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Modular construction on the rise

SINGAPORE. In the Clement Canopy project, Dragages Singapore is building the tallest towers ever erected using modular concrete and positioning itself as a leader in this very promising market.

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Challenge accepted

Singapore in the morning. Alagusundaram Palaniappan is supervising the installation of a concrete module in the Clement Canopy project (Dragages Singapore), in which two 140 meter residential towers are being constructed in the Jurong Lake student quarter in a western neighborhood of the capital. The chief surveyor is watching to see that the tricky operation goes off smoothly. A precast module weighing 23 tons is being lifted to the seventeenth floor of one tower so that it can be placed on the top of the other. Several things immediately strike one as unusual. First, only two men are involved in lifting the module; then a small team of just four men set it in place in ten minutes. No noise of trucks, no dust produced by concreting operations, no scraps of steel or plastic visible.

A prefabricated module is eased into place on the 17th floor of one of the two towers in the Clement Canopy project.

Clearly, Clement Canopy is different from other projects. It is being carried out with a modular construction technique, or more precisely, with Prefabricated Prefinished Volumetric Construction (PPVC), as it is called in Singapore. The blocks that make up the building are prefabricated and mostly finished both inside and out at plants offsite. They are then brought here and assembled. This technique is very popular with the Singapore government, which is eager to increase productivity in the construction sector and is now demanding in many projects that 65 percent of the building superstructures be constructed with PPVC.

Never seen before

Dragages Singapore’s know-how in PPVC comes from experience acquired in the 2014 extension of the Crowne Plaza Hotel, the first project of its kind in Singapore, and in the construction a year later of an assisted living facility, the Woodlands Crescent Nursing Home. Nevertheless, the Clement Canopy project presents some new challenges. The loadbearing steel structure that supports the modules in the previous projects is replaced here by reinforced concrete, a material preferred by the buildings’future owners because of its durability. The materials are also heavier, meaning that two cranes capable of lifting modules weighing up to 31 tons had to be brought from Germany.

“It’s quite simple. Constructing a tower this high, with this quantity of concrete modules – 1,866 in all – with walls barely 8 centimeters thick, is an all-time first anywhere in the world,” explains Allan Tan, executive director of Dragages Singapore. “Stacking modules one on top of another like Lego blocks might seem like child’s play, but that’s not the case at all,” adds Seng Swear Wern, the production manager on the project. “This operation calls for the precision of a goldsmith, with a tolerance of two millimeters for the joints between the modules. Anything greater would threaten the building’s stability.”

Alagusundaram Palaniappan and Paul Joginder, Deputy superintendent director, at the Clement Canopy worksite.
They talk about it
Lawrence Wong
Minister for National Development and Second Minister for Finance Singapore Government
“We certainly welcome Dragages Singapore’s very proactive stance in leading the productivity movement in our construction sector.”
Liam Wee Sin
Deputy Group Chief Executive Offi cer UOL Group Limited
“For this unprecedented project, we decided to work with Dragages Singapore because they have shown the capability and experience in developing projects using the PPVC method, and are able to work with the authorities to roubleshoot issues to move the project along smoothly.”
Outfitted head to toe

Checking that the modules are aligned and that the mortar poured between them is up to standard; seeing that deadlines and safety instructions are respected: nothing escapes the eye of Palani and his coworkers at the top of the tower, where four modules are installed each day. They are performers in a continuous ballet orchestrated according to a meticulous strategy in terms of planning and logistics. And that is also true at the first link in the module production chain, sixty kilometers from here in Senai, Malaysia, where they are cast, and at the Tuas plant, west of Singapore, where the finishing work is done.

The plant at Senai, Malaysia, where modules are precast for the Clement Canopy project.

In fact, the first module installed this morning, measuring 22 sq. meters and containing a main bedroom, a bathroom, and a toilet, arrived from Tuas yesterday, with its windows, doors, floor and wall coverings, closets, shower, mirror, electrical outlets, switches, and air conditioning already installed, with all the plastering and painting done, and with everything from floor to ceiling tested. All these operations are performed offsite and under roof, which allows the Dragages Singapore workers to better control the work environment. PPVC has many advantages: construction time reduced by up to 50 percent, 30 percent fewer workers on site, less noise pollution, improved worksite safety and a higher-quality finished product...

The plant at Tuas, in western Singapore, where the finishing work is done on the modules for the Clement Canopy project.

...Plus the possibility of reusing materials in a circular economy approach. Julien Esch, director of Dragages Singapore, Vietnam, Indonesia and Malaysia at Bouygues Bâtiment International (a subsidiary of Bouygues Construction), says, “This innovative construction method is a key added value for Dragages Singapore, which is now positioned as a leader in this very promising market.” This article was originally published by Ludmilla Intravaia in le Minorange #90. For further information, visit BYLINK. https://bylink.bouygues.com/en/communications/publications/bouygues-group/internal-publications/le-minorange

505
apartments, 40 floors
297
construction workers
93,75
M€, contract's amount
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