Efficient Construction Logistics: Setting 91 Modules in Five Days

Stream Modular

February 5, 2024

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Summary:

In comparison to the average project, which typically sets 8-12 modules per day, Stream Modular was part of a team which achieved an astounding average of 18 modules per day in a recent project.
The key to success was meticulous planning, tight coordination, and impeccable communication.
Stream Modular’s project management services extend far beyond mere transportation service, allowing for increased efficiency in on-site builds.

Increasing efficiency in modular construction logistics

In a large modular construction project, the average number of modules set on any given day ranges from eight to twelve. At Stream Modular, we believe we can increase that number with more efficient construction logistics. Recently, we had the opportunity to test this theory with Proset and Impact Housing on The Adams Project. Starting with an initial goal of 16 modules per day, our efficiency actually increased, with the final day of construction seeing 21 modules set in one day.

Advanced planning, excellent communication, and contingency plans that considered any potential obstacles contributed to these results. In this article, we provide an overview of how Stream Modular’s logistics planning came together to allow an average of 18 modules set per day, for a total of 91 modules in less than a week. The preplanning portion for this project played a vital role as we needed to plan for contingencies like arranging backup drivers and addressing traffic control in a densely populated residential area requiring traffic blockades.

Why condensing a set schedule is worth pursuing

The number of modules set per day on a build site is a number worth optimizing because of its potential impact on the budget of a project. Highly skilled labor teams and crane rentals are extraordinarily expensive and have fixed availability. If you plan for a project to take one week and it takes ten days instead, the last three days will ultimately blow the budget and timeline.

Conversely, the more a set schedule can be condensed, the lower the cost per module.

Stream Modular’s scope of work for modular logistics

In order to meet the ambitious goal of 16 modules set per day for The Adams Project, we invested dozens of hours over the course of a couple months leading up to the start of the project.

Before the set process began, we spent weeks transferring modules from the factory to the staging yard. When unloading the modules to the staging yard, we deliberately arranged them to be organized based on the set sequencing to ensure we had efficient access to the right modules at the right time.

Armed with this knowledge, we were able to create a realistic and accurate estimate of how long each trip between the build site and staging yard would take. For example, one step of the planning process took into consideration the distance between the staging yard and the site. To get it right, Stream Modular hired a professional route surveyor to drive the route and offer transit guidance. With this information, we were able to identify the proper route and potential obstacles that might increase any risks for the drivers.

With a distance of 23 miles between staging yard and jobsite, we know there would be plenty of variability in the transit time when considering traffic, curfew hours, and other constraints. With an awareness of possible delays and the most efficient route, we figured out what resources were needed to achieve the 16 modules set per day.

Building in buffers for delays

With the constraints and goals in mind, we recommended the project move forward with a total of eight drivers, each of whom could transport a minimum of two loads per day. Considering the times for loading at the staging yard, transit to the build site, unloading at the build site, and return journey, we believed eight drivers was the minimum number needed to make the goal of 16 modules set each day happen.

In an ideal setting, there would be no delay for the trucks. The driver would pull up to the build site, take off the straps, remove the wrapping, and begin to hoist the module immediately. But, as we all know, we cannot plan on the ideal situation always occuring. So, we designed a traffic control plan that would allow for two trucks to be staged in a queue line while one truck was getting unloaded. This assured that the crane would never be waiting for the next module, increasing the efficiency and predictability.

Thanks to our meticulous pre-planning, the work grew more and more efficient. The set crews found their rhythm, and the project reached a point where some of the drivers were able to deliver three modules in a day instead of the projected two. This led to the culmination of setting 21 modules on the final day.

The future of efficient modular construction logistics efficiency

After this experience, Impact Housing approached Proset with a request to set an average of 20 modules per day for the next project. Proset agreed knowing that Stream Modular could design a transport strategy that could keep up with the set crew.

In a process where a single missed detail could trigger cascading delays, Stream Modular’s focus on logistics keeps projects running smoothly. Keeping all involved parties on the same page with excellent communication, spending time on the actual site logistics ensures smooth project execution.

The preplanning work, contingency plans, coordination with site crew and drivers (and back-up drivers) are just a few pieces of the logistics puzzle we solve. Together, they facilitated our ability to surpass expectations, paving the way for setting 18+ modules per day with minimal slack in the loading, unloading, and setting process, thus ensuring maximum efficiency.

If you are interested in learning more about how to make your modular construction build as efficient as possible, consult with professionals to identify the best route to logistical success for your project

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Stream Modular is a transportation logistics company specializing exclusively in modular construction. We help modular manufacturers and builders transport mods, pods, and panels so they arrive on time and safely to the build site.