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Copyright © 2010 SubOptic Page 1 of 9 conference & convention enabling the next generation of networks & services RISK MITIGATION THROUGH INDUSTRIALIZED CONSTRUCTION: INTEGRATING PREFABRICATED, MODULAR CABLE LANDING STATIONS INTO BUILD-OUT PROGRAMS Author: Amy Marks (Kullman Buildings Corp.), Email: [email protected] Co-Author: Tom Collington (The David Ross Group), Email: [email protected] Kullman Buildings Corp., One Kullman Corporate Campus, Lebanon, N.J. 08838, USA Abstract: A case study demonstrates how four Modular Cable Landing Stations (MCLS) have been utilized to reduce overall project risk in extreme environments and remote locations for SEACOM. Using industrialized construction, 3-D BIM technology and lean project- delivery systems, project teams are shown to significantly reduce construction time and minimize schedule, cost and performance risks associated with permitting, inclement weather, site constraints, limited availability of experienced cable station engineering and construction resources, and material theft and damage. The modular facilities and manufacturing/construction approach are described. Results include making stations available to East African retail carriers ahead of conventional schedules, allowing for the potential of earlier revenue generation for licensees and end users. 1. INTRODUCTION: ADDRESSING RISK BY USING MODULAR AND INDUSTRIALIZED APPROACHES FOR BUILDING NEW LANDING STATIONS Case studies in four African locations show how prefabricated modular cable landing stations have been utilized to reduce overall project risk in extreme environments and remote locations. The case studies demonstrate that this method is an effective approach. Through the utilization of industrialized construction techniques, lean project- delivery systems as well as Revit and NavisWorks software for three- dimensional building information modeling (BIM), project teams working in East Africa have been able to reduce construction time of these stations by close to 50%. The team also successfully eliminated risks associated with weather, site constraints, limited availability of experienced cable station engineering and construction resources, and material theft and vandalism and helped to mitigate permitting delays which otherwise might have been significant to overall cable station construction programs. Overseas construction in remote and unfamiliar areas has long been known to add a high-risk element to any program schedule and budget, both statistically and anecdotally. 1 The biggest challenges facing owner-operators of cable systems include loss prevention, cost estimating and budgetary control, vandalism and other criminal acts, as well as the basic challenge of finding experienced work crews, good suppliers, and even potable water and electricity service or generators within a few hundred miles of the project start. Maputo, Mozambique setting phase 1 “Risk Management for Overseas Construction Projects,” He Zhi, International Journal of Project Management, Vol. 13, Issue 4, 1995, pp. 231-237.

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Copyright © 2010 SubOptic Page 1 of 9

conference & convention enabling the next generation of networks & services

RISK MITIGATION THROUGH INDUSTRIALIZED CONSTRUCTION: INTEGRATING PREFABRICATED, MODULAR

CABLE LANDING STATIONS INTO BUILD-OUT PROGRAMS Author: Amy Marks (Kullman Buildings Corp.), Email: [email protected] Co-Author: Tom Collington (The David Ross Group), Email: [email protected] Kullman Buildings Corp., One Kullman Corporate Campus, Lebanon, N.J. 08838, USA Abstract: A case study demonstrates how four Modular Cable Landing Stations (MCLS) have been utilized to reduce overall project risk in extreme environments and remote locations for SEACOM. Using industrialized construction, 3-D BIM technology and lean project-delivery systems, project teams are shown to significantly reduce construction time and minimize schedule, cost and performance risks associated with permitting, inclement weather, site constraints, limited availability of experienced cable station engineering and construction resources, and material theft and damage. The modular facilities and manufacturing/construction approach are described. Results include making stations available to East African retail carriers ahead of conventional schedules, allowing for the potential of earlier revenue generation for licensees and end users. 1. INTRODUCTION: ADDRESSING

