How Fluor’s 3rd Gen Modular Execution Process Is Enhancing Prefabrication For Major Projects


Fluor has developed a unique modular execution process known as 3rd Gen Modular Execution which is a project execution solution developed to address the needs of our clients to reduce costs on capital projects and improve overall predictability of project execution. Fluor is introducing this innovation as a response to mining capital efficiency challenges.

The company has realised multiple benefits from the model, including a large reduction in plant footprint and consequential reduction of bulk material quantities, maximum transfer of labour hours to a higher-efficiency and lower-cost module fabrication yards, less construction time, and fewer associated project risks.


Ahead of

Modular Construction 2016, Peter Gopfert, Vice President of Project Management at Fluor, shares insight into how the 3rd Gen Modular Execution process has not only enabled the company to achieve savings, but consistently exceed client expectations and project parameters.

The 3rd Gen Modular Execution process involves a unique amount of hardware featured on the module design – approximately 90 per cent. This is not traditionally achieved in modular rotation, such as 2nd Gen modules that achieved 70 per cent.

That said, the modularisation process entails more than just the amount of hardware that goes with the module. It actually describes the proprietary design process Fluor developed for optimising plant layout and reducing project quantities.

An analogy to this would be to apply an offshore design approach to onshore facilities. If you imagine a petrochemical plant without pipe racks, that is a visual analogy for what 3rd Gen Modular Execution entails.

The 3rd Gen Modular Execution process involves looking at the problem in front of you, on its own merits. And establishing a design process that commences by analysing what you have to do – free of any previous design optimisation approach including all the previous project excessive specifications and standards, “gold plating”, outdated technology, and preferential features.

The 3rd Gen Modular Execution process has been recognised in the market:

  • Global Best Project, Engineering News-Record, 2015 (Power/Industrial category)
  • Nominated for the 2015 Platts Global Energy Awards Engineering Project of the Year
  • Alberta Construction Magazine Top Project Award for Industrial Design, 2015
  • 3rd Gen Modular Execution – Bronze Edison Award for Innovative Project Execution Approach
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