Modular Fabrication in Cincinnati
More and more companies across multiple industries are opting to use modular fabrication to construct production equipment. This technique makes modular process skids designed and created in a controlled environment instead of at the worksite. Industrial fabrication can streamline your construction project and provide more control over the final product.
PCI Services' expert engineers can manufacture modular buildings, piping systems, skid systems for industrial plants, and more. As skilled labor is on the decline, we are fully staffed to provide high-quality fabricated modular skid work for nearly any project worldwide. Read on to learn how modular skid fabrication works and how our modular fabrication process can transform your construction workflow.
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OUR FABRICATED SYSTEMS PROCESS
DESIGN & Engineering
The skid fabrication process begins with our in-house design team collaborating with our clients to fully assess the purpose and operational demands of the project. Engineers will then create a design that they will refine over time to find the right dimensions and components for the equipment. The design criteria change for each project, but engineers will consider the following factors:
Our in house design staff consisting of engineers, draftsman, and controls specialists can provide custom design per job as necessary. The design criteria varies but often consist of following:
Pressure tests up to 300 PSI
Clear connection points for all external control devices for faster installation
Thermal breaks on all pipe supports and U‐bolts
120V components used throughout
U.L. listed panels and single-point electrical connection
Choice of main disconnect or main fuse block for enhanced AIC protection
Module Construction
Our highly trained staff of union welders and pipefitters begin the fabrication process by cutting, welding and assembling all steel and pipe. Once complete all electrical and controls work continues in house. All shop work goes through a series of checks to ensure dimensional accuracy, completeness, quality, and conformance to the design and specifications of the customer. The full fabrication process is all completed from start to finish under one roof.
Skid Assembly
With all the parts in place, we then create a skid assembly. Skid assemblies comprise all the equipment, piping, and machinery required for modular skid fabrication. The process does not have to be installed on the factory floor.
TESTING & COMMISSIONING
Once a modular process skid is created the fabricated product undergoes testing as specified, such as x-ray, dye-penetrant checks, hydrostatic testing for piping systems, and point-to-point checks for instrumentation and electrical work. We can customize a complete test package specific to a customer or project in agreement with the end user if required.
FINAL TOUCH
Once complete, we provide our own system design and piping drawings. Our experienced drafting dept. understands the unique requirements of modular construction and our design group compiles all equipment specifications to give customers a complete finished package. We can provide onsite implementation as well as controls start-up and support as necessary.
Industries We Work With
Modular process skids are can be used to service various industries. Here are some of the common industries we work with when providing modular process solutions.
Oil and Gas Industry
Modular skids are very important to companies in the oil and gas industry. They facilitate operations that process oil, raw materials, and natural gas. Skids help refine these materials to be used as fuel, and are used to assemble off-site systems then transported to the site for installation. Modular components for oil and gas often include pump skids, gas processing units, and control systems.
Chemical Processing
Modular skids are commonly used in chemical processing plants for numerous processes, such as:
Batch processing systems
Chemical mixing and blending
Centrifuge systems
Chemical reactors and processors
Distillation systems
Pharmaceutical Manufacturing
To ensure that pharmaceutical products are made with the necessary level of precision, modular process skids are utilized throughout the formulation, blending, and purification processes. Modular fabrication of pharmaceutical production lines at our off-site manufacturing facility ensures that those modules are completed in a controlled, safe environment.
Water and Wastewater Treatment
Modular skids are used in water distillation systems and desalination plants to filter out chemicals, substances, and bacteria and keep communities healthy.
Food and Beverage Industry
Food and beverage manufacturers employ modular skids to support their flavor mixing and blending systems. They are also used in food processing and waste processing systems.
Advantages of Modular Skid Fabrication
Faster Installation
You might assume that the process behind modular fabrication would be time-consuming, but it is faster to install than on-site construction. Bad weather near your worksite won't impact your team's ability to put skids in place. The equipment is also built to integrate with your existing systems quickly, allowing you to get back to work quickly.
Reduced Site Work
Modular skid fabrication takes construction away from the worksite and into the controlled environment of a fabrication shop. This location change isn't just safer and more efficient than traditional construction techniques. It also leads to fewer labor hours spent building equipment, minimizing any disruption to your operation.