RISK BY USING MODULAR AND INDUSTRIALIZED APPROACHES FOR BUILDING NEW LANDING STATIONS

Case studies in four African locations show how prefabricated modular cable landing stations have been utilized to reduce overall project risk in extreme environments and remote locations. The case studies demonstrate that this method is an effective approach. Through the utilization of industrialized construction techniques, lean project-delivery systems as well as Revit and NavisWorks software for three-dimensional building information modeling (BIM), project teams working in East Africa have been able to reduce construction time of these stations by close to 50%. The team also successfully eliminated risks associated with weather, site constraints, limited availability of experienced cable station engineering and construction resources, and material theft and vandalism and helped to mitigate permitting delays which otherwise might

have been significant to overall cable station construction programs. Overseas construction in remote and unfamiliar areas has long been known to add a high-risk element to any program schedule and budget, both statistically and anecdotally.1 The biggest challenges facing owner-operators of cable systems include loss prevention, cost estimating and budgetary control, vandalism and other criminal acts, as well as the basic challenge of finding experienced work crews, good suppliers, and even potable water and electricity service or generators within a few hundred miles of the project start.

Maputo, Mozambique setting phase

1 “Risk Management for Overseas Construction Projects,” He Zhi, International Journal of Project Management, Vol. 13, Issue 4, 1995, pp. 231-237.

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In the African locations observed and cited in this paper, the project teams also dealt with relatively small local populations and no communications systems at all. The possibility of security threats increase in any remote site, no matter where it is located in the world; in fact, crew members on these projects experienced at least one assault. Also, a lack of the relevant technical knowledge and experience needed to provide construction support (e.g. current construction techniques, materials and tools) regionally makes any technical construction project a challenge. The methods employed by Kullman on the SEACOM project successfully ensured that new cable-landing stations were brought on-line ahead of conventional schedules, resulting in the potential of earlier revenue generation for licensees and end users than otherwise might have been possible. The East Africa Case Study examines a build program consisting of four (4) modular cable landing stations in Dar es Salaam (Tanzania), Mtunzini (South Africa), Mombasa (Kenya) and Maputo (Mozambique). The project team included SEACOM (with their technical advisor, The David Ross Group), Tyco Telecommunications and Kullman Buildings Corp., an offsite construction provider. The cable system under development is designed to perform reliably for 25 years. The prefabricated modular stations deployed in SEACOM have been tested for a variety of parameters to last at least 50 years. The cable system will provide African carriers with equal and open access to inexpensive bandwidth, removing an international infrastructure bottleneck supporting economic growth in East and Southern Africa.

On 23 July 2009, the SEACOM subsea fiber-optic cable began operations, providing the East African countries of South Africa, Tanzania, Kenya, and Mozambique, with high-speed internet connections to Europe and Asia. The launch was described by the CEO of SEACOM as being “a historic day for Africa that marks the dawn of a new era for communications between the continent and the rest of the world.” Upon being switched on, the owners of the cable stated that it would reduce Internet costs by up to 95% to wholesale customers, while providing far greater speeds of internet connection. 2. HISTORY AND TYPOLOGIES OF

INDUSTRIALIZED MODULAR BUILDINGS

The use of modular prefabricated buildings dates to the early 1900s and began wide-scale use in residential dwellings and commercial structures in the period from 1910 to 1940. 2 With improved manufacturing, transport and site assembly capabilities, by the end of World War II industrialized construction had grown to a large percentage of the residential and commercial buildings market.

Lean Manufacturing line takt time: 1 comm shelter every 4 hrs Over the last two decades, the technology sophistication of prefabricated, modular construction has increased significantly, leading to applications in a variety of industries with rigorous performance 2 Modular Today, 2008

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specifications and technical requirements. Industrialized construction is now routinely used for very large structures, high-rise buildings, and construction in remote areas with limited access or extreme climatic or social conditions, or both. The efficiency of constructing with a modular approach is also well established.

Modular Cable Landing Stations (MCLS) en route to site via truck in Africa. 3. APPLICATION OF MODULAR,

PREFABRICATED TECHNIQUES TO CABLE LANDING STATIONS

The use of factory-built enclosures and buildings for the undersea cable market dates to the mid-1990s, and more recently has been shown to speed the delivery of undersea cable connectivity. Equipment suppliers and carrier customers have employed modular building systems in the Middle East, Asia, the Caribbean, North America and Africa.3 The building process for modular systems begins at the design phase using AutoCAD/Revit and Building Information Modeling (BIM) systems. The stations are

3 Capacity Magazine, 2008

designed and engineered according to specifications developed by the fiberoptic cable system network operator. The building process benefits from current manufacturing techniques which are not common in traditional on-site (local) construction, such as lean manufacturing and QA (quality assurance). Using repetitive assembly-line techniques and pre-engineered assemblies reduces time/motion requirements. Once the modules are constructed at the factory, they are transported and set, typically by crane, on a permanent foundation. The resulting structures can be customized to meet the same aesthetic requirements as conventionally constructed landing stations, complying with any local regulations. The Modular Cable Landing Station (MCLS) can be built to a variety of technical and design specifications. A typical station features galvanized steel structural framing with internal hoist connections, a 4” composite concrete floor, and façade materials to meet the station operator’s branding, local codes and other preferences. The Modular Cable Landing Station (MCLS) is typically equipped in the factory with electrical and plumbing leads as well as heating, ventilation and air-conditioning (HVAC) equipment that is pre-installed and factory tested. Secondary power (generators) can be mounted within the modules and tested prior to shipping. The primary considerations for erecting and operating a cable landing station include: (a) wind loading; (b) seismic effects; (c) interior environmental stability; (d) security, including forced entry, ballistics, and blast protection; (e) RF-EMI

Growth of modular buildings, United States 1920 - 2010

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shielding; (f) military and intelligence requirements for SCIF (Sensitive Compartmented Information Facility) installations; (g) business and commercial logistics, such as schedule, budget, and loss prevention. In some cases, protection against (h) corrosive environments, such as coastal areas, is also important. The track record for Modular Cable Landing Station (MCLS) application is well established. More than 10,000 communication enclosures and landing stations have been delivered as industrialized construction projects by Kullman 4 in North America, South America, Africa, Indonesia, the Middle East and Asia. 4. MODULAR CABLE LANDING

STATION REQUIREMENTS FOR SEACOM

SEACOM builds and operates a submarine fiber-optic cable network connecting communication carriers in southern and eastern Africa for wholesale international capacity to global networks via India and Europe. SEACOM’s focus is to deliver affordable bandwidth in many countries previously relying on expensive and slow satellite connections, including the countries cited earlier, as well as inland countries such as Uganda and Rwanda. Two operational fiber pairs have a combined design capacity of 1.28 Tbit/s. SEACOM construction was planned as an 18-month turnkey program; commencing in late 2007, it reached Ready for Provisional Acceptance (RFPA) in mid-2009 in spite of a range of construction risk factors.

4 Kullman Buildings Corp., 2009

Mtunzini, South Africa generator MOD in setting phase. A number of project and site challenges influenced the selection of modular construction methodology. The most critical was local Construction Risk: SEACOM’s plan for minimizing the risk of local construction delay was to contract for the supply inclusive of prefabricated Modular Cable Landing Station (MCLS), designed and constructed by a provider “with knowledge and experience with cable stations.” 5 In April 2008, Tyco Telecommunications engaged Kullman Buildings Corp. to work with SEACOM for the East Africa build program consisting of four Modular Cable Landing Station (MCLS) installations in Dar es Salaam (Tanzania), Mtunzini (South Africa), Mombasa (Kenya) and Maputo (Mozambique). The method of factory-built Modular Cable Landing Stations (MCLS) was utilized in order to achieve the scheduled end date, since conventional construction was deemed extremely difficult from many perspectives, especially schedule. SEACOM directly undertook the local civil work for these Modular Cable Landing Station (MCLS) projects, using an experienced African-construction team familiar with local practices and people to manage associated site work, foundation engineering, and related construction specifications required for the Modular

