Modular Solutions services are delivered by Exential, part of the Exentec family.

Our OSM and both small- and large-scale modular solutions address process utilities, capital equipment, and tool installations, saving valuable time and expense while improving quality, safety and time to market.

We specialize in integrated engineering, procurement, construction and project management (EPCM) services. We also offer design and off-site construction of process systems for utilities-intensive high-tech facilities, including:

• Modular engineering, construction detailing, rigging design, and assembly integration
• Tools and equipment foundations with integrated utilities
• Clean room and raised metal floor (RMF) installed compact utility modules
• Prefabricated and skidded assemblies
• On-site installation, joining, testing, and commissioning

Large-scale Modularization

• Schedule reduction of over 25%
• Completely integrated with on-site Owner or GC managed BIM coordination process and 3D, 4D, and 5D virtual facility or digital twin
• Greatly improved job-site efficiency and coordination for on-site activities as a result of the provided by a fully sequenced and scheduled modular build
• Greatly improved predictability for predecessor and follow-on construction activities as a result of the fully sequenced modular build schedule
• Modularization of “plan of record” to reduce impact to and disruption of third party engineering (AE), via custom solutions and methodologies to address challenges

Productivity by Design

We recognize that communication is key, and the process starts with an in-depth client consultation to understand project risks and challenges and more deeply understand the design intent. This initial design effort culminates in a Modular Program document that becomes the basis of design for the project execution. We then perform the LOD (Level-of-Detail) 400 construction modelling and detailing to enable fabrication of services in lower cost, higher capacity geographies outside of the project locus. Finally, we develop the site modular installation schedule and sequence with the Owner’s on-site construction team to enable more granular, reliable planning of the predecessor and follow-on activities, greatly improving on-site construction efficiency.

Our process, successfully employed on advanced technology projects of the highest complexity and difficulty, has consistently succeeded in delivering cost and schedule certainty to our clients.

Modular Advantages

• Substantially increases both on-site and off-site construction productivity through robust engineering, construction planning, and manufacturing grade processes.
• Vast majority of welds and joints removed from site, reducing trade labor requirements and schedule durations.
• Improves jobsite safety by reduction in exposure to elevated and congested work conditions and related safety incidents, as well as vastly reducing the number of individual rigging and high-risk lift activities associated with traditional construction methods.
• Robust supply chain management, progress tracking, and long lead procurement processes.
• Compressed base-build construction durations by sequencing and rigging large scale prefabricated modules on-site.
• Robust upstream and downstream Quality Program, leading to compressed testing and commissioning durations.
• On-site infrastructure requirements are reduced due to the elimination of material laydown and storage/staging areas normally required for traditional construction methods.

Engineered Productivity Solutions

We deliver construction productivity by design. We design and preplan our projects for absolute schedule certainty which allows the entire site construction team to plan and schedule effectively, reducing manpower and increasing overall site efficiency.

We design and preplan our projects for absolute schedule certainty which allows the entire site construction team to plan and schedule effectively, reducing manpower and increasing overall site efficiency.

What makes our engineered productivity solutions successful?

• Our DNA – Modular engineering from “BIM to Fab” - We are the known pioneers of the modular construction process for high tech projects: Programming and deployment of documented procedural based modular processes. Modular construction is our core competency throughout the organization - 100% of our projects are modular.
• Proven results at scale - 30% schedule reductions are consistently achieved. With early-stage integration, we can improve the way process utilities are standardized, fabricated, assembled, and erected on-site to deliver fast-tracked completion milestones.
• Experienced team - We address each project’s construction constraints by taking ownership and responsibility from start to finish. Our end-to-end, turnkey capabilities eliminates the typical customer concern of “who owns it?”
• Zero learning curve - We have decades of experience in modularized construction. Educating the owner and contractor's team early in project programming with open communication allows the Owner to leverage this experience across the larger on-site construction team.
• Latest best practices - Facilities are becoming highly sophisticated and complex to construct, own, and operate. Implementing the latest construction technology will allow you to maximize improvements in time, costs, materials, energy, skill and labor. We bring that leading edge technological expertise to the project with LOD 500 modelling, 4D and 5D data integration, and asset management platforms.
• Emphasis on safety -  Modular construction practices promote and enable improved safety at the module assembly site as well as the client facility and fits with our strong organizational commitment to safety. Over a span of three recent modularization projects, totaling over 200,000 man-hours, we recorded zero reportable accidents at both the module construction and client facility sites. According to a survey in the Safety Management in the Construction Industry SmartMarket Report, "Firms using prefabrication … have significantly higher adoption levels of nearly all the safety practices measured in the survey."

Modularization and Environmental Sustainability

Modularization and prefabrication building methods inherently encourage Green Building Practices. Offsite pre-fabrication and modularization happen in a controlled environment, increasing efficiencies in labor and material planning. This also reduces exposures to weather, noise and contamination, simplifying quality control practices compared to on-site construction. Industry experts have determined that traditional construction generates 50% more waste than modular construction. We reduce waste in time, costs, materials, energy, and labor productivity and prioritize technologies, processes, and methods that have the greatest potential to reduce these wastes.

Semiconductor Utility Equipment Modules

Exentec’s OSM and smart modular product solutions bring process utilities to capital equipment and tool installations, saving valuable time and expense while improving quality, safety and serviceability.

As a pioneer and global leader in Modularization we offer Modular Process Utilities, Panels, Laterals and Skids as well as Engineering Services, Design, Building Information Modeling, Fabrication and Fabrication of ISOs.

Our Modular Product Solutions are designed to support advanced technology manufacturing equipment installations. We identify equipment utilities, design site-specific modular packaging or “form factors”, and standardize layout and components to support a programmatic approach to manufacturing equipment installation and tool hook-up.

Step 1: Develop Standardized Designs

• Space Planning: Provides the Owner’s layout team “template” designs to populate
• Space Savings: Dense packing of components creates extremely space-efficient modules
• Space Coordination: Field contractor has “point-to-point” routing benchmarks during installation
• Safety and Ops: Engineered and planned ergonomic access to valves and components
• Design Flexibility: Allows for reconfiguration modules to accommodate change

Step 2: Early Long Lead Procurement

• Standardization allows bulk procurement and inventory of components in OSM warehouse
• Partial buy-out for cost savings – monitor stock levels to accommodate changes in equipment requirements
• Long lead materials removed from site installation packages

Step 3: Assemble Modules in OSM facility

• Built-to-order: allows late change to design and eliminates unnecessary components and cost
• Assemble and ship to site prior to tool delivery date to allow early installation by field contractors, reducing construction activity around tool and reducing critical path schedule