Infrastructure and Logistics
Modularization moves mountains
Modularization has emerged as a strategy to improve flexibility, efficiency, and scalability while reducing costs. Modularization involves breaking down complex systems or processes into smaller, self-contained, and standardized units, called modules.
Putting the pieces together
In the infrastructure segment, modularization takes form through modular construction— the process of constructing buildings or structures in sections (modules) in a factory setting. These modules are transported to the construction site and assembled into the final structure. Modular construction within the mining sector is not new, but as the demand for Chile’s metals soars and capital in the industry dwindles, it is becoming increasingly popular. “Mining is catalyzing a global reevaluation, revealing the indispensable role of modular construction. Situated in remote locations, mining demands stringent security and quality standards, but at the same time, the costs of operating in mining are high, and time is gold,” said Cristóbal Schneider Guzmán, general manager at Promet.
40% of Chile's copper is produced from mines located at altitudes above 3,000 meters (9,800 ft) above sea level. Building facilities that can withstand harsh weather conditions at high altitudes (e.g., strong winds, freezing temperatures) often results in a 20-30% increase in construction costs compared to similar facilities at lower altitudes. “The mining industry in Chile presents unique challenges due to its remote locations, adverse weather conditions, and limited resources,” said Pablo Rosales CEO at Tarpulin. “Modular solutions are ideal for this sector, offering cost-effective alternatives to traditional construction methods. Furthermore, given the prevalence of temporary projects in mining due to environmental constraints, modular construction emerges as an efficient and environmentally responsible option”.
“Chilean ports currently possess the capacity to satisfy the present demand for copper and lithium, but it is important to strengthen our readiness to address future demands and potential contingencies.”
Tomás Valenzuela Somerville, Mining, Energy & Regional Offices VP, AGUNSA
Chile is one of the most seismically active countries in the world, experiencing over 1,000 earthquakes a year. This raises construction costs. Modular construction provides a solution. Tecno Fast constructed a seven-story 34,000 square-meter wooden hotel for Anglo-American in one month. “To ensure its safety and stability in response to earthquakes, we carried out detailed testing, placing modules on a platform to simulate seismic stress and testing them up to seismic grade 12. These tests showed that the modules could withstand significant seismic forces without failing,” said Cristian Goldberg Aichele, general manager at Tecno Fast.
The benefits of modular construction can be felt before the construction even begins. “Modular solutions allow us to work with our clients earlier in the design stages. By assisting earlier in the process, we can greatly impact construction workflow productivity, improve assembly safety, and reduce environmental footprint,” said Jose Luis Villalón Spoerer, general manager at Hilti.
The factory setting of modular construction also enables benefits. “Prefabrication reduces emissions and pollution by centralizing manufacturing in environmentally responsible facilities. Modular solutions can be disassembled, reused, or repurposed, providing sustainable solutions over time,” said Tomas Fischer Ballerini, general manager at Edyce.
Modular construction also allows for unique ways to support sustainability in the sector. In their construction of warehouses for client SQM, Tarpulin introduced the circular economy into the modular construction space. “Our modular floor is made in Chile using recycled plastics (HDPE) instead of traditional concrete slabs,” said Rosales.
“Our ownership of the terminal grants us autonomy, enabling us to operate efficiently without the constraints often associated with third-party management. This autonomy is a strategic advantage, especially in a bay like Mejillones, known for high congestion.”
Diego Rodríguez, General Manager, Terquim / Odfjell Terminals
Logically modular
Modularization is also being applied in the logistics space to save time, increase efficiency and safety, and lower emissions.
Logistics company Mammoet is involved in the Front-End Engineering Design (FEED) stage, allowing the firm to integrate transportation logistics into the design process. “Mammoet completed the transportation and installation of a ship loader for a prominent mining client. We introduced a modular approach for this client, transporting their load in two sections instead of numerous smaller loads,” said Vanessa Labana, sales manager Chile at Mammoet. “This not only streamlined the assembly process but also enhanced safety,” Labana continued.
Mintral, a mining logistics firm, found that designing shipment containers with a modular approach benefits them. “Our adapted containers have trays in the middle of the truck which allow us to combine two trips into one, providing economic savings for clients and improving safety by reducing the number of trucks on the road,” said Phillip Schaale, general manager at Mintral. “This initiative saved 5,000 trips last year, equivalent to 3,200 tons of CO2 emissions.”
The ease and speed of modular construction allows for fast and cost-effective mine development while driving the industry towards safer, and more sustainable solutions.
“As the mining industry embraces automation, electromobility, and technological integration under the Mining 4.0 paradigm, we envision the evolution of plant designs to streamline construction and relocation processes, thereby enabling equipment reuse.”
Vanessa Labana, Sales Manager Chile, Mammoet
Article header image courtesy of Tarpulin