Inside DyCat Solutions’ Modular Roadmap: Implementing Modular Construction in Heavy Industrial Projects

A Proven Framework for Modular Success

DyCat Solutions’ Modular Execution and Design Roadmap offers a phase-driven strategy for implementing modular construction in heavy industrial projects. By structuring execution into three distinct yet integrated phases:

1. DBM (FEL2): Design Basis Memorandum / Front-End Loading Phase 2

2. FEED (FEL3): Front-End Engineering Design / Front-End Loading Phase 3

3. Implementation (EPFCC): Engineering, Procurement, Fabrication, Construction, and Commissioning

The roadmap aligns project goals, mitigates risk early, and enables scalable, predictable delivery. This methodology is especially valuable for owners and EPCs seeking to reduce cost, optimize schedules, and improve constructability through standardization and lean design.

DyCat Solutions is an industry leader in modularization and lean project delivery, providing specialized tools, methodologies, and consulting services that enable organizations to execute capital projects with greater precision, speed, and cost control.

DBM (FEL2) Phase: Establishing Feasibility and Strategic Fit

The Design Basis Memorandum (DBM) phase focuses on determining the suitability and optimum amount of modularization for the project and establishing the foundational plan to implement it. Key activities include:

• Decide to modularize, define the business case, and align with preliminary transport/logistics data, Class V estimate, and level 1 schedule.

• Identify factors influencing modularization, determine its degree, and develop an optimum modular plot plan with module breaks on PFDs.

• Establish modular execution, governance, risk management, material handling, and module material management strategies.

• Perform transportation/logistics study, qualify potential module yard contractors, and develop the AWP strategy with path of construction and constructability/fabricability reviews.

• Prepare Class IV estimate, level 2 schedule, and start-up planning to support decision-making.

By validating feasibility and aligning stakeholders early, this reduces the risk of downstream changes, strengthens cross-discipline coordination, and embeds modular strategy into the project from the outset.

Interested in assessing modular viability for your project? Contact DyCat Solutions for a feasibility workshop.

FEED (FEL3) Phase: Design Validation and Execution Readiness

The Front-End Engineering Design (FEED) phase refines and validates the modularization strategy, translating it into detailed plans, designs, and contracts to prepare for execution. It involves:

• Confirm the business case, influencing factors, modularization scope, and optimal layout.

• Finalize transportation/logistics plan and contracts; select and engage module yard contractors.

• Produce detailed execution plan, modular plot plan, design table, 3D model, and P&IDs.

• Define assembly/transport details, vendor data management, material handling, and module material management plans.

• Prepare weight and COG management plan, finalize path of construction, start-up planning, and pre-construction plans.

This phase minimizes uncertainty by transforming conceptual plans into data-driven, buildable modular designs, enhancing design precision and strengthening collaboration and governance across all disciplines.

Need support during FEED? Leverage DyCat’s expertise to ensure modular alignment and risk reduction.

Implementation (EPFCC) Phase: Controlled Execution and Delivery

The Implementation phase executes the modularization strategy, integrating engineering, procurement, module fabrication and assembly, site construction, and commissioning into a coordinated delivery plan. It is where planning meets execution:

• Align the project team with business case objectives and FEED deliverables.

• Implement transportation/logistics, AWP, governance, risk, and material management plans.

• Finalize modular plot plan, design table, 3D model, assembly/transport details and issue IFC deliverables per work package.

• Manage contracts, vendor data, and weight/COG controls while monitoring schedule and budget.

• Execute module fabrication and assembly, transportation, site construction and module integration, and start-up plans

Building on the validated execution plans from earlier phases, this stage accelerates delivery, reduces field rework, and ensures strict compliance.

Facing execution challenges? Engage DyCat for oversight and governance of your modular rollout.

Integrated Governance and Lean Coordination Across Phases

A standout feature of DyCat’s roadmap is its cross-phase integration. Governance structures evolve through all three phases, ensuring continuity. Tools like:

• Modular Plot Plans – Provide a clear visual framework for module layout and scope.

• Iterative Risk Reviews – Continuously identify and mitigate risks throughout the project lifecycle.

• Lean Design Principles – Streamline engineering to reduce waste and optimize productivity.

• Facility Standardization Strategies – Promote repeatability and efficiency across projects.

Advanced Work Packaging underpins these tools, enabling end-to-end alignment across engineering, procurement, module fabrication and assembly and site construction, breaking down silos and optimizing workflow.

Ready to standardize your modular execution process? Explore DyCat’s Modular Design and Execution Roadmap Services.

Why DyCat’s Modular Roadmap Sets the Industry Standard

DyCat Solutions’ Modular Execution and Design Roadmap delivers a clear, proven path for executing heavy industrial projects with modularization. Its structure enables:

• Early identification of modular opportunities – Spot potential benefits before design is locked in.

• Informed decision-making with validated data – Use evidence-based insights to guide scope and strategy.

• Seamless handoffs between phases – Maintain momentum and continuity from concept to execution.

• Efficient delivery driven by lean principles – Streamline processes to minimize waste and maximize values

Whether you are planning a new facility or scaling up modular strategies across your portfolio, this roadmap offers the rigor, tools, and insight to reduce risk and drive performance.

Start building with confidence. Book a consultation with DyCat Solutions today.