Planning and constructing a 128-ft-tall, 139-ft-long, 62-ft-wide, 2,800-ton cracking furnace, then transporting it a mile before carefully connecting it was a puzzle that took some out-of-the-box thinking and next-level coordination.

The team, including contractor PCL Industrial Construction Co. and owner Chevron Phillips Chemical Co., coordinated closely to accomplish a modular approach to the project, the feasibility of which many members of the team initially questioned. Preconstruction services began in October 2019, and modular assembly started in September 2021. One year later, the massive supermodule was transported one mile to be connected to the plant’s eight existing units, with all tie-ins completed in August 2023.

The original furnace layout was not conducive to modular construction, the team says, leaving engineering and constructability teams to redesign the entire furnace to accommodate the modular plan.

Danny Evans, PCL construction manager, says one of the biggest takeaways from the project is the power of alignment between owner, contractor and engineering firm.

“We built a strong, unified approach where all stakeholders prioritized what was best for the project rather than individual interests,” he says. “That level of collaboration allowed us to navigate challenges efficiently and maintain momentum.”

Each of the 17, 140-ton preassembled modules that make up the furnace had its own set of design challenges and sequence requirements, leading the engineering team to redesign modules to consider deflection from the extreme weights being stacked atop each other. Additionally, extensive planning and tracking for all additional supports was essential, as the module could not weigh more than 3,000 tons.

Evans says the team’s commitment to safety and quality is carrying forward, with the strategies and processes that led to a recordable injury-free project being replicated at its current project, including early engagement with the client to establish clear expectations, reinforcing a culture of accountability among crews and leveraging the experience of field leaders who were instrumental in the project’s success.