5 Seacom, 2010

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Cable Landing Station (MCLS). The sharing of responsibility, leveraging each party’s expertise, proved to be an effective approach, according to SEACOM. 5. MODULAR CABLE LANDING

STATION (MCLS) DESIGN AND SPECIFICATIONS FOR EAST AFRICA

The team of Tyco Telecommunications and SEACOM selected a prefabricated Modular Cable Landing Station (MCLS) approach in large measure to dilute overall project risk in extreme environments and remote locations. This first consideration informed the design and specifications of four prefabricated Modular Cable Landing Station (MCLS) systems produced for: Dar es Salaam (Tanzania), Mtunzini (South Africa), Mombasa (Kenya) and Maputo (Mozambique). The project team determined that the most suitable build program would employ offsite construction using a controlled environment with a staff experienced in fiberoptic cable infrastructure projects. The Modular Cable Landing Stations (MCLS) would be designed, produced and tested in the same northeastern U.S. facility before shipping to the four African sites. This engineering-based turnkey procurement method provided the most quality control and risk management and met the aggressive schedule of the project. Each Modular Cable Landing Station (MCLS) comprised of 6 modular units (modules) totaling about 1,500 square feet (140 m2) with an attached generator building of 2 modules (about 500 square feet, or 46.5 m2.) The stations were designed with the following specified features: Exterior: A neutral, natural-colored stone aggregate wall finish was selected for all four locations to complement the local topography and coloration. Utilizing Modular Cable Landing Stations (MCLS)

allows for end users to select any exterior to ensure complimentary integration to the local architectural landscape. Structure: A galvanized W-12 steel base frame set in precast concrete floor slabs. The assemblies were engineered and tested to withstand Seismic Zone 4 racking forces (1:10 likelihood of tremors with active peak acceleration level of 0.04g) and lateral wind loads of 150 mph (sustained). The all-steel frame with internal hoisting attachments was designed for a life span of 50 years. Access: Stainless steel doors with security locks. Fire safety: A fire-suppression system using the inert gas FM-227 connected to a high-fog mist system. HVAC: The HVAC package was designed to adhere to SEACOM engineering requirements for air exchanges and cooling, as well as to meet the atmospheric conditions expected in East Africa. A coastal package for improved protection against humidity and corrosion was included. Cable and fiber: Facilities included installed fiber ducting, cable tray racking with seismic rated installation, and other proprietary cable station accessories. Security and continuity: The Modular Cable Landing Station (MCLS) design for the four locations includes a high-grade security package for continuity of operations. This included: (a) enclosure design to ballistics requirements, interior and exterior cameras with remote monitoring. Factory Integration of Equipment: Equipment was installed and tested in the Modular Cable Landing Station (MCLS) modules before oversees shipping.

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Generators and back-up power: Modular generator buildings included pre-piped attachments, battery rack, tank and the like, to provide backup power for as long as 3 months. In the design phase, a Revit 3-D BIM model was created and used to ensure seamless integration of the modules. Also, the model was used to detect any potential clashes in the structural, mechanical,

electrical, plumbing or finish materials prior to fabrication. BIM allowed multiple changes to be carried automatically through all project documentation, and referenced a parametric database describing each element of the mod assemblies. The fabrication and assembly of the Modular Cable Landing Station (MCLS) modules employed accepted industrialized construction techniques. Also, a “lean” project-delivery system and lean manufacturing techniques were employed that additionally reduced construction time at the stations. Ultimately, the use of the Modular Cable Landing Station (MCLS) approach reduced the project schedule by about 50% as compared to conventional, on-site construction approaches. This methodology ensures schedule predictability thus reducing risk to licensees and end users. As seen below, the Modular Cable Landing Station (MCLS) approach was also shown to successfully eliminate risks due to inclement weather, site constraints, limited availability of experienced cable station engineering and construction resources, material theft and damage. 6. MODULAR CABLE LANDING

