for installation and
Facade Maintenance
- Connection and support details.

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Design Stage – Modular Types

Multi-Service Modules
• A single frame service module that include a range of MEP
services e.g. domestic water, ACMV, CHW/CDW pipe,
fire protection system, drainage as well as electrical
services comprising of basket, tray and/or ladder.
• Ideal arrangements for Common Corridors or typical floors Engineering
were a number of services are condensed into tight areas
and eliminates extensive hanger rods and induvial service
supports.
• These Modules can be fully connected in the factory
including pipe pressure tests before being dispatched to
site.
• The Modules can be developed to install Final fix items such
as Lights, Cameras, Motion detectors, etc.…

Fabrication Installation

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Design Stage – Modular Types
Riser Modules
• Riser modules designed and manufactured to any size or form and can house the full range of
mechanical and electrical building services.
 Ideal arrangements for Common Risers through high rise developments and can be designed to include:
 Flooring and kick plates can be included if required.
 As part of the structural design, lifting and slinging points will be identified and installed to ease off-
loading and final positioning.
 Fire stopping barriers can also be incorporated to ease site complexity.

Engineering Fabrication Installation

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Design Stage – Modular Types
Pla nt Room Modules
 These modules are a fully loaded plantroom in sections which are then delivered to site and assembled with mechanical
fittings. Eliminates the risks from welding on-site and improves the overall quality of the final installation.
 A packaged plantroom can be manufactured far in advance of the lay down area being completed. They can incorporate
all types of plant, from Clarifiers to Pumps and from LV panels to CHP plant.
 These modules can also include all necessary pipework, ductwork, containment, isolator and inverters required, with only
final pipe connections wiring and commissioning once they have been fixed into position on site.

Engineering Fabrication Installation

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 3.0 Types of
Connection Methods

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Types of Connections Methods

Containment

Pipes

Ductwork

Cables

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Types of Connections Methods

Mecha nica l Couplings

• Mechanical Grooved Coupling are designed for a wide type of applications and can be
easily connected with the use of a gasket, housing and nuts / bolts.
• Used for, Chilled water and condenser water pipe, domestic water pipe, fire sprinkler, etc…

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Types of Connections Methods

Pipe Crimping
• Mechanical Grooved Coupling are designed for a wide type of applications and can be
easily connected with the use of a gasket, housing and nuts / bolts.
• Used for, domestic water pipe, fire sprinkler, etc…
• Typical for Stainless Steel and Cooper Pipework

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Types of Connections Methods

Pre-Insula ted Ductw ork

• Pre-insulated ductwork is a rectangular or similar profile ACMV ductwork system that can
be install in a single fix.
• Using this system, it removes some of the problems associated with galvanized sheet steel
lagged with mineral fibre.
• Lightweight and reduces the loading onto the MEP Module supports.

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Types of Connections Methods

Ca ble Conta inment

Quick fastening Systems of connecting a variety of cable containment systems cab be adopted.

Ca ble Connections
Modular Wiring techniques can be applied for pre-fabricated PLUG & PLAY installation from
Distribution Boards to Final Outlets.

Traditional

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Types of Connections Methods

Mecha nica l Connection W elded Connection

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4.0 Factory Start Up

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Factory Set-up and the Key Elements

• Location

• Raw Material

• Storage

• Equipment

• Lifting & Logistics

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Factory Set-up and the Key Elements

• Work Areas

• Quality Checking

• Testing

• Safety

• Finished Goods

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Factory Set-up and the Key Elements

It comprises of the following areas as shown in Figure below (these are the areas
the module has to move through in the production area)
1. Cutting area (With automatic cutting machines)
2. Frame assembly
3. Pipework service manufacture area
4. Pre-assembly Coating and Finishing area
5. Module assembly lines (for various types)
6. Final Finish area

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5.0 Assembly of MEP Modules

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Manufacturing

Multi Purpose Corridor Modules

Modula r fra mes fa brica tion Modula r M& E services

completed insta lla tion

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6.0 Logistics, Deliveries
and Planning

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Logistics, Deliveries and Planning

Main Contactor Manufacturing

Production
Scheduling of delivery
Factory Output
Sequence of Works
Updating
Ordering / Procurement
QA/QC
MEP Subcontractor

Logistics
Freight & Terminal
Transportation
Packaging
Delivery Time

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Logistics, Deliveries and Planning

Planning the deliveries to consider the following:

• Logistical Pre-arrangements Plan before Production “Just-in-time Deliveries”
• Protective Packaging after production.
• Customs Clearance & Freight Management.
• Road Survey & Traffic Management
• Consequence of Delivery
• Streamlined Installation and Crane Hoisting at site

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7.0 Safety

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Safety

Traditional MEP work involves multiple

trades that need to be installed one by one

• Scaffolding is needed for each trade,

resulting in increase in RISKS of FALLING
FROM HEIGHT.

• This RISK is multiplied as numerous trades

have to work at height to install their
respective MEP fixings

• Reduces Hot Work

• Reduced Plant Equipment

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8.0 Installation

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Installation

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Installation – Key Take Away

• Setting out and spending time on the engineering to ensure the

hangers and fixing details are correct.

• Sequence the works correctly and maintain communication with the

factory. Things change, they need to be managed.

• Manage the Deliveries and Programme. Space is a premium and

you cannot afford to congest the site.

• Plan the connection details and congested areas.

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Quality Control & Quality Assurance

 All MEP Modules inspected and tested

 Inspection and Test Plans (ITP’s) executed
with hold points before delivery.
 All Welding NDT and test reports provided
 All Modules are shrink wrapped with
assigned QR code and modular asset
number

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Q&A

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