Multi-Phase Development of a Modular Industrial Decarbonization Technology

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Project Summary

A Global Fortune 100 energy company initiated a multi-phase program to develop a novel modular industrial decarbonization technology intended to demonstrate the commercial viability of an emerging clean-technology process. The program progressed through several development units, each designed to validate specific subsystems before maturing into a large-scale demonstration platform. The systems were based on a modular, containerized architecture engineered for efficient factory fabrication, global transportation, and rapid on-site assembly.

ASR served as the primary mechanical and structural engineering partner throughout the program. Our role encompassed mechanical and structural design and analysis, advanced simulation, OSHA-driven layout development, airflow optimization, thermal analysis and insulation of select assemblies, routing and layout development, BOM and part-number management, procurement support, and hands-on engineering oversight during fabrication and installation.

While ASR performed limited specialty fabrication in-house for prototype components and high-cycle test articles, the majority of fabrication and installation was performed by external manufacturing partners under ASR’s engineering direction. During early development phases, ASR collaborated closely with a dedicated subcontract fabricator. For the demonstration-scale system, the client engaged a large modular fabrication company, with ASR providing engineering oversight, real-time problem resolution, and clarification of design intent to maintain alignment between engineering requirements and fabrication practices.

This combination of advanced engineering leadership, manufacturability-focused design, and on-site engagement enabled the client to progress from concept through multiple development phases to a modular industrial demonstration system suitable for commercial evaluation.

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Engineering Scope & Key Constraints

The engineering scope centered on developing a modular industrial platform that behaved structurally like a multi-story system while remaining transportable, maintainable, manufacturable, and economically viable. The work required balancing building-scale structural behavior with the constraints of modular construction and rapid field deployment.

Key constraints addressed during the program included:

• Significant structural retrofits to container-derived modules that altered existing load paths and stiffness characteristics
• Meeting environmental and operational load requirements per ASCE 7, including wind, gravity, and applicable load combinations
• Meeting ocean shipping and transport load requirements per ISO standards
• Integrating large mechanical, electrical, and fluid systems within highly constrained geometries
• Maintaining OSHA compliant access, including walkways, clearances, headroom, and fall-protection systems
• Optimizing airflow performance while preventing bypass around critical flow paths
• Managing corrosion, environmental exposure, and durability risks in a harsh operating environment
• Designing for rapid field erection with reliable and flexible module-to-module alignment under real-world tolerances
• Producing detailed engineering drawings and managing revisions for components, assemblies, and site construction
• Validating performance and durability through high-cycle and fatigue testing
• Supporting part and assembly configuration management, supplier coordination, and procurement activities
• Responding rapidly to discoveries inherent in a first-of-its-kind technology development program while maintaining project momentum

Addressing these constraints required a tightly integrated mechanical, structural, and process-engineering approach across all phases of the program.

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ASR’s Approach

Advanced Multiphysics Analysis, High-Fidelity Design and Structural Engineering

ASR led the analytical and structural engineering effort using a combination of high-fidelity simulation and detailed mechanical design to inform system architecture, validate performance, and guide design decisions across all phases of development.

ASR developed detailed global and local finite element models using ANSYS Mechanical to evaluate:

• Structural performance under ASCE 7 load combinations, including dead, live, wind, seismic, and other applicable loads
• Load effects and structural behavior during global transportation in accordance with ISO shipping and handling requirements
• Frame modifications, reinforcement strategies, and overall stiffness characteristics
• Modal behavior, resonant frequencies, and fan-induced vibrational response
• Nonlinear behavior at critical interfaces and connection points

To support process performance and energy efficiency goals, ASR performed CFD simulations using ANSYS Fluent to:

• Establish airflow requirements needed to meet system performance targets
• Refine internal airflow paths and distribution
• Evaluate flow uniformity and pressure-drop characteristics
• Identify and mitigate bypass risks and airflow inefficiencies

These analyses were tightly integrated with mechanical design development. SolidWorks was used to produce high-fidelity 3D models and fabrication-ready documentation, enabling direct alignment between analysis, design intent, and manufacturing execution. ASR’s design and documentation efforts included:

• Modeling of all components, assemblies, and interfaces
• Development of complete engineering drawing packages for components, assemblies, and tooling
• Creation and management of fully defined Bills of Materials (BOMs) to support procurement and manufacturing
• Generation of structured model packages to support collaboration with fabrication partners

This integrated approach ensured that analytical insights directly informed design decisions while maintaining manufacturability, configurability, and traceability throughout the program.

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Safety, Maintainability, and OSHA Compliance

Worker safety, maintainability, and operational uptime were foundational design drivers throughout the program. OSHA requirements and client safety standards were integrated early and continuously into the system architecture rather than addressed as downstream constraints.

ASR worked closely with the client’s Human Factors Engineering (HFE) team to develop layouts and access strategies that supported safe operation, efficient maintenance, and reliable long-term performance. Key considerations included:

• OSHA-compliant aisle widths, headroom, and walkable surfaces
• Properly designed guardrails, fall-protection systems, and access platforms
• Equipment layouts that enabled safe, efficient servicing and minimized unnecessary exposure
• Automated or externalized solutions for frequently serviced components to reduce confined-space entry
• Electrical and plumbing routing strategies that avoided interference with walkways and eliminated trip hazards

By embedding safety and maintainability requirements directly into the mechanical and structural design, ASR helped ensure that the system could be operated and maintained efficiently while minimizing downtime and reducing operational risk.

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On-Site Engineering Support, Testing, and Validation

ASR worked directly with multiple fabrication partners throughout the program, providing continuous engineering support from early prototype development through demonstration-scale fabrication. During early phases, a subcontract fabricator constructed prototype units, with ASR supplying engineering drawings, clarifying design intent, and providing ongoing technical guidance.

When fabricated parts or assemblies deviated from drawing specifications, ASR evaluated the discrepancies in the context of the full engineered system. Leveraging a detailed understanding of load paths, interfaces, and performance requirements, ASR identified engineering paths to acceptance—often enabling the use of out-of-spec components through targeted design adjustments rather than costly rebuilds. This approach preserved system performance while preventing unnecessary scrap, reducing schedule risk, and conserving project resources.

ASR engineers were present during critical fabrication and assembly activities to ensure that engineering intent was maintained in the field. On-site support included:

• Interpreting engineering drawings and clarifying technical intent
• Resolving emergent fabrication and fit-up issues in real time
• Coordinating with certified inspectors overseeing fabrication activities
• Supporting connection sequencing, interface alignment, and tolerance management
• Verifying that fabrication practices remained consistent with analytical assumptions

In parallel with field activities, ASR conducted testing and validation work at its own facility. These efforts included:

• Fabrication of select components and assemblies for evaluation
• High-cycle fatigue testing of critical subsystems to validate durability and analytical predictions

This combination of hands-on field engineering, analytical oversight, and targeted testing ensured that the system performed as intended while maintaining schedule momentum and design integrity throughout the program.

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Documentation, Configuration Management, and Procurement Support

ASR managed the full engineering documentation and configuration control framework required to support a multi-phase development program and multiple fabrication partners. Documentation was developed to maintain traceability, support procurement and manufacturing, and ensure consistent execution across engineering, fabrication, and field installation activities.

ASR’s documentation and configuration management responsibilities included:

• Development and management of comprehensive Bills of Materials (BOMs)
• Part numbering systems and configuration control across multiple development phases
• Engineering change management to track design evolution and maintain alignment between models, drawings, and fabrication
• Coordination with suppliers and support for sourcing and procurement activities
• Preparation of complete manufacturing, fabrication, and construction drawing packages

Clear, well-controlled documentation enabled seamless communication between engineering teams, fabrication partners, and installation crews, reducing ambiguity, minimizing rework, and supporting efficient execution throughout the program lifecycle.

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Collaboration and Verification

Successful execution of the program required close coordination among ASR, the client’s internal engineering teams, multiple fabrication partners, certified weld inspectors, installation contractors, and an independent local Professional Engineering Firm.

ASR led the system design, engineering analysis, and documentation effort, serving as the primary technical authority throughout the project. An independent local PE Firm performed confirmatory structural evaluations of key load cases and methodologies, providing an additional layer of verification. This dual-level approach strengthened confidence in the engineering and ensured compliance with ASCE 7, OSHA, applicable ISO standards, and internal client requirements.

ASR’s consistent presence—both at fabrication facilities and during site installation—helped ensure that engineering intent was preserved throughout manufacturing and construction. Ongoing collaboration enabled timely resolution of technical questions, alignment across stakeholders, and smooth progression from design through fabrication and field deployment.

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Outcome

ASR’s multidisciplinary engineering leadership enabled the client to successfully advance a novel modular industrial decarbonization technology from early concept through multiple development phases and into a commercial-scale demonstration platform.

Through the integration of advanced analysis, detailed mechanical and structural design, manufacturability-focused engineering, and hands-on fabrication and installation support, ASR delivered a robust modular system that met performance, safety, and durability objectives while remaining practical to manufacture, transport, and assemble in the field.

Key outcomes of the program included:

• A modular industrial platform that met ASCE 7 environmental and gravity load requirements
• Verified structural and dynamic performance through detailed FEA and targeted high-cycle fatigue testing
• Improved airflow performance with reduced bypass and pressure losses, supporting system efficiency
• OSHA-compliant access, maintainability, and safety features integrated directly into the design
• Reliable module-to-module interfaces that supported rapid field erection and alignment
• Reduced fabrication risk and schedule impact through engineering-driven acceptance of nonconforming components
• Successful coordination across multiple fabrication partners and project phases

By serving as the primary engineering partner across design, analysis, fabrication support, and validation, ASR helped de-risk the development process and position the technology for commercial evaluation. The project demonstrates ASR’s ability to lead complex, first-of-a-kind engineering programs from concept through large-scale demonstration while maintaining technical rigor, execution efficiency, and confidentiality.