STATION (MCLS) TRANSPORT AND INSTALLATION

The highly engineered and pre-equipped modular cable landing stations were shipped to East Africa by sea and then by truck transport. All craning and setting of the modules as well as finish work was provided by the turnkey Modular Cable Landing Station (MCLS) supplier, Kullman. Tyco Telecommunications and SEACOM staff, working with local crews, oversaw final systems integration. The maximum size of modules is limited by national and local laws. While modules can be most economically transported if they do not require a permit or escort, the Installations close to completion in Maputo,

Mozambique (top) and Mombasa, Kenya

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four African locations required permitting and such approvals as ROW and EIA. The maximum module weight for transport is typically 44,000 lbs. Modular Cable Landing Station (MCLS) modules are not exposed during transport and are covered by custom polyethylene tarps and include an interior moisture defense system. Crane selection for setting the modules was based on weight and reach. Typical required capacities are greater than 5 tons, and can be in the range of 50-100 tons. Rigs and spreader bars are used to hoist some modules, but typical communications modules are smaller, and can be set using direct lifting at internal hoist locations. Once the riggings were set in place, modules were maneuvered “on hook” using guide-ropes. A ½-inch space between the module frames speeds the placing process. Tool-and-die based interlocking assemblies increased the accuracy and speed of the setting process. The modules are fastened to a 3/8” steel plate with a 1-1/2” stiffening lip at top and bottom using 5/8” blind rivets. The rivets have a sheer strength of 15,950 lbs. and a tensile strength of 10,250 lbs. Fastening plates and hardware were fireproofed as needed in the field. Field finishing was kept to a minimum in order to maximize the economic benefits of modular landing-station construction. 7. PROJECT RISK AND MODULAR

CABLE LANDING STATION (MCLS) CONSTRUCTION RISK MANAGEMENT

Tyco Telecommunications and Kullman planned the SEACOM construction program as an 18-month, turnkey delivery. Even with several challenges within the territorial boundaries, in particular permitting, the mid-2009 RFPA was achieved in good part due to the reduced and predictable schedule using modular industrialized construction. The same

results would not have been possible using a conventionally built station.

In general, the Modular Cable Landing Station (MCLS) approach allowed the reduction of various types of project risk identified by SEACOM and Tyco Telecommunications prior to the project start: Environmental risk: Issues related to inclement weather and site constraints were successfully mitigated as assembly and construction of the cable landing stations occurred offsite. These risks were limited to the placing of concrete and concrete block foundations, as well as associated site work and final placing and finishing of the Modular Cable Landing Station (MCLS) components.

Dar es Salaam, Tanzania completed site. Social risk: In the areas where the landing stations were needed, a limited availability of experienced cable station engineering and construction resources as well as the likelihood of material theft and damage by vandalism were identified as high probabilities. The Modular Cable Landing Station (MCLS) approach is credited with helping to minimize those risks.

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Local construction risk: SEACOM and Tyco Telecommunications planned to minimize the risk of local construction delay was to contract with Kullman for the supply inclusive of the prefabricated Modular Cable Landing Station (MCLS) delivery, designed and constructed by the U.S.-based team with knowledge and experience of current cable station practices. To further guarantee the success of the mission, SEACOM directly undertook the local civil work, using their own experienced African-construction team to manage the foundations and site work and related tasks required for the station. This ensured that SEACOM had people managing the civil works who were highly familiar with local practices and available trades people and other resources. This work was also done concurrently to the fabrication and shipping of the Modular Cable Landing Station (MCLS) further reducing the overall schedule. Outside of the prefabricated Modular Cable Landing Station (MCLS) produced in the US, the only other work needed to complete the project was constructing the building foundations and integrating the cable into the building. According to SEACOM, “The sharing of responsibility, leveraging each party’s expertise, proved to be the best approach.” Remote locations: Regardless of country, building new cable landing stations in very remote areas must always be planned with proper measures for property and personal security, and must be planned for accordingly. In addition to the challenges of finding suitable means, materials and crews for local construction work, basic project conditions include loss prevention, dealing with potentially dangerous populations, and transport of imported materials, tools and equipment.

The use of Modular Cable Landing Station (MCLS) systems helped eliminate or mitigate many of the associated risk factors, according to SEACOM and other project participants. Additional steps taken included: loss prevention analyses and detailed cost estimating for budgetary control. Careful preconstruction work, logistics and route surveys ensured that the selected sites would allow for all work needs and Modular Cable Landing Station (MCLS) transportation, craning and setting as well as lodging for US work crews. Issues of limited knowledge and limited experience of cable technologies, local construction techniques or available materials and tools, are mitigated by using a Modular Cable Landing Station (MCLS). Using a Modular Cable Landing Station (MCLS) overall improves the risk profile of the project dramatically. Permitting risk: As a subset of the construction risk, the project team had to manage hundreds of permits required. Regular permit coordination meetings to manage this program helped reduce delays for EIA approvals and right-of-way (ROW) finalization, as well as property purchase closures. Local approval processes for the spectrum of permissions required were not always well defined, but there were no delays attributable to permits or approvals. Although, there were construction delays on site because of permits, the modular approach helped to mitigate the impact of these delays on the RFPA, as the construction of the buildings was isolated from the permit process to a large degree. Removing fabrication of the Modular Cable Landing Station (MCLS) from the SEACOM scope of responsibility allowed the team to focus on site permitting and technology integration resulting in a better

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Modular Cable Landing Station (MCLS) and successful completion date and within the budget. Piracy: The escalation of piracy near the Gulf of Aden was another overall program risk factor, though it was not known until the project had already began. According to SEACOM, the piracy issue is so pervasive that the risk they pose in terms of delays and cost (including marine insurance and security personnel) is now being factored into any new submarine cable plan which transits the region. Kullman coordinated shipment of the MCLS modules to reduce potential piracy impact on cable station completion. In general, the risk factors faced by the SEACOM were largely addressed through the choice of the Modular Cable Landing Station (MCLS) construction approach. The Modular Cable Landing Station (MCLS) system limits environmental, social and local construction unknowns. Many of these risks impact construction schedule and operations starts, which directly benefit the bottom line. 8. Conclusion Risk management for landing station projects requires an analysis of project-specific challenges. The Modular Cable Landing Station (MCLS) approach by Kullman used in the four SEACOM Africa projects has been found to work well for many specific and general considerations related to erecting and operating a cable landing station. The case studies demonstrate how the use of sophisticated prefabricated Modular Cable Landing Station (MCLS) reduced overall project risk in remote locations with extreme environments and difficult work conditions. Through the use of industrialized construction, 3-D BIM software, and lean project-delivery systems the project team has been able to reduce construction time for the stations by almost 50% and have successfully eliminated risks

due to inclement weather, site constraints, limited availability of experienced cable station engineering and construction resources, material theft and damage. These methods used have successfully insured stations coming on-line ahead of conventional schedules resulting in the potential of earlier revenue generation for licensees and end-users. The Modular Cable Landing Station (MCLS) systems may also address the primary considerations for erecting and operating cable landing stations, including: (a) wind loading; (b) seismic effects; (c) interior environmental stability; (d) security, including forced entry, ballistics, and blast protection; (g) business and commercial logistics, such as schedule, budget, and loss prevention. The four Modular Cable Landing Station (MCLS) build program undertaken by SEACOM, David Ross Group, Tyco Telecommunications and Kullman in East Africa will perform reliably for 25 years, and the prefabricated stations have been tested to last 50-plus years. The installations will help provide African retail carriers with equal and open access to inexpensive bandwidth, removing the international infrastructure bottleneck supporting east and southern African economic growth. 9. REFERENCES [1] See Footnotes.