DISSERTATION

MODULAR SYSTEMS

SUBMITTED BY
SUDHARSAN.S
AC15UAR100

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 CONTENTS

CHAPTER 1: ABOUT MODULAR SYSTEMS PG.NO

1.1: INTRODUCTION 4
1.2: NEED OF THE STUDY 5
1.3: AIM OF THE STUDY 5
1.4: OBJECTIVES OF THE STUDY 6
1.5: SCOPE OF THE STUDY 6
1.6: LIMITATIONS 7

CHAPTER 2: LITERATURE STUDY

2.1: CRITERIA 7
2.2: HISTORY 8
2.3: BUILDING CONCEPTS 12
2.4: CONSTRUCTION PROCESS 14
2.5: CLIMATE 21
2.6: APPLICATIONS 22

CHAPTER 3: NEED OF MODULAR

3.1: WHY MODULAR 28
3.2: ADVANTAGE 32
3.3: DISADVANTAGE 34
3.4: MODULAR SYSYTEMS IN INDIA 36
3.5: MYTHS IN MODULAR CONSTRUCTION 38

CHAPTER 4: MATERIAL STUDY

4.1: PRODUCTION 40

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 4.2: PROCEDURE 41
4.3: ADVANTAGE 44
4.4: DISADVANTAGE 45
4.5: PROPERTIES 45

CHAPTER 5: CASE STUDIES

5.1: COMPARISON 47
CASE STUDIES BASED ON INDIAN CONTEXT
5.2: CASE STUDY-1 49
5.3: CASE STUDY-2 52
5.4: CASE STUDY-3 55
5.5: CASE STUDY-4 57
INTERNATIONAL CASE STUDIES
5.6: CASE STUDY-5 61
5.7: CASE STUDY-6 67

CHAPTER 6: CONCLUSION 70

BIBLIOGRAPHY 83

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MODULAR SYSTEMS

1.1: INTRODUCTION
Currently, the global economy is in severe slowdown mode amidst deepening
credit crunch and upsetting developmental targets of economies across the world.
In the prevailing scenario, infrastructure remains a top priority for addressing
developmental gaps as it is considered omnipotent with potentials of lifting
economies out of the financial turmoil.
The governments around the world are pumping money to generate demands for
goods and services by creating jobs through higher spending into physical and
social infrastructure. Likewise, the Indian government on its part is not lagging
behind on this score and has taken concrete steps to revive the sector to regain
its past glory.
According to a recent Indian government committee constituted to estimate
poverty, nearly 38% of India’s population (380 million) is poor. This report is
based on new methodology and the figure is 10% higher than the present poverty
estimate of 28.5%.
Since 1972 poverty has been defined on basis of the money required to buy food
worth 2100 calories in urban areas and 2400 calories in rural areas. In June this
year a government committee headed by NC Saxena committee estimated 50%
Indians were poor as against Planning Commission’s 2006 figure of 28.5%.
Poverty is one of the main problems which have attracted attention of sociologists
and economists. It indicates a condition in which a person fails to maintain a
living standard adequate for his physical and mental efficiency. It is a situation
people want to escape.
For the U.S., modern prefabrication/Modularization is said to have started in the
early 1900s. Housing started being developed using prescheduled procedures
based on modern mass production. Aladdin and Sears Roebuck Company sold
prefabricated houses that were delivered to customers as mail-order homes.
Prefabrication/modularization was increasingly used during World War II due
to the need for mass accommodation for military personnel. The United States
used Quonset huts as military buildings. These all purpose, lightweight
buildings could be shipped anywhere and assembled without skilled labour.

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1.2: AIM OF THE STUDY:

To Help the people to build their own home faster and economical and adaptive
to climate, so the number of homeless in our country will reduce through
understanding the importance of the modular construction in current scenario.
Since it is a highly efficient and sustainable method of construction in terms of
the time taken to finish a building and energy consumed in the process.

1.3: NEED OF THE STUDY

Modular building systems in India are slowly getting a hand on with many
builders and construction companies now adopting the methodology in India.
As far as the world is concerned, this system has already been accepted and has
gained a lot of popularity.

Currently, prefabricated modular buildings comprise of merely 1% of India’s

total $100 billion real estate market. However, given the extended fall in the
residential real estate, with inventories at an all-time high, developers believe
that its popularity will rise. The reason behind this is the much faster completion
of projects due to prefabrication which further decreases the overall costs.

According to the experts, if it takes a year to complete a housing project using

conventional methods, it takes only 5 to 6 months using modular construction,
with the scale being the same.

In India, the government currently aims to provide housing for all by 2022,
which requires constructing 30 million low- cost houses along with building 98
smart cities. Both these proposals are expected to provide a boost to the modular
system.

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From International Journal of Research in Engineering, Science and Management
Volume-1, Issue-10, October-2018 www.ijresm.com

1.4: OBJECTIVES OF THE STUDY

 To study about the Origin and Evolution of Modular Architecture.

 Comparative study between Modular Construction and

Normal Construction.

 To Understand the Benefits of Modular Construction.

 To Study about the Construction process in Modular

Construction.

 To study about the Materials used in Modular Construction.

 To Analyse about various Case Studies.

 To Study about the applications of Modular Construction.

1.5: SCOPE OF THE STUDY

 The study is based on the importance of the modular
construction in current scenario.

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  Through this study we can acquire a basic ideology about the
need,benefits,materials,applications,examples of the modular
construction.
 By analysing the following procedures, it can help the homeless
to build their own homes faster and economical.

1.6: LIMITATIONS
 This is limited to study part and will not end up in design.
 No live case studies have been included.

2.1: CRITERIA
In India, the technology adopted for housing components should be of the order
that, the production and erection technology be adjusted to suit the level of
skills and handling facilities available under metropolitan, urban and rural
conditions. In other words, the structural systems and components selected
should ensure minimum material utilization with maximum structural
advantage. However, the component and systems so designed are to be
manufactured and erected by manual means in villages, semi mechanical
techniques in towns and more or less fully mechanical operations in the
metropolitan cities.
In urban areas, the concentration of construction activity does not justify
prefabrication. The answer is hybrid construction. In residential buildings,
balcony projections can be provided along the partially precast joists, designed
with an overhang carrying super imposed loads for balcony as specified in IS:
875-1964, in addition to the self-load and the load due to balcony railings. The
main reinforcement of the overhang provided at the top in the in-situ concrete
attains 14 sufficient strength. The savings achieved in practical implementations
compared with conventional RCC slab is about 25%.

Mass housing targets can be achieved by replacing the conventional methods of

planning and executing building operation based on special and individual
needs and accepting Common denominator based on surveys, population needs

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and rational use of materials and resources. No single approach and solution is
available which can satisfy the community at large. However, what is ideal and
desirable is to have a system which can provide choice for people and also
appropriate techniques to meet the situation. The essence lies in the system
approach in building methodology and not necessarily particular construction
type or design. Adoption of any alternative technology on large scale needs a
guaranteed market to function and this cannot be established unless the product
is effective and economical. Partial prefabrication is an approach towards the
above operation under controlled conditions.

The methodology for low cost housing has to be of intermediate type. Less
sophisticated involving less capital investment.

From a DISSERTATION REPORT- PREFABRICATION OF

BUILDING

2.2: HISTORY OF MODULAR ARCHITECTURE

Prefabrication in the construction industry is evolutionary, not revolutionary,
based on successful and unsuccessful experiences. The earliest prefabricated
cases was recorded in 1624, when houses were prepared in England and sent to
the fishing village of Cape Ann, in what is now a city in Massachusetts. In 1790,
simple timber-framed shelters were shipped from England to Australian
settlements in New SouthWales as hospitals, storehouses and cottages. Years
later, a similar system was erected in Freetown, Sierra Leone and Eastern Cape
Province of South Africa; these structures were simple and shed-like, with timber
frames, clad either with weatherboarding or board-and-batten siding. Although
these structures were not extensively prefabricated, they represented a significant
reduction in labour and time compared to on-site methods then. In 1830, the
Manning Portable Colonial Cottage for emigrants, an improvement of the earlier
system, was developed. The house was an expert system of prefabricated timber
frame and infill components, designed to be mobile and easily shipped.
An early example of prefabrication/modularization use can be found in Britain’s
great exhibition of 1851, featuring a building called the crystal Palace. Designed
in less than two weeks, the building used light and cheap materials: iron, wood
and glass. The construction period lasted only a few months and consisted of

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assembling the prefabricated components. After the exhibition, the palace was
taken apart, piece by piece, and moved to another location.
From 1908-1940, Sears Roebuck popularized the mail-order house, selling over
100,000 units .Much of the company’s success can be attributed to the variety
of housing options and financing offered, which, paradoxically, also led to their
failure. Sears suffered a catastrophic loss in the 1930s during the great
depression from defaulting loan repayments.But Sears wasn’t the only suffering
company—all of America was in trouble, with rampant homelessness and
poverty.
Very few customers were capable of paying the premiums of custom-designed
new residences. Thus, it was at this time that many architects, engineers, and
real estate developers tried their hands at modular housing, promising an
affordable price, good design, and high quality through manufacturing. This
shift was by and large attributed to a new social need: quick, cheap housing for
a broad audience. Additionally, with Henry Ford’s “Flow” assembly line
method of manufacturing that made the Model-T successful, a precedent was
created to showcase the benefits of streamlined manufacturing.
. Walter Gropius and Konrad Wachsmann’s “Packaged House” proposal was a
visionary design, but due to limited factory and business experience, it took
them five years to start production after finishing the original designs (Smith,
2011). By this time, the government had pulled funding and the product died
before it ever could start. Le Corbusier endeavoured to create a modular
housing concept for the masses as well, but like his predecessors, saw no
commercial success in the enterprise. His most-known prototype, the “Citrohan
House” was meant to be a “machine for living”, an affordable, quality house
design for the masses. Though well-intentioned, Le Corbusier never actually
built a single home from prefabricated building methods—his theories and
designs were all (expensive) talk. Even his prototypes proved far too expensive
for any hope of mass production. American architect Frank Lloyd Wright also
shared the dream of modular, and in 1932 he spoke about the Usonian
“assembled house”, a home made up of standard units and spatial building
blocks that would define rooms. Wright designed and built 100 prefabricated
dwelling units between 1936-1938. But without the discipline to quit designing
and start building, his projects, too, proved far too customized and expensive for
a broad audience (Panjehpour, Abdullah, & Ali, 2013). The 100 units were

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homes to wealthy clients, uniquely designed and finely crafted. While social
factors encouraged.

Modern Beginnings:
Prefabrication/modularization was increasingly used during World War II due
to the need for mass accommodation for military personnel. The United States
used Quonset huts as military buildings. These all-purpose, lightweight
buildings could be shipped anywhere and assembled without skilled labour.

Following World War II, both Japan and Europe had massive rebuilding needs
and turned to prefabrication and off-site construction to fill the demand. It is
because of this early adoption and acceptance that European and Japanese
companies are still considered some of the most advanced in terms of modular
construction techniques.

In the U.S, commercial applications of modular construction like hotels, offices,

hospitals and schools began to emerge throughout the ‘70s, ‘80s, ‘90s, and into
the 2000s as demand exceeded the supply of existing structures.

Recent Evolution:
Recent innovations over the past few decades have allowed the prefabrication
and modular construction industry to make significant advances in developing
processes and materials to build and deliver more sophisticated and complex
facility types.

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An example of this is the Hilton Palacio del Rio hotel in San Antonio. Built by
zachry Construction Corporation for the Texas World’s exposition of 1968, the
500-room deluxe hotel was designed, completed and occupied in an
unprecedented period of 202 working days. All the rooms were placed by crane
in 46 days. Still in use, the hotel is believed to be the tallest modularly
constructed facility in the United States. The project is a testament to the
durability of modular construction.

A current example of just how well accepted modular units have become is their
use in the construction of the new cruise liner Queen Mary 2, which is one of
the largest and most expensive cruise liners in the world. The ship owners chose
to use modular passenger cabins to ensure all cabins were built to the higher
standards that are available in a factory environment; even their VIP suites
utilized the modular building process.

Prefabrication/modularization is also becoming more widely recognized as a

resource-efficient and greener construction process. A clear example of this is
the use of modularization at the fort Sam Military barracks being built in San
Antonio, Texas. The buildings are on track to meet leed silver certification due
to reduced material waste and pollution and increased use of recycled materials.

Prefabrication/modularization has not had a steady increase in use over time;

instead, it has fluctuated based on the level of drastic need during war and
economic booms. However, technological advancements over the past 20 years
have increased what prefabrication/modularization can achieve in the
construction industry.

BIM, quality modern materials and sophisticated manufacturing facilities now

offer significant productivity gains on projects not possible before. Recently a
committee of experts appointed by the national research council identified
“greater use of prefabrication/modularization” as a key breakthrough

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opportunity that could significantly improve the efficiency and competitiveness
of the U.S. construction industry going forward.
With a construction market facing acute shortages in onsite skilled labour and
also where players are trying to be leaner, many believe the time is right now,
more than ever, for widespread adoption of offsite
prefabrication/modularization solutions on a major scale in the construction
industry.
From Prefabrication and Modularization: Increasing Productivity in the Construction
Industry (SMART MARKET REPORT 2011)

2.3: BUILDING CONCEPTS:

Degree of prefabrication refers to the size and complexity of prefabricated
components or configuration of the final product.Decreasing the size of
prefabricated components increases the degree of on-site construction labor and
vice versa. Prefabrication can be categorized into:

Components allow for the greatest degree of customization and flexibility within
the design and execution phases, but they become numerous on construction sites
and laborious to account for. Componentized systems also require more joints
and connections, and require more careful alignments and infiltration checks.
They are single fabricated elements such as stairs, gable ends, roof trusses.

Panels are 2D planer elements used to build structural walls, floors, and roofs,
alongside columns. Panels enhance the speed and convenience of delivery of
walls to a site. Included in this category are structural insulated panels (SIPS),
metal frame panels, and curtain walls. A typical example of panel system is the
30-story hotel near Dongting Lake in the Hunan Province of China, that was built
in 15 days.

Modules are made in complete 3D boxlike (volumetric) sections, multi section

units, and stack-on units . Unlike in panelized or component levels of
prefabrication, in modular construction most of the interior and exterior finishes
are put into place in the factory. They are up to 80–95 percent complete when
they leave the factory . Modules are designed for ease of assembly. The size of a
module is a factor of module location in the building, manufacturing constraints,
and transportation limitations. It is worth mentioning that a category of prefab

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called a mobile home uses the modular concept, but generally employs lighter
construction and with a metal chassis as part of the floor system; thus, as the name
implies, it can be moved around quite often and easily. The air-tightness and
thermal performance of modular buildings can be much higher than previous
prefab levels due to tighter tolerances of joints . A typical modular building is the
Mini Sky City, a 57-story apartment skyscraper constructed in 19 working days.

Hybrids usually combine panel and modular prefabrication systems to construct

a whole building. An example is the Meridian First Light House, The house is a
net zero energy dwelling designed to maximize energy drawn from the natural
climate using a combination of passive and active energy strategies. The house is
made up of six independent prefabricated modules and wooden decking
surrounds the house linking the interior to the surrounding environment.

Whole buildings are standardized building units prefabricated to the highest

degree of finish as compared to components, panels, modules, and hybrids.
More work is done under controlled factory environment (with larger building
structures), providing the opportunity for the manufacturer to take.
control of quality and speed of the final product. However, sometimes their bulk
size and weight
presents difficulties in transportation from the factory to the building site.

2.4: CONSTRUCTION PROCESS

The main feature of the modular construction is the identical or standardised
three-dimensional or room size volumetric units. The three-dimensional or room
size volumetric units are mass produced in a controlled factory or
manufacturing facility that generates less waste, and high-quality modules.
Manufacturing facilities or factories have stringent quality assessment/ quality
control (QA/QC) programs with the independent inspection and testing
protocols that promote a superior quality of construction.The difference
between the construction schedule of Modular and Site built construction are
shown below.

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To discuss about the construction/Manufacturing process a case study has been
taken below.

CASE STUDY OF MODULAR CONSTRUCTION INTHE

MALAYSIAN CONSTRUCTION INDUSTRY

The case study is the construction of 72 lecturer office units using an innovative
and revolutionary construction technique known as the Modularcraft
system.The system is jointly developed by Portland Group of Companies and
University Malaysia Pahang (UMP). Thecase study is also part of University
Malaysia Pahang’s new Green Policy of using recycled industrial commodities
and adapting to sustainable building construction technologies, in line with
global efforts toward protection of the environment. The Modularcraft system
comprises the use of shipping containers as the basic building module combined
with Primer’X’- a thermal insulation coating or G-Bricks that used in masonry
works. The essential products in the Modularcraft system package are made of
recycled material and are the results of extensive research carried out by
UniversityMalaysia Pahang (UMP). The case study that involves the important
use of Primer-X on shipping containers demonstrates the habitability of
shipping containers despite our equatorial climate. The creations of custom built
buildings are mobile, sustainable, environmentally friendly and greater
efficiency by the drastic reduction of construction time when compared to

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conventional construction method. The Modularcraft system also significantly
reduces the use of reinforced concrete or other labour-intensive construction
methods and minimiseon-site disruption.

Design development

There are five design approaches for the case

study. There are:
 Passive energy design (Orientation) - The orientation of the building is
designed to adopt passive lighting hence reduce the energy consumption of the
building.
 Passive energy design (Cross Natural Ventilation) -The design also has
considered natural air ventilation to lessen the use of the active cooling system.
 Utilize site profile - The design of the pilot project also considers the
surrounding site profile. The building has three levels consist of ground level,
first level, and second level. The entrance to the building is
the bridge connecting the first level and elevated counter near the existing road.
 Circulation -The entrance to the building is through the bridge to the lobby.
There are two staircases located the east and west of the building.
 Using shipping containers

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Manufacturing process

The manufacturing process of the shipping container in a factory offers a

controlled and better production environment. It reduces wastage, fast
construction and reduces defect.

Cleaning, cutting and primer coating works.

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 Insulation, electrical and piping installation.

‘
Finishing and fittings installation Transportation of the containers to
site

CONSTRUCTION METHOD:

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Earthwork and foundation preparation Site installation of the shipping
Containers on site

Site installation of staircases, floor joists and other structures between

stack shipping containers.

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 Site installation of floorboards and railings

Site installation of roof structure and coverings.

Mechanical and Electrical (M&E) and fittings installation

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SUMMARY:

Based on the results of the case study, the easiest way to adopt modular
construction is to use shipping
container. Shipping container suits the main feature of modular construction
which is the three-dimensional and room unit feature. The shipping container is
found to be the most suitable solution or material to be used for modular
construction. There is a misconception amongst the Malaysians that the shipping
container is modular construction. The shipping container is mainly a material or
solution to modular construction because it fulfills the main criteria of modular
construction that is a three dimensional unit with value added factors on strength
and durability.

The three-dimensional units or room units used for modular construction can be
produced using timbers, galvanised lightweight steel, composite materials or any
materials that can withstand the rigor of transportation and structurally strong.

Nobody knows what the shipping containers carried previously. The goods
transported in the containers might be something hazardous and dangerous to
any human and living creature. Malaysia is lack of expertise or the technology

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and knowledge to produce a three-dimensional or modular unit. However,
Malaysia can produce cabin that suits the modular construction main feature
that is the three-dimensional unit. The cabin may not have the strength and
durability of the used containers that have been used in modular construction.

From https://www.researchgate.net/publication/305550264 and Towards the

adoption of modular construction and prefabrication in the construction
environment: A case study in Malaysia.

2.5: CLIMATE

One of the most significant influences on vernacular architecture is the

macroclimate of the area in which the building is constructed. Buildings
invariably perform well when built with regard to the local climate rather than a
technological trend that may not be as appropriate. The local environment and
the construction materials that market can produce govern many aspects of
prefab development. Vernacular, by definition, is sustainable, and will not
exhaust local resources. For a country that has followed vernacular practices
successfully for generations, like India, moving to a concept like prefab may not
prove to be climatically as suitable. For example, in many hot regions of India,
masonry walls that are heavy and dense conduct heat slowly. This simple
process, called thermal lag, reduces peak cooling loads in summer and peak
heating loads in winter. The result is a more comfortable home all year long that
produces significant savings in energy. However, in India there are 6 distinct
climate zones ranging from cold and dry to warm and wet. Therefore, India’s
architecture is varied in its use of materials, style of construction and cultural
difference that cannot be generalized. Prefabrication in a technology transfer
mode struggles take into consideration these vernacular differences.

Modular construction has often been regarded as an offspring of the modernist

train of thought. However, if we look into the basic concept of modularity, it
has pre-existed humanity itself. The origins of prefabricated building involve
neither factory nor mass-produced materials (Marquit, 2013). It is not
specifically a factory and manufacturing unit based concept. The natural world
has always shown examples in its dwelling units. A bird’s nest or a spider’s web
cans conceptually be regarded as pre-fabricated dwelling units, as there is a
tendency to use materials which have undergone fairly elaborate manufacturing
processes to make them useable, like sticks, twigs and silk.

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Panelized construction is one of the commonly used forms or pre-fabrication. It
is partnership between in-situ construction and industrial manufacturing. The
structural framework is erected on the site, (RCC or wood/bamboo) and pre-cast
wall panels are fitted in the framework. These panels are already finished and
equipped with electrical and water lines. A hybrid prefabricated/site-built strategy
for construction has the potential to integrate sustainable design principles and
advanced construction strategies with traditional local construction methods and
available resources. (Arriaga, 2008)
Pre-fab architecture is slowly shedding its reputation for having low structural
integrity and architectural ingenuity, and its capabilities as a quick and efficient
construction technique are being highlighted. Over the past decade, the
sophistication in the design and construction process of modular buildings has
greatly increased, with pioneering work of assembling large modules to create
even larger building systems with the use of overhead cranes of capacity of over
100 tons.
From a Dissertation Report – MODULAR/PREFAB ARCHITECTURE
IN RURAL EDUCATION INFRASTRUCTURE.

2.6: APPLICATIONS:

Lean Construction

The strong increases in productivity offered by using prefabrication and

modularization fit squarely into the lean building model. The difficult
economic conditions in the construction industry have increased the appeal of
lean methods and practices.

BIM

The increasing use of BIM also contributes to the potential for increased use of
prefabrication and modularization. In a recent study about the use of BIM on
green projects, McGraw-Hill Construction (MHC ) found that the use of BIM
model-driven prefabrication on more than one quarter of their projects is expected
to increase from 37% to 73% among practitioners who use BIM for green work.
Even those who are currently not using green BIM expect an increase from 22%
to 57%. BIM helps enable prefabrication of tightly integrated MEP systems,

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allowing designers to maximize space for other uses in high-tech buildings like
hospitals.

Green Building

Green building has grown into a substantial part of the overall construction
market. MHC ’s Green Outlook 2011 estimates that non-residential green
building will comprise 28%–35% of the total market by the end of 2010. This
dramatic increase in market share, from less than 5% in 2005, reflects the fact
that green building sustained steady growth throughout the recession, even as the
overall construction market shrunk by nearly one-third.MHC also predicts that
the growth of the market share for green will not abate as the construction industry
recovers from the recession. By 2015, MHCprojects that 40%–48% of non-
residential construction will be green. As the results of this study demonstrate,
this has strong implications for rising interest in prefabrication and
modularization, which helps eliminate waste onsite and conserve resources.

FURTHER DEVELOPMENT

Computer integrated construction and intelligent building are the recent

innovations in building technologies. There are some studies about use of robots
in manufacturing of building components . Intelligent or smart building has been
defined in different ways.However, it should be precisely defined as the building
which adopts its condition according to the surrounding changes . The idea for
this prefab home emerged from sundial by a group of designers from London in
early 2011. This prefab home has the ability to be adjusted according to
temperature changes by transforming into different shapes. It is situated on
curved shaped rails which can pivot. The parts of house can be moved around and
set up indifferent positions . It is designed and developed as an ecologically
sensitive house in Sweden and Lapland. However, researchers are trying to
change this single designed prefab home to the mass production.

Currently, prefabrication /modularization is being used on many types of building

projects demonstrating its applicability across non-residential construction. the
five sectors using prefabrication/modularization in over 40% of projects are:

 HEALTHCARE (49%)
 HIGHER EDUCATION (42%)

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  MANUFACTURING (42%)
 LOW RISE OFFICE (40%)
 PUBLIC (40%)

These sectors also present strong opportunities in the construction market, which
bodes well for a vigorous prefabrication/modularization future market.

Healthcare:

Healthcare is a sector that is well-suited for prefabrication/modularization

techniques. The interior layout of hospital rooms allows for efficient use of
modularization, and it is a sector highly responsive to strategies that shorten
schedule—a particular benefit prefabrication brings to a project.

According to McGraw-Hill construction’s economic forecast, the market activity

for healthcare construction is expected to increase in 2011 and 2012 to become
more than a $28 billion market opportunity in 2012.

Dormitory and Education Projects:

Like healthcare buildings, dormitories and school projects have features that are
well-suited to prefabrication/ modularization. Dorms and classrooms allow for
use of modular room design, and these projects also benefit from faster
construction schedules.

As the largest construction sector by value (over $43 billion in 2011), education
presents a significant opportunity for prefabrication/modularization—both
currently and in the future.

Variation by Player:

Contractors: Across the board, contractors report heavier current involvement

in prefabrication/ modularization, predominantly in healthcare (61%),
dormitory/education (50%) and public buildings (46%).

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Engineers: Engineers are using prefabrication/modularization most often in
manufacturing buildings (46%), followed by commercial warehouses (43%).
Engagement in the other sectors is 30% or lower.

Architects: their heaviest use is in low-rise office (43%) and healthcare

facilities (36%), with less than a third reporting use in other sectors.

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Users of Prefabrication/Modularization:

Today, there is broad use of prefabrication/modularization on building projects—

85% of respondents are using these strategies to design and construct projects at
some level. While this level of use is encouragingly high, the activities that are
included under the broad definition of prefabrication/modularization can range
widely from entire modular rooms to floor planks to racks of mechanical
ductwork. The impact on reducing site materials, labour demands, project budget
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and schedule and waste can vary significantly depending on how
prefabrication/modularization is used on a project.

Future Use of Prefabrication/ Modularization:

By 2013, 98% of industry players (current users and nonusers) will be users of
prefabrication/modularization.

Current Users: Virtually all current users will still be using

prefabrication/modularization in 2013.

Current Non-Users: 87% of current non-users will become users over the next
two years, resulting in a decrease in the overall number of non-users from 15%
of the industry in 2009 to an insignificant 2% in 2013.

Various factors are impacting this increased use, including growing concerns
about construction productivity, advancements in prefabrication and the quality
of prefabricated materials, and the wider adoption of BIM, which helps enable
more intensive, productive use of prefabrication.

Level of Use:
The level of use of prefabrication/modularization is also expected to increase. The
number of players using prefabrication/modularization on over 50% of projects
is expected to increase from 37% in 2009 to 45% in 2013.
From Prefabrication and Modularization: Increasing Productivity in the
Construction Industry Smart Market Report.

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3.1: WHY MODULAR

Architectural design involves a complex process of multiple creative stages. An

overview of these actions will set the scenario to host the next concepts that will
be further developed. Architecture as an interactive and subjective discipline
implicates a mix of ideals, actors and elements tightly
related, contributing together to the configuration of architectural product.

Prefabrication in US construction has steadily risen over the last two decades,
leading to an average use of 35% in new construction in 2016 (Parsons, 2017).
The percentage of fully modular new construction, however, is far less
significant, limited to around 3% of single family houses and around 1% of multi-
family residences between 2000 and 2014 (Kamali & Hewage, 2016). In Texas,
there has been a considerable swell in the number of modular units produced in
the last five years, though descending in the past two. The total number of
modular units in 2016 in Texas was 4,387, of which 708 units were housing
(TDLR, 2017). This, in comparison to the 165,853 total units of housing
permitted in 2016, leads to a figure of roughly .4% of all new housing
construction in Texas (Census, 2016). These numbers paint a striking picture of
just how underused modular is in Texas housing. Modular projects hold a far
greater market percentage in other regions, however, showing that Texas is a
relatively underserved market.

Worldwide adoption of modular construction has shown far greater growth in

other locations across the world. Sweden, by far the world’s leader in its use, had
as much as 85% of their new housing stock in 2016 constructed by prefabricated
methods. Japan, noted as the second greatest adopter by percentage of total
construction, had nearly 15% prefabricated homes in 2016 (Japanese Statistics
Bureau, 2017). While there are numerous explanations for why modular
construction methods are less likely to be implemented in Texas compared to
other regions and nations, climate is one of the most probable.
.
BUILDING SCHEDULE (TIME)

Modular prefabricated architecture allows the freedom of overlapping module

construction processes with on-site work, as a result compressing the building
schedule. This is clearly a quicker method to construct a building. While the
modules are being assembled on site, new modules can constantly be created in

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the factory. These modules can then be transported directly to the site precisely
when they are required.

A McGraw-Hill study found that in 66% of modular and prefabricated

construction projects the schedule was positively affected with time savings of 4
weeks or more in 35% of projects. For the 34% of projects not reporting time
savings, 6% said that prefabrication/modularization increased the project’s
duration while the other 28% noted that prefabrication/modularization made no
difference to the project’s schedule. The schedule was measured from the
beginning of design through project completion. Time savings are achieved
through concurrent factory and on-site work, fewer weather delays, and less on-
site material staging.

The production rate of modules, and thus of a prefabricated building, depends

on various parameters. The time taken for completion depends on the size of the
manufacturing unit, the complexity of the module, the degree to which modules
in the buildings are alike, the type of building and the extent to which
completion of module is required before it is transported to site.
The reduced time for construction also has major implications on energy
consumption of a building. As discussed before, a building consumes energy in
four phases, Design phase, Construction Phase, Operation phase and Demolition
phase. Modular architecture has a capability to majorly reduce the energy
consumption of a building during the construction phase as well as design
phase, solely by virtue of its design and construction process. Quicker
construction directly relates to reduced energy consumption while erecting the
building. It leads to reduced time expenditure on site, hence reduced fuel and
energy consumption by machinery and vehicles.

COST
Working in a regulated factory environment is quicker than working on the site.
This is majorly because of controlled climate, no weather interruptions,
ergonomic factory organization and optimized repetition, along with a better
possibility of mechanical help. The base wages of workers is lower in factory
based construction as compared to on-site construction. This is due to
manageable commuting distances and scheduling consistencies. A worker in a
factory can manage accommodation near the factory, whereas a worker working
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on a site has to move from one site to another, which adds to travelling expenses
and hence the base wages. Scheduling consistencies mean that the work finishes
as per schedule, thus avoiding extra payment to workers due to extension of
working hours.
Because of speed of construction and mechanical aids, the crew sizes in a
factory are smaller than they would be on site. This directly influences the
overall labour cost of the building.
The material cost in prefabricated construction can also be significantly
reduced. Assuming there is enough space in a factory to store materials, the
manufacturer can buy materials in bulk at the start of the contract, thus reducing
the potential of price escalations and repeated delivery charges.
However, transportation of finished modules adds onto the overall cost of the
building. Shipping costs have to be weighed against the savings in labour cost
and material cost to analyse the feasibility of adopting modular construction.
The location of a factory also plays a major role in cutting down the cost of
construction.

QUALITY
Modular projects report lower errors and defects, higher worker productivity
and safety, improved material quality, building performance, and improved
sustainability (Rahman, 2013).The quality of the finished product is
significantly better than on-site construction.

Because components of modular units are constructed in a factory setting, the

overall process can result in a higher quality product. In the factory, workers
can mock up an entire module and work out many of the design defects before
the rest of production begins. This process can reduce the amount of unseen
defects associated with typical on-site stick built construction.

The factory setting also offers improved physical access to workstations, as well
as a faster flow of work. Improved ergonomics, and working on a ground level
rather than multiple stories above the ground, helps keep workers safe and
focused. Additionally, tools and materials are centrally located. Rather than

30
lugging equipment from floor to floor, factory workers are able to move from
module to module, or even have the module come to them. This helps create a
production flow, and enables the overall schedule decrease.

Due to higher degree of workmanship and installation quality, air infiltration

can be expected to be significantly low in modular buildings. The thermal
insulation of the building is also enhanced because of easy and efficient
integration of insulators in the module. The enhanced building performance is
important when considering the sustainable aspect of modular construction.

The idea of recyclability and reusability are inherent with modular architecture.
The assembly line method of construction allows predictability and consistency
in parts and materials, which significantly reduced building waste in modular
construction. Modularity increases the ease associated with the disassembling of
parts required in order to recycle building materials after the building is no
longer used.

“Though modularity has been a longstanding part of construction, its adoption is

still hampered by an association with poor quality components and design
limitations.”

3.2: ADVANTAGES
GENERAL BENEFITS:
Speed up project schedule, whereby modular buildings can occur simultaneously
with the site and foundation work; modular construction projects can be
completed 30% to 50% sooner than traditional construction. 60 - 90% of the
construction is completed inside a factory, which mitigates the risk of weather
delays.

Three-dimensional or modular units are built with quality materials and using
factory QA/QC management and control. Modular buildings are constructed to
meet the same building standards as site conventional constructed structures.
Modular buildings are also built with the same architect-specified materials
used in conventionally constructed buildings such as wood, concrete, and steel.

31
Ability to service remote locations: It is hard to build a house in Hill area using
conventional construction method due to problems with transporting materials,
difficulty due to the terrain if surrounding the area and other factors. A house
built using modular construction in a hillside is easily built since the house
building or structure complete with finishes is already completed in the factory.
The only assembly of the house’s modular units is required and the construction
of the foundation.

Modular buildings are movable and flexible. Since the modular building is made
up of assembled three dimensional units, the modular building can be easily
moved by removing the joints and connections.

Eases renovation and refurbishment work. The required and selected three-
dimensional or modular units can be easily added to the existing modular building
or conventionally constructed building for renovation work. The same goes for
the refurbishment work, whereby the required refurbished modular unit can be
moved to another location for refurbishment work or replace by a new modular
unit.

Safer Construction. The indoor construction environment (factory or

manufacturing facility) reduces the risks of accidents and related liabilities for
workers.

ECONOMICAL:
For modular construction to be cost efficient and economical, the three-
dimensional units need to be mass produced identically with the same design
and materials in a factory.

Modular construction saves on commissioning, defect, and low repair costs. It

can be achieved through high-quality materials and using factory QA/QC
management and control. Defects usually occur for traditional construction
method due to lack of workmanship and low-quality materials.

Saving through wastage reduction because modular units are produced in a

factory with controlled condition and environment.

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PROMOTES SUSTAINABILITY:

Modular construction stands up well to the characterisation of sustainability.

Modular construction improves the sustainability of the construction process and
the performance of the completed modular buildings.

Less site disturbance from workers, suppliers, and equipment since the three-
dimensional or modular unit are produced at the plant. Also, the bulk of transport
mostly materials is moved to the factory.

Modular buildings can be dismantled and relocate to a new location or refurbish

for new use. Thus, modular buildings reduce the demand for raw materials and
minimizing the energy to create new building.

Modular construction produces less wastage by recycling materials, controlling

inventory and protecting construction materials since three dimensional, or
modular units are produced in the Factory.

Improved air quality: the three-dimensional or modular unit is completed in a

plant or factory using dry resources. Therefore, the potential of high levels
dampness trapped in the new construction is eliminated.

Modular construction improved safety on the site and factory, and fewer
accidents on the site and factory. The three-dimensional or modular units can be
installed with pre-attached barriers or protective cages as part of the lifting
system.

3.3: DISADVANTAGES

Modular architecture can be considered as the ‘oldest new idea in architecture’.

Every now and then, modular architecture is advertised as the next big thing,
even though it has been there for over 25 years.

Design and construction of modular buildings, however, require high levels of

collaboration among project parties, especially architect, structural engineer and
manufacturer, in the early design process to account for major constraints in the
design with respect to transportation of modules, installation logistics, permits
and inspection schedules.

33
More specifically, weight and size of the modules to be transported and installed,
and the structural capability of the final product need to be carefully considered
in the design of modular buildings. Pre-fabricated construction is subjected not
only to the local building codes of the area, but also have to deal with and satisfy
the local transportation codes, in relation to transportation through trucks. The
weight and size of each unit has to follow the regulations setup by the transport
authorities, and needs to be below the maximum permissible load as per the
norms.

The perception of the end user is of great importance for the growth, development
and adoption of modular architecture as a commonly used practice for building
construction. However, the users are still sceptical towards using modular
architecture as a construction technique, especially in India. Even though pre-
fabricated construction is considered as a first choice practice for construction of
buildings like industries, schools, hotels, dormitories, prisons etc., it still has to
gain acceptance in other building typologies like residential construction.

One of the major reasons why modular construction has failed to gain popularity
in developing nations, like India, is that it requires intensive infrastructural
investment to establish factories and warehouses where such large scale
constructions can efficiently happen, before the design and construction process
even starts. Though it can be treated as a one-time initial investment, pre-planning
and large amounts of funding is required. The involvement and co-operation of
government in this process of modular construction is also very important. A
large number of permits have to be taken to establish such factories and
warehouses. Inspections have to be passed, which takes up a lot of time before
these manufacturing units can be set up.

These manufacturing units also require skilled labour which specializes in factory
based construction and in specific types of jobs required during construction.
Finding such labour in the countries with a large unskilled and unemployed
population is also a major task at hand. The claim that pre-fabricated construction
techniques produces jobs is not particularly true for all members of the
population, as a high level of specialization and training is required.

34
Even if the issue of finding skilled labour is resolved, the issue of co-ordination
between contractors still exists. Most contractors in India specialize in on-site, in-
situ construction. These contractors have much more on-site expertise and hence
lower costs in doing the site works than the modular manufacturers, hence the
modular manufacturers do not generally perform site work. Small to mid-size
general contractors seem unwilling to take the risk of new technology and
construction systems such as modular prefab unless there is significant proven
benefits and demand for the modular construction type – a ‘wait and see’
approach (Rahman, 2013). It is observed that large scale developers with huge
financial backing support modular manufacturing.

This makes it easy to use pre-fabrication technology in large scale housing

projects etc., as these developers are the financers and owners of the projects and
majorly influence decisions. However, small scale contractors still show aversion
to use new techniques and technologies, because they see large amounts of risks
involved.

Very often, quicker and cheaper construction is perceived to be lacking in quality.

Also, due to design constraints, factory based modular construction tends to lose
its ingenuity in design. It fails to provide a unique identity to a building which the
user can relate to. This is due to limitations on sizes and shapes of modules.
A few disadvantages of prefab home which have not been paid attentions to
should be given emphasis among designers. There has always been stereotype
about factory-built home due to its lower cost and tendency for depreciation
compared to site-built home.

Moreover, manufactured homes cannot be refinanced if only one segment

Cannot be placed on a permanent foundation. The major issue about
disadvantages of prefab homes is safety factor. The history has shown that mobile
home, manufactured home, and home trailer could be lethal place during tornado.

35
3.4: MODULAR SYSYTEMS IN INDIA:
India is yet to be hit the tidal wave, which is pre-fabricated architecture. The
construction industry is yet to get out of the inertia of traditional architecture.
However, modularity is not a new concept for India. There are distinct traces of
modularity which being showcased in the vernacular architecture of almost all
parts of the country.
The traditional architecture of the north-eastern states of India is essentially
based on natural, renewable materials like bamboo, mud, grass, straw, cane
leaves etc. They usually build bamboo frames for the basic structure of the
house and later add bamboo or straw weaved inlays as partition. These houses
are constructed over bamboo posts and bamboo diagonal bracings are tied to
form the stilt areas. The structure above is formed by horizontal members tied
across the bamboo posts with jute ropes and using dowel and Tenon joints. The
stilt height is typically 1.50 to 2.00 meters from the ground level. The space
below the stilt is often used to store a canoe for emergency usage during floods
.The stilted houses are typically designed to keep out the effects of heavy
monsoon and flash floods.

Conceptually, this method of construction can be regarded as modular, namely

panelized, because the bamboo weaved inlays are added as prefabricated
wasections to the pre-existing bamboo structural frame. These inlays are often
covered with mud plaster, mainly for insulation and to prevent infiltration.

36
Such techniques can be observed in various other corners of the country.
Exploiting these ingenious methods of construction through organized and
regulated pre-fabrication can create a unique type of modular architecture which
is innovative, local and also very sustainable, both in qualitative and quantitative
measures. Developing these means of building construction can help grow past
the obstacle of extensive infrastructural requirements for modular architecture.

This will lead to a re-evaluation of modular architecture with rural and

vernacular guiding principles. The promotion of local materials and skills into
pre-fabricated design methods can lead to an amazing amalgamation of
traditional ideology and modernist train of thought. Such an ingenious
technology which involves local knowledge of materials and building
techniques along with the efficiency, time saving and quality associated with
manufacturing in a climate controlled, regulated factory environment. This
merge of technologies can give rise to a system of construction which is both
modern as well as sustainable.

37
This will possibly create a new style of architecture which meets the current
requirements of loading, structural stability, aesthetics and ease of construction
along with being sustainable and vernacular in its techniques, materials and
ideologies.A response to such thoughts would be an attempt on introducing pre-
fabrication of wall sections in the vernacular setting of North-East India.
Interventions like off-site fabrication of wall sections in a controlled environment
of a portable workshop could lead to significant decrease in the amount of time
taken to complete the building. Also, structural members and joints would be
more precisely made, with proper reinforcements which would provide structural
integrity to the building. Introduction of electrical lines and water pipes and new
technologies for insulation, acoustic performance, passive cooling etc., would be
easier and more feasible.

In 1950’s, the prefabrication knowledge started to import to different countries.

Designers and contractors tried to detect a specific schema for prefabricated
buildings market, since there are different kinds of methods were available and
they promoted their knowledge to make the market ready for their works and
products. In last decades as time goes on, different problems occurred in
construction issues and in many developed countries the governments chose
prefabricated buildings as one of their solutions in construction. However the
prefabrication market has not been the same in different countries but it
illustrates, different market schema in different developed countries but almost in
all developed countries it displays rapid increase in tough periods of time such as
Second World War.

In the past, the prefabrication market focused mostly on home’s market. Today,
the market has extended to other building commercial ventures that incorporate
health awareness, instruction, and business structures. Around 85% of
respondents are utilizing these procedures to outline and develop those business
ventures at a few levels in developed countries (Smart Market Reports: McGraw-
Hill Construction, 2011). Still, the largest prefabrication market is the housing
market. “Prefabricated housing can be categorized into modular, mobile (HUD
code), production builder, and
panelized . Below is the market share:
1. 63 percent of all new housing is being built by builders/dealers.

38
2. 56 percent is panelized.
3. 33 percent production is onsite building.
4. 7 percent is modular.
5. 4 percent is HUD-code mobile.
From a Dissertation Report- Modular/Prefab Architecture in Rural
Education Infrastructure.

3.5: MYTHS IN MODULAR CONSTRUCTION:

Myth 1 – Modular means temporary

It is correct to say that modular buildings can provide temporary solutions but if
the interim accommodation is supplied from a leading manufacturer, it will
actually be constructed to permanent building standards.

Modular schemes generally have to meet the same Building Regulations

requirements and standards as facilities constructed using site-based building
methods. In fact, compliance can actually be easier with off-site construction.

The reality is that you are just changing the process – the building materials, such
as the structural steel frame, remain the same as a site-based solution but
construction takes place off site in a more controlled factory environment. This
means better quality because the process is not subject to poor weather – which
can cause serious quality issues post-completion, as well as a greater risk of
delays and budget overruns.

Myth 2 – Modular is all about ugly, grey boxes

Individual building modules do look like grey boxes but these units form the
structure of the building and can easily be clad or combined with full-height
glazing and a pitched roof for a completely different appearance.

There have been huge developments in modular construction and the approach
can now deliver award-winning architecture and landmark buildings. There is a
much wider range of aesthetic options that allow designers to achieve

39
 architectural variety for the building envelope, with all the speed and quality
benefits of building off site.

Columns are no longer visible either internally or externally, for a seamless

façade that can be specified with or without cladding. Options include a palette
of attractive colours or claddings such as cedar, terracotta tiles, stone, composite
metal panels, brick, and render.

Full-height curtain walling can reduce the reliance on artificial lighting and
enhance the internal environment, and windows in ribbon, punched hole or
composite configurations are factory-installed to improve safety on site and build
quality. Roofing options range from standard flat, barrel vaulted, pitched or
glazed atria.

A good modular building system will also create unrestricted internal spans of up
to 12m using modules up to 18.75m in length for ease of space planning, and
buildings up to six storeys high.

Myth 3 – Modular construction is completely inflexible and restrictive in

design and aesthetics

One of the biggest criticisms of modular construction is that these building

systems lack flexibility in design and appearance. This is simply not the case.

A technically-advanced modular solution can deliver more architectural and

bespoke buildings with a much greater degree of design freedom. And the latest
innovations offer even more options and flexibility:

 A much wider range of module length, height and width options for thousands
of configurations, permutations and layouts.
 The option of using larger but fewer modules to reduce cranage, transport costs
and site works.
 An wider choice of window and fenestration options, including full-height
glazing.
 Sustainability features such as green roofs, ground and air source heat pumps,
solar panels, solar shading and rainwater harvesting.

40
 A traditionally-constructed building can even be extended with modular
accommodation, and a wider range of module height options will facilitate the
linking to existing buildings.

Modular buildings can be expanded both vertically and horizontally, without the
need for decanting, and installation can be timed to take place at weekends or
during holiday periods. The floor area can also be reduced or increased very
quickly in line with local needs and capacity requirements.

Myth 4 – Modular buildings have bouncy floors

If you choose a modular building supplier that offers a range of floor options, you
can easily avoid the issue of floor vibration.

A good manufacturer should offer a high performance pre-installed concrete floor

which is ideal for high-traffic areas such as secondary schools and buildings that
need to accommodate heavy loads or sensitive equipment, such as operating
theatres.

A pre-installed concrete floor system integrated into the steel-framed modular

manufacturing process allows concrete to be poured into individual modules in a
controlled factory environment, for cleaner, safer and quieter work on site.

Performance specifications for high performance floors should include:

 A point loading of 7kN.

 A uniformly distributed load (UDL) of up to 9kN/m2.
 A concrete floor which is pre-installed to minimise work on site, reduce
disruption and improve quality..

It is also important to note that specifiers are often not aware of the range of floor
performance options that are now available with an advanced modular system.
This should be able to deliver the different floor response factors required for a
variety of applications and prevent over-specification. Hospital theatres and night
wards, for example, require the highest specification, whereas offices have less
stringent floor performance requirements.

41
Myth 5 – Modular means sub-standard accommodation

There should be absolutely no compromise on the quality of the accommodation

because a building is manufactured off site in a factory.

As the demand for modular construction continues to increase, so has the number
of specialist contractors. It is therefore critical to recognise that not all specialists
are the same and the level of technical expertise and quality can vary hugely
between suppliers. In the selection of a modular partner, construction clients
should take care to compare solutions that are like for like.

Always visit completed buildings to assess the quality of construction and finish.
Talk to other end users who have used the system and use their experience to
differentiate the leading specialists from any poor performers.

Ask for statistics to show how much of the manufacturer’s business is from repeat
customers. Ideally this figure should be more than 50 per cent – a good indicator
of track record for delivery on time, and commitment to quality.

Myth 6 – Modular buildings are cold in winter, overheat in summer

The quality of insulation for any building is key to ensuring it has a comfortable
internal environment. All buildings should be designed to be warm and easy to
heat in winter and to not overheat in summer.

The modular wall construction should offer good quality insulation in order to
achieve the targeted U value. A production system that uses the latest open pour
polyurethane insulation technology will deliver more consistent quality as well
as zero ozone depletion potential, and reduced manufacturing time.

A modular building can achieve the same U values as a traditionally-constructed

facility. A high-quality modular building can actually exceed Building
Regulations requirements for air permeability.

4.1: PRODUCTION
The material is pre-fabricated at the factory and are erected at the specific site.
This ensures the building construction in short time. The Material can be reused

42
in case of relocation of minimum wastages. The Material is corrosion resistance
and highly durable.

Prefabricated construction or prefab, involves constructing portions of a building

(walls,sections,roofs,floors) off-site (usually indoors),then transporting those
sections to the job site where they are assembled quickly into a finished building.

Prefab is green because it allows for more efficient use of Building materials,
prevents structures from getting wet before they are protected and saves
construction time.

CONCRETE:
Many current modular construction projects are using precast concrete as a
common material when it comes to meeting the demands of their clients. This
material can cast in reusable forms and moulds which is cured in a controlled
factory setting, transported on the site, and assembled. Even manufacturing of
the concrete in the precast plant can assure the highest quality control, thus
providing high-quality materials to construct modular buildings. Precast
concrete can be meticulously controlled to meet the demands, project’s
aesthetic, and structural requirements. Because of the advanced innovation
offered by the precast concrete, it has paved the way to faster design and
construction timeline while saving costs on material handling, logistics, and
transportation.

The ALC (Autoclaved lightweight concrete) is available in the form of blocks,

floor and roof slabs and wall panels for all type of buildings especially multi
storey buildings.

WOOD:
Wood, as an insulator, helps to control the energy loss better than any other
building materials. Due to the shrinkage and expansion caused by moisture, wood
tends to improve its strength properties. Therefore, it makes it a sustainable
43
modular building material to protect from inclement weather as the materials are
manufactured in a factory setting during modular construction. Since wood is
manufactured in a controlled environment, it also results in fewer air quality
issues for those who occupy the finished building.

STEEL:
Steel is more durable, has greater corrosion resistance and has a higher resistance
in harsh environments. The steel-frame construction allows a large beam span
with limited components than a wood-framed construction. This results in using
fewer raw materials during the construction process, hence reducing overall costs.
Moreover, steel building materials are often more consistent compared to wood
in terms of design, quality, and sustainability. Using structural steel in the
modular construction project helps in erecting fire-resistant buildings.
No matter what type of materials you choose for constructing your modular
building, they always contribute to saving costs compared to traditional stick-
built construction. So choose the right materials that best suit your project needs
and design a flawless modular building.

4.2: PROCEDURE
In case of blocks, the concrete is poured directly in the moulds whereas in case
of slabs firstly the reinforcement is put in the moulds then the concrete is poured.

The concrete is poured only till half of the mould but in another the concrete id
poured only till half of the mould but in another 10 to 15 minutes due to foaming
or chemical reaction the volume of concrete rises and the mould gets filled till the
brim.

After pouring the mixture in the moulds it is left for 5-6 hours since certain
amount of softness is required for cutting of blocks. The mixture can neither be
too hard nor too soft. Thus, the softness is tested using ball test.

44
Ball test: In this test after 5-6 hours small balls are dropped from a fixed height
on the mixture. Due to their fall impressions are formed on the mixture in the
moulds. Then the diameter of the impression is measured. The diameter should
be 20mm + 2mm. if the diameter is so then the prepared mixture is ready with the
desired softness for cutting it as blocks or slabs.

After the ball test venting is done to liberate the excess heat of hydration from
the mixture. Vents are created in the mixture with the help of bars. In case of
blocks the vents have to be created but in case of slabs the reinforcement (vertical
bars) has to be taken out.

The moulds are taken from their position to the cutting machine through this
overhead operating machine that lifts the mould and places it below the cutting
machine.

The machine moves across the mould both horizontally and vertically in case of
blocks and only vertically in case of slabs. The thread attached to the machine
cuts the blocks and slabs while moving through it. These are the Siporex stamped
blocks cut of size 200mmX240mmX650mm which are ready for steam curing.

The blocks or slabs cut are then steam cured in autoclaves in cycles under 185-
220 deg Celsius temperature and 13.5kg/cm^2 pressure up to 16-18 hours. The
full strength of alc is 30-35kg/cm^2. The function of autoclaves is similar to that
of a pressure cooker.

The alc blocks have to undergo following four cycles for steam curing in the
autoclaves for 16-18 hours:

 vacuum creation
 pressure rise
 steady pressure

45
  release of pressure

12 moulds can be placed at one time in the autoclaves and after remoulding, the
blocks are sent for storage and the slabs are sent for milling process.

The milling machine is used to create tongues and grooves on the slabs. These
grooves are made for proper interconnection of slabs through tongue and groove
joints in flooring and roof slabs.

After the milling process the slabs are taken for the test of bending moment to
check the deflection according to the design. The slabs are finally packed as per
the required order and stacked one over the other with arrow embossed on the
slabs showing the direction of inner reinforcement.

4.3: ADVANTAGES

1. Speedy return on investment due to speedy construction and earlier starting of

production in case of factories.

2. Saves cement, steel, construction and supervision cost, construction time, water
used in construction and most importantly the timber used for centering and
formwork used in conventional system.

3. Uniform quality assured due to mass manufacture in factory.

4. Convenient for use in congested and water deficient areas. Also useful for multi
storied buildings, cold storages, spinning mills etc.

5. Checking of anti-corrosion coating given to steel reinforcement in slabs and

wall panels.

6. The different products manufactured by alc form between them an open

building system that can constitute the whole structure of a low rise building upto
2 storeys.

46
7. Due to bigger size of siporex blocks there are less no. of joints in the masonry,
therefore saving on the cost of cement and sand.

8. Due to light weight, the dead load on foundation is reduced, thereby saving on
concrete and steel.

9. High thermal insulation and fire resistance properties help to reduce fire
hazards. Installation and recurring air conditioning costs also reduce
substantially.

4.4: DISADVANTAGES

1. Skilled and artistic work cannot be done in pre-cast buildings

2. Being a new technology , people are not creative enough to produce artistic
work

3. The moment the artisans start working on this aspect , the cost increases

4. Not becoming popular where mass production is not there .

4.5: PROPERTIES:

LIGHT-WEIGHT:
Oven dry density of siporex is 400 to 650kg/m ideal for low bearing soils
,seismic zones and for adding storey’s to existing buildings

HIGHLY INSULATING:
k value 0.122 kcal /hr /m c used as insulating material for boilers, heat
exchangers.

47
FIRE RESISTANT AND INCOMBUSTIBLE:
Offers twice the fire protection of concrete. Ideal for fire walls and for fire
protection of structural steel siporex roof slabs, wall panels, load bearing blocks.

HIGH STRENGTH TO WEIGHT RATIO:

For Siporex 18 to 22 against 16 for concrete of M-150 grade.

WATER PENETRATION :
Siporex structure being of closed cells, there is less capillary action and high
surface activity allows for fast evaporation of moisture

WATER REPELENT:
Silicon oil is added in slabs and wall panels which makes the product water
repellent.

COMFORTABLY WORKED:
It can be easily drilled , chiselled or nailed

SOUND ABSORBTION:
For 3” and 4” walls is 38 to 40 dB, and for 8” thick walls is 45 dB hence ideal for
theatres and auditoriums.

CORROSION RESISTANT:
Reinforcement bars used in Siporex slabs and wall panel are treated with patented
highly effective anticorrosive– silicon oil is also used.

ENVIORNMENT FRIENDLY:
siporex eliminates the use of timber and thus helps to conserve our forests siporex
also eliminates the use of bricks which consume valuable fertile soil required to
grow food for our vast population.

48
5.1: COMPARISION

49
50
5.2: CASE STUDY-1 THE KINDERGARTEN, AUROVILLE,
TAMIL NADU

The Kindergarten is located at Centre Field, in Auroville. This is a pre-primary

school in Auroville. It is designed by Ar. Suhasini Ayer-Guigan. The
Kindergarten was conceived in the year 1984, and provides for children from 3
to 7 years of age. The school is function between 8a.m. to 1p.m. The school is
provided with two playgrounds and two pools.

The case-study was chosen because it had a potential to be an extraordinary

example for a better design philosophy of rural school design. It is a fine
precedent to define the type of spaces which could foster a conducive learning
environment in rural setups.

It is a low cost, low energy building, with the major structural elements being
pre-cast and CSEB clocks used as walls. It is a fine example of rural school
architecture.

Plinth area of the building is around 560sqm. The climate of the place is warm
and humid. The construction was majorly an undertaking of the local workers,
who were trained by the contractor and the architect. The construction started in
1991 and was finished in 1992. The cost of the project is around 1.5 million.

51
DESIGN PRINCIPLES:

ORIENTATIONS:

The building is oriented along the north-south axis. Zoning is done based on sun
path. The main hall is on the south face, thus blocking the harsh south sun. The
pools are provided towards the north of the building so as to prevent excessive
heat gain by the water.
LANDSCAPING:

Landscaping has been carefully designed, keeping the needs and likes of small
kids. Every classroom has small attached gardens. The major open spaces and
pathways are shaded by trees or covered with pergolas. Creepers and planters also
provide shade in transition spaces.

SPACES:

The Kindergarten is essentially a cross shaped building. It is an inward looking

design with all the spaces spilling into the central hall. This reduces circulation
and enables this hall to act as a courtyard and enhance the ventilation in the
building.

52
CONSTRUCTION:
MATERIALS:

CSEB and concrete are the major materials which were used for the construction
of the building.
All the walls are load bearing walls. The pillars and walls are made up of CSEB
blocks which are stabilized with 5% of concrete. Only natural finishes are used
on the walls. No paint or water-repellent chemical is used.
The roof consists of pre-fabricated rafters, which were castes near the site, at
Pondicherry, and then transported to site and assembled on site.

ROOFING:

Roofing is made up of precast concrete rafters with Mangalore Tiles as a

Covering. Those prefabricated Rafters were transported on a small truck
from Pondicherry where it was casted. This provided an efficient and quick
construction on Roofing systems. The covering material is baked
Mangalore tiles with voids covered with glass to provide light. There are
ventilation tiles in the Roofing System. These tiles allow hot air to escape
more efficiently and hence provide passive cooling in the building.

INFERENCE:

The Kindergarten gives us a unique and inherent idea of the type of spaces which
can help produce a more conducive learning environment for kids, especially in
the rural context. There are varied levels of interactions between the built and the
natural environment. Through such spaces, the architect has successfully
eliminated the character of monotony from the school. This goes a long way
towards improving the way knowledge is shared in schools.

In a place like Auroville, like most other rural setups, the involvement of the
residents, especially the children, with the surrounding natural environment is
very intrinsic. The possibility of a coherent existence of a flourishing human
society with the natural environment is very efficiently reflected in the design of

53
the school and its spaces. Such schools can be considered as guiding examples
for designing schools in non-urban setups. They can help develop conceptual
templates for rural school design. The Kindergarten can be used as a catalogue
by architects when dealing with task of designing schools in a rural
environment.

The use of pre-fabricated roofing system to cap the structure constructed

predominantly through locally available material, primarily by local volunteers is
a precedent of how new technologies can be incorporated in a rural setup. This
involves a high level local participation. Such interaction can be very healthy in
developing a flourishing education infrastructure in villages.

5.3: CASE STUDY-2

GOLCONDE,PONDICHERRY,TAMILNADU

Golconde is designed as the Residential Dormitory For Aurobindo Ashram in

Pondicherry, Tamilnadu.This is the first attempt on Modular Construction in

54
country. It was one of the most advanced buildings of its time, in its method of
construction and techniques used,built in one of the most remote parts of the
country.

Golconde is a perfect specimen for a study of possibilities and probabilities of

pre-fabricated architecture in a sub-urban/rural environment. It can give cues as
of how modular architecture be made viable in non-industrialized areas,
especially villages.

Guiding Principles and Construction:

The building was completed primarily by unskilled volunteers and members of

the ashram, with the most uncertain of supplies. However, virtually every fitting
is pre-fabricated.

The construction of the building commenced in October 1938.It almost took an

decade to complete.It was designed by Architect Antonin Raymond.

Although Raymond Originally envisioned the six month time frame for the
Construction, this schedule did not account for Sri Aurobindo’s desire to protect
the tranquil ashram environment from the din associated with a commercial
construction. This is one of the major reasons why it took a decade for a
prefabricated building to build.

The immaculately maintained building uses a spare material palette reinforced

concrete primary structure, bowed concrete shell roof, and polished Cuddapah
floors.

The modular RCC shell roof has pre-cast curved tiles on the top with ventilated
air space over the deck.
Each room is identical measuring
4mX5.5mX3.5m h. These rooms are
separated from the corridors by teak

55
wood sliding doors which are
designed to allow air to pass through it
without sacrificing privacy. The
partitions between the rooms are made
of pre-cast concrete panels.

The north and the south facades are

beamed with pre-cast, operable
concrete louvers, which ensure
constant air circulation between the
north and south facades.

The staircases too were cast off-site

and fitted in place while construction.
Each handrail consists of a single
board of oiled teak, anchored into the
Precast banisters with custom brass
hardware.

INFERENCE:

Modular construction is perceived to

be closely related with extensive
industrial involvement and
infrastructural investment. However,
the Golconde proves otherwise. It was
built in a place which can be
considered almost hostile for pre-
fabricated construction, especially in
1938. This building paves the way for
pre-fab/modular architecture in sub-
urban/rural areas.

56
From Modular/Prefab Architecture in
Rural Education Infrastructure.

5.4:CASE STUDY-3 AUM HOUSE,GUJARAT

The initial idea was to create a disaster resistant and cost effective house, which
could be precast anywhere and transported by lorry to the place where the disaster
occurred. The technical concept satisfied this requirement. The house was cost
effective, even with the provision for disaster resistance, but the transportation
cost was more than the house cost.

The prototype of this 23m2 AUM House has been built during the India
International Trade Fair 99 at New Delhi. The house was prefabricated at
Auroville and transported in a single lorry. The house weighed around 22. 5

57
tons and the lorry took 5 days to cover 2,900 Km between Auroville, Tamil
Nadu, and New Delhi.

The packing of the house was done in such a way that only 8 blocks arrived
broken out of 2,280 blocks. Ferro cement pieces had only little hair cracks. The
superstructure of the prototype house has been assembled in 66 hours by the 18-
man team of the former AVBC/Earth Unit. This AUM House prototype was
sponsored by HUDCO. The India Trade Promotion Organisation awarded this
house a Gold Medal for the excellence of its special demonstration.

58
5.5 CASE STUDY-4 GARDEN ESTATE IN VIJAYAWADA.

INTRODUCTION:
Penda has released plans for their first project in India. Based on a modular
building system, the Pooja Crafted Homes will allow residents of Vijayawada to
design their own high-rise apartment by selecting prefabricated modules from a
catalogue that will then be inserted into the tower's frame.

"In an age of mass-production and a certain conformism in the building industry,

we try to use modern construction techniques to bring back a level of
individualism and flexibility for the inhabitants of a high-rise. A kind of
individualism one would have in building his own house," says penda.

59
The tower, due to break ground in 2016, will be divided into eight separate
elements: the structure, walls, facade, ceiling & floors, infrastructure, balconies
and plants. Much like a modular shelving system, the tower's structural grid and
infrastructure will be the only consistent elements in the building. Each home will
be uniquely customized by its occupants in a way that will also allow for future
modifications.

"The modules are ranging from different floors, to facade element, to railings and
a variety of pots for plants to grow along the home. By choosing their own
elements, we offer the homeowners a tool to become the designers of their
individual apartment," adds penda.

The building's varying facades and open hallways will support constant airflow
and natural ventilation for all residents, thus the architects have referred to the
project as a "breathing tower." A grey water system will also be implemented to
collect and reuse rainwater for all the plants and balcony gardens.

DESIGN:

The Architects Found Inspiration in the previous project a small-storage space

designed for a Beijing-café and decided that only constant element in the building
should be the structural grid and Infrastructure.

All other components can be fully customized by the use of Prefabricated

Modules. Large amount of vegetation will populate the terraces and will be
irrigated with Rain water.

The Architects created a Framework that can be filled with a chosen

configuration, which is fabricated off site and then inserted into the structure.
Indian Residential developer Pooja crafted Homes commissioned Penda to design
the Vijayawada Garden Estate that allows residents to personalize their homes.
The Building is meant to be located on a corner plat near Krishna River, and will
provide a fantastic views of Surroundings.

Optimal configuration of Modules will facilitate natural ventilation,while the

plants will help preserve fresh air and natural appearance of High-rise.

60
A grey water supply system collects rainwater on the roof and reuses it for
watering the plants on the balconies. This air-purifying vegetation will use the
grid on the façade as a giant trellis, slowly immersing the building in foliage.
These ‘natural’ elevations also help regulate the scheme’s indoor climate, while
open hallways support a constant airflow throughout the tower. Located in
Vijayawada, India, the project is due to start construction in the second quarter of
2016.

61
62
5.6: CASE STUDY-5 THE ATLANTIC YARDS, NEW YORK
It is the tallest modular building in the world with 32 floors with height reaching
322 feets. Its architect - Shop broke down the monolithic size one expects to
encounter street-side by composing the facade in a series of alternating bands of
curtain glass and rusted-steel grid work.

63
64
The modules/units used to construct
the complex. All Modules are pre-
assembled at the navy dockyards,

transported here and then completed.

Modules are picked directly from the
truck and placed onto the building by
a crane within the construction fence
and set by a team of workers. Modules
are bolted together work is undertaken
to complete the connections of pre-
installed building system components
within each module.
Each module has a floor level, but no
ceiling. When the joining is done, it is
kept in mind that the floor of the upper

65
level module will act as a ceiling for
the lower level. This further reduces
the cost of construction.

66
67
.

68
5.7: CASE STUDY- 6 HABITAT-67

INTRODUCTION:

Habitat 67 is an experimental modular housing complex in Montreal, Canada,

designed by architect Moshe Safdie as a vision for the future of urban living.
The building was created as the showpiece for Expo 67, one of the largest world
fairs which was held in Montreal in 1967.

Safdie had originally conceived the building as part of his university thesis. He
had travelled across America and become disillusioned by the high-rise
apartments and unsustainable suburban sprawl that he saw as the prevailing
modern architecture. He was inspired in part by the movement of Brutalism
which had attempted to reinvent urban architecture, as well as the post-war
Japanese movement known as Metabolism. This was characterised by buildings
that were designed as organic, living systems of prefabricated cells.

69
Located on Cite du Havre, a man-made peninsula, Habitat 67 is now regarded
as an architectural landmark despite its failure to achieve Safdie’s aim of
‘reinventing the apartment building’ in the high-density urban environment.

DESIGN:

Safdie was approached to develop the master plan for the building which was
approved by the federal government and financed for completion by the time of
Expo 67, where housing was to be one of the central themes.

Habitat 67 comprises 354 prefabricated stacked concrete modules arranged in

various geometric configurations to reach 12 storeys in height. The interlocking
forms are connected via walkways and include landscaped terraces. By creating
a series of properties that each feature its own roof garden and access from an
external ‘street’, the idea was to combine the urban garden residence with the
modular high-rise apartment building.

Fifteen different housing types were developed that varied between 60 and 160
sq. m. To increase the energy efficiency of the building by preventing
unnecessary journeys, six large elevator pillars were constructed to allow for
vertical access that stops only on every fourth level.

While the original master plan envisaged more than 1,000 residences, together
with shops and a school, the completed complex featured just 158 apartments of
varying sizes and formations, the reduction being due in part to the higher-than-
anticipated per-unit cost. A factory had been built beside the site so that the
prefabricated construction of the modules could take place in close proximity,
before being connected by high-tension rods, steel cables and welding. Far from
being the most cost-effective solution, as had been thought, the costs escalated to
CAD$22 million (which translated to around CAD$140,000 per apartment).

70
POST-COMPLETION:

Despite being experienced by some 50 million people during Expo 67 and being
lauded as a ‘fantastic experiment’ by critics, it did not inspire the ‘revolutionary
uptake’ of prefabricated, modular development that had been hoped for by Safdie.
Plans were proposed to replicate the design in New York, Puerto Rico and Israel
but never realised.

After Expo 67 the Canadian government sold the building to a businessman for
CAD$10 million. In 1985, the tenants formed a limited partnership to purchase
the building for CAD$11.5 million, and since then it has come to be seen as a
leading example of a successful co-operative.

Today, it stands as an icon of Canadian architecture and a key tourist attraction,

with apartments occasionally being let for very high sums.

RESTORATION:

In November 2018, Safdie Architects completed a comprehensive renovation of

the 10th floor publicly-accessible unit of Habitat 67, to commemorate the
building's 50th anniversary.

The repairs to the duplex unit, which were undertaken over a 2-year period,
involved extensive interior restoration, technical upgrades to 21st century
energy conservation standards, and tackling water damage sustained since the

71
building's completion. This required that the exterior concrete walls were
stripped, before insulation and waterproofing could be carried out. The original
timber parquet flooring was also restored, as well as the installation of slot
detailing to improve the circulation of air.

The unit is to remain open to the public as well as being a place of scholarly
research. Safdie Architects are to continue their involvement in the complex's
ongoing restoration.

CONCLUSION:

Targets can be achieved by replacing the conventional methods of planning and

executing building operation based on special and individual needs and accepting
common denominator based on surveys, population needs and rational use of
materials and resources. No single approach and solution is available which can
satisfy the community at large.

However, what is ideal and desirable is to have a system which can provide choice
for people and also appropriate techniques to meet the situation. The essence lies
in the system approach in building methodology and not necessarily particular
construction type or design. Adoption of any alternative technology on large scale
needs a guaranteed market to function and this cannot be established unless the
product is effective and economical. Partial prefabrication is an approach towards
the above operation under controlled conditions.

Prefabrication technology has not transferred as easily when compared with other
technologies because it is a production technology or knowledge based and not a
consumption technology or product based. Technology transfer of prefabrication
is not as pertinent to architects as it is to manufacturers of building products, but
we are caretakers of culture in the AEC industry. In many cases we are asked to
help with many of the transfers that are occurring by way of global practice or
working for multi-national firms that are producing prefabricated components
and entire buildings for India and elsewhere. Although transfers will continue to
occur, especially in the area of prefabrication in building, we should be well
aware of how the decisions of U.S. and western architects may have an effect on

72
the ethical dilemmas regarding less developed countries’ development and
culture.

The use of prefab can help to achieve results for the society’s immediate needs
because the fast changing environment, business, economics, industrialization,
residential needs, settlements and many other factors of transportation like
bridges, towers, railways calls for fast settlement and requirement for buildings,
offices and industries, hence prefabrication is the solution for fast and time saving
construction.

PROCESSING OF RESEARCH DATA:

This Report consists of the Research Data of the Modular Systems,

The chapter-1 consists of the Overall Synopsis of the Research

 Aim
 Need
 Objectives
 Scope
 Limitations

The chapter-2 is about,

 Criteria for Modular Systems which describes about the current scenario
in the Field of Construction.
 A Brief History about Modular Systems which deals the Origination and
Evolution of Modular concepts.
 Concepts Involved in the Building Typologies.
 Steps involved in the Construction Process with a case study
 A Data about the Climate Responsiveness in terms of Modular
Construction
 Various Applications of Modular Systems

The Chapter-3 is about,

 The Justifications based on the adaptations of Modular Systems
 Advantages of Modular Systems

73
  Disadvantages of Modular Systems
 The Current Situation of Modular Construction in India
 The Myths about the Modular construction

The Chapter-4 is about,

 Production process of the Prefabricated Materials
 Procedures which includes all the tests that are needed for the material.
 Advantages of the prefabricated materials
 Disadvantages of the prefabricated materials
 Properties of the prefabricated materials
 Applications of the prefabricated materials

The Chapter-5 is about,

 Comparative Study between Onsite and Offsite Construction
 Case study-1:
A kindergarten,Auroville and is a primary school
 Case study-2
Golconde,Pondicherry, a Residential Dormitory
 Case study-3
Aum House, Gujarat, a moveable House done by Auroville
 Case Study-4
Vijayawada Garden Estate, a Residential High-rise Building

The above case studies are to the Indian Context

 Case study-5
Atlantic yards,Newyork, a High-rise Apartment
 Case study-6
Habitat-67,Montreal,Canada, a Housing Complex

ANALYSIS OF PROCESSED DATA:

COMPARISION BETWEEN OFFSITE(MODULAR) AND ONSITE(TRADITIONAL)

CONSTRUCTION

74
What?

Modular construction is an off-site based construction method, during which

individual components are manufactured in a factory, transported to the site
entirely complete and assembled on location.

The term ‘traditional’ is often used to describe the types of linear construction,
where each individual step is not only constructed entirely on site, but also needs
to be completed before the project can move on to the next phase.

Why?

Modular Construction
 Component
 Prefabricated
 Simultaneously in-factory and on-site work make modular up to 50% faster
to occupancy.
 Consistent, Quality-controlled manufacturing process
 Modules arrive up to 95% completion

Traditional Construction
 Conventional
 Stick-Built
 Every step to be completed before the next can begin
 Weather damage and Inconsistent labour yield can affect quality
 Since all construction occurs on-site the schedule is dependent on weather
conditions.

How?

Design/Engineering,Permits,Approvals &Site Development

Both Modular and Traditional Construction start the same.Once the projects are
ready to break ground,they two take dramatically different approaches.

DAY-1
75
MODULAR CONSTRUCTION TRADITIONAL CONSTRUCTION

Grading and Site Preparation Grading and Site preparation

DAY-10
Foundation,

Foundation, construction begins Foundation, construction begins

Start Building Modules

DAY-40
Foundation,
Foundation Completed Foundation Completed

Start Shipping Modules

DAY-45

Start Shipping Modules Framing begins

DAY-65

Interior/Exterior Finishes Roofing,Siding,Insulations

76
 DAY-80

Site Clean-up & Landscaping Installing Windows & Doors

DAY-90

Grand Opening Electrical and Plumbing Works

DAY-115

25 days after Opening Interior/Exterior Finishes

DAY-135

45 days after Opening Finished Electrical & Plumbing

DAY-170

77
 80 days after opening Site Clean-up & Landscaping

DAY-180

With up to 50% of time savings after Grand Opening

90 days from opening

Why it is not Adaptive in India?

Access:
As they come ready to put in place, modular construction requires careful
consideration to be given to access for delivery, not just the site itself but
approaching roads.

Change:
Traditional building methods allow for late changes in design to be made,
whereas modular construction is less likely to be able to factor this in and requires
client sign-off far earlier.

Rigorous planning:
The logistics of individual module assembly demands far more rigorous planning
to ensure a project goes smoothly.

The benefits would appear to directly outweigh the pitfalls. However, every
project needs to be considered individually. The pros, cons and limitations of both
traditional and modular construction should be carefully assessed to ensure the
ultimate desired outcome is achieved.

78
DRAWBACKS FOR MODULAR HOUSING:

Restrictions on the land – Some areas have covenants on the land which specify
that only brick homes can be built. These are often found in housing estates.
Although modular homes can be built with brick facades, they usually raise the
cost and reduce the sustainable value of the home, and so are often avoided.

Luxury builds – High end luxury builds can be incompatible with modular
homes. This is because the features and design may not suit the materials and
style. If this is the case, a traditional construction may be the best option.

Built up areas – Although modular homes take a lot of the hassle out of the
building process, particularly built up urban areas can be difficult to negotiate
when assembling the sections. For example, a skinny lane with multiple power
lines may not be ideal to bring in pre-made sections as it could delay the build
and escalate installation costs.

You can’t customize as much - If you’re big into custom homes, modular
probably isn’t for you. While you have some customization options with modular
buildings, most designs have limits on how much you can alter their shape or
look.

You need to be near the factory- Modules are absolutely massive, since they
are literally assembled parts of a house. As a result, the cost of transporting such
large objects outside 500 miles becomes prohibitive, so you’ll need to be
relatively near the factory that produces them

Zoning is an obstacle- Zoning gets a little weird when it comes to modular

structures. Modular buildings are relatively new to the construction industry, and
local zoning boards are still catching up. You may run into some outdated zoning
rules that may be a drain on the project or even block you from building
altogether.

FINDINGS:

Modular Buildings are based on below criteria’s,

79
  Timescales: The time from the start of completion to construction
 Construction costs: Initial construction costs of Building(prices excluding
external works)
 Design: The Aesthetics and how buildings can be integrated into existing
structures.
 Flexibility: Adaptive changes considering
extension,repurposing,portabilities & resale capabilities
 Lifespan: The Effective Lifespan of Buildings

 A Modular Building can be up to 35% cheaper

 It can save up to 50% of time compared to Traditional Construction

 It can functional despite of weather,condition,festival times

 Errors can be less compared to Traditional Construction

 It takes up to 67% less energy consumption as these modules are

Made in Factories

 In terms of site situations,the construction is mainly based on the distance

and the transportation

 Modular Buildings are suitable for the areas who are in need of quicker and
cheaper construction( For Example-Flood Prone Regions etc.)

INSIGHTS & OPPORTUNITIES:

Modular buildings are extremely versatile – they can be used instead of

conventional methods on a huge range of different projects. Today, modular
buildings are commonly used for the construction of temporary, long term and
permanent buildings across a huge range of different sectors, including:

80
 Education
 Healthcare
 Housing
 Public sector
 Apartment blocks, offices and mixed-use buildings
 Hotels
 Industrial facilities
 Commercial and marketing buildings

It can be used in place of traditional construction or alongside conventional

construction methods in pretty much any project, across a full range of industries,
and in a full range of environments.

BIBLIOGRAPHY:

 Marquit, A., 2013. From Sears & Roebuck to Skyscrapers: A History of

Prefabricated and Modular Housing. New York: New York University Press.

 https://www.nist.gov/sites/default/files/documents/el/economics/Prefabrication-
Modularization-in-the-Construction-Industry-SMR-2011R.pdf.

 https://www.researchgate.net/publication/305550264

 https://www.researchgate.net/publication/305550264_Towards_the_adoption_of_mod
ular_construction_and_prefabrication_in_the_construction_environment_A_case_stu
dy_in_Malaysia.

 https://www.nbmcw.com/report/construction-infra-industry/1835-construction-sector-
current-scenario-and-emerging-trends.html

 MODULAR SYSTEMS IN ARCHITECTURE-An overview of modularity through

case studies.

 Modular buildings in modern construction-Samara State University of Architecture and

Civil Engineering, Molodogvardeyskaya St 194, Samara, 443001, Russia

 A REVIEW OF PREFAB HