DL E&C announced on July 7th that it has completed the installation of the Pre-Assembled Pipe Rack (PAR) modules at the construction site of the Shahin Project, which is the largest investment initiative in South Korea's petrochemical industry led by S-Oil. The PAR modules serve as crucial structures supporting pipelines that transport raw materials and products, playing an essential role in plant operations.
A total of 17 PAR modules have been installed. These modules were manufactured in Mokpo, Jeollanam-do, and transported to the Shahin Project site in Ulsan's Onsan Industrial Complex. The modules include massive units measuring up to 47 meters in length, 22 meters in width, and 36 meters in height, with the entire weight reaching approximately 10,000 tons. Transport operations were conducted over ten rounds since February.
Precision was key in the module installation due to the physical differences between manufacturing and installation environments. DL E&C enhanced accuracy by adopting 3D scanning technology, which uses lasers to create digital representations of spatial structures. This technology allowed for a 3D reproduction of the actual installation site at the manufacturing plant, enabling the production of custom-fit modules according to the terrain. Consequently, the spacing error between modules was contained within 3mm.
In addition, DL E&C adopted the 'SWHU (Single Weld Hook Up)' method, which helped reduce welding volume by about 50%, thus improving process efficiency. This method is more precise and efficient compared to the traditional technique of using piping to correct module discrepancies.
The modules were transported 450 km by sea to Ulsan Newport on a barge. To minimize risks of damage or capsizing during transport, DL E&C analyzed the volume and center of gravity of each module to determine optimal securing positions, employing special cradles and fastening devices to apply maritime transport technology.
Upon arrival at Ulsan Newport, the modules were transferred overland using Self-Propelled Modular Transporters (SPMTs). SPMTs are specialized equipment used for moving large structures; in this task, they were connected in two rows of six to cover a 2km stretch. An ultra-slow movement method was applied to minimize vibrations, taking approximately two hours for the transfer.
The modular construction method is less sensitive to environmental and workforce variations compared to onsite construction and allows for enhanced quality and shortened timelines through pre-manufacturing. DL E&C has accumulated relevant technological expertise both domestically and internationally, currently constructing the world's largest polyethylene plant in Texas using modular methods. Previously, DL E&C also executed the S-Oil RUC project, applying the largest single module in South Korea weighing 3,400 tons.
DL E&C, in collaboration with Hyundai Construction and Hyundai Engineering, is executing 'Package 1,' the core process of the Shahin Project, which is progressing smoothly toward its completion in June 2026.
Yoo Jae-ho, head of the Plant Business Division at DL E&C, stated, "The Shahin Project marks a significant expansion of DL E&C into the petrochemical plant sector," adding, "Thanks to thorough preparation and accumulated technological capability, we've successfully completed the complex modular transport and installation."