Improved Quality Control
On-site construction projects carry inherent risks because of the daily operations likely to occur nearby. Since modular fabrication occurs off-site, skids can be created in a safer locale where parts can be tested before they are sent to the worksite. This allows you to standardize skids' quality, ensuring higher production consistency and that all regulations will be met.
Cost-Effective
The heightened efficiency of modular skid fabrication significantly reduces project costs by decreasing the labor hours needed to construct parts and the expense of materials.
Flexibility
Modular skid fabrication provides a higher level of flexibility during and after construction. Equipment is made more space efficient, giving you more choice over where to place parts after they're built, whether on a worksite or in storage. Process skids can also be scaled up or down depending on your production needs.
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ELEVATE YOUR OPERATIONS WITH PCI'S MODULAR SKIDS
Pride in our work, coupled with a highly trained and capable staff, yields consistent, high-quality, dimensionally accurate modular skid fabrication day after day. Our fabrication shop has long had success with modular skid and piping fabrication, however, those capabilities have greatly expanded. We’ve upped the ante in terms of providing turnkey solutions to skid-mounted modular fabrication projects. We have an engineering staff with the various skills needed to take these projects from design through on-site start-up.
If you're interested in enlisting PCI Services for your next construction project, contact us through our website or call us at 513-251-2211.
Start Your ProjectFacilities & Equipment
Our 55,000 Square Foot Fabrication Shop and Assembly Facility includes:
One (1) large bridge crane, 40’W x 48’L with 26’ under the hook
Multiple 5-ton cranes for material handling and small fabrication
Large fabrication area for base and pipe fabrication
Large assembly area for oversized projects
25 welding machines and 15 positions that are best in the industry
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ELEVATE YOUR OPERATIONS WITH PCI'S MODULAR SKIDS
Pride in our work, coupled with a highly trained and capable staff, yields consistent, high-quality, dimensionally accurate modular skid fabrication day after day. Our fabrication shop in Cincinnati has long had success with modular skid and piping fabrication, however, those capabilities have greatly expanded. We’ve upped the ante in terms of providing turnkey solutions to skid-mounted modular fabrication projects. We have an engineering staff with the various skills needed to take these projects from design through on-site start-up.
If you're interested in enlisting PCI Services for your next construction project, contact us through our website or call us at 513-251-2211.
Features & Benefits of Our Service
Accurate 3D modeling for integration into the overall system design. PCI also supports REVIT model generation upon request
Major piping and base fabrication performed in a large fabrication shop with experienced pipefitters. Weld certificates and material tracing reports (MTRs) available on request
Pre-designed major pipe supports as part of the base fabrication for additional strength
Optional full 3/16” deck plate for base tops to offer additional vibration dampening and safe working surface
Center of gravity calculations with proper lifting lug design
Electrical system protected to 65,000 AIC
Proper conduit locations designed to avoid trip or service hazards. All wiring in EMT for additional protection, with flexible conduit only at motor connection. Rigid conduit available as specified
Qualifications
& Licenses
Our welders are certified through ASME Section IX, the most stringent requirements in the industry, and are approved by the State of Ohio. While undergoing vigorous ASME welding procedure inspections we maintain the following ASME code welding stamps:
"U" stamp to manufacture and assemble unfired pressure vessels
"R" stamp to perform alterations and repairs to power boilers and pressure vessels
"PP" stamp to fabricate and assemble pressure piping
PCI Services. is certified to build, repair, and alter pressure vessels and repair and alter boilers per ASME Section VIII, and NBIC pressure vessel codes. We are also certified to fabricate and install pressure piping per ASME B31.1 and B31.3 piping codes.
We have weld procedures for the following materials:
Carbon Steel
Stainless Steel
Chrome Moly P-11/P-22/P-91
Nickel 200/201
Monel 400 & R-405
Hastelloy (all alloys)
Nicofer 6025HT
CyTemp CY-40
VDM 59
SM2060Mo
AllCorr
CRHC2000
CRM21
SM2050
SM2550
Inconel (all alloys)
Carpenter 20
20Mo6
HR120
SM2035
Haynes Alloy 20
AL6X
AL6XN
JS700
Incoloy (all alloys)
VDM 1925
25-6Mo
Tell Us About Your Project
If you’re in need of commercial mechanical services or construction contact us today and experience what makes PCI the top contractor in our field. We pride ourselves on doing work the right way the first time. We hold true to our values and will work hard to see that your project or services are executed to the best of industry standards.