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Case Study: Optimizing Modular Construction for Limited Laydown Space

Writer's picture: DyCat SolutionsDyCat Solutions

When a major industrial company based in Italy faced the challenge of limited laydown space during the construction of their new plant, they knew they needed an innovative approach to their modularization strategy. With space at a premium and the project team concerned about rising costs, they sought expertise to rethink their original plan. That’s when DyCat Solutions stepped in to help guide the way.

Note: To protect our client’s privacy and competitive advantage, their name has been withheld. However, this case study is based on a real project.

The Challenge: Limited Laydown Space and a Costly Modular Plan

Our client was facing a significant hurdle with their plant construction. Their facility had very limited laydown space—the area used for storing and assembling large components during construction. They had explored modular construction options to move a portion of the work off-site, but their initial modularization plan was proving to be cost-intensive.

This raised two key concerns:

  1. Space limitations that could lead to on-site bottlenecks.

  2. Rising project costs associated with their current modularization strategy.

They needed a solution that could address both the space constraints and bring costs under control, all while keeping the project on schedule.


How DyCat Solutions Guided the Client

At DyCat Solutions, we understand that no two projects are the same. Our approach is always focused on developing tailored solutions that match the specific needs of the client. When this company reached out, we began by conducting a thorough review of their existing modularization plan.

We worked closely with their team to:

  • Analyze the initial design and the strategy behind it.

  • Identify inefficiencies and areas where improvements could be made.

  • Develop a new module concept that was both cost-effective and practical for the limited space they had on-site.


The Solution: A New Piperack Module Concept

Through our analysis, it became clear that the original modularization strategy was too expensive and not as space-efficient as it needed to be. We proposed an entirely new approach centered around piperack modules.

Here’s how our solution worked:

  • The new concept involved moving as much work off-site as possible. By reducing the amount of on-site assembly, we helped minimize the impact of the limited laydown space.

  • This approach also addressed the project’s cost concerns. While the primary focus was solving the space issue, our piperack module concept achieved a modest cost reduction of approximately 2-3% compared to the original plan.


The Result: A Practical and Cost-Effective Modularization Strategy

Our client’s project team quickly recognized the value of the new piperack module concept and accepted it as the go-forward strategy for the plant construction. While the cost savings were helpful, the real win was in optimizing the limited space they had available.

Currently, the project is in the execution phase, and DyCat Solutions continues to support the client’s design team to ensure everything runs smoothly. We’ve been with them every step of the way, making sure the new modular strategy is implemented efficiently and that they meet their construction goals without the worry of space constraints slowing them down.


DyCat Solutions Delivers Tailored Modularization Solutions

This case study highlights DyCat Solutions’ expertise in addressing complex challenges like limited laydown space and high costs in heavy industrial projects. By taking a closer look at the initial modularization strategy, we were able to develop a solution that not only reduced costs but also enabled the client to maximize off-site work—the key to overcoming their space issue.


If you’re facing similar challenges in your industrial project, whether it’s limited space, rising costs, or an inefficient modular strategy, contact DyCat Solutions today. We’re here to provide the expertise and guidance you need to ensure your project’s success.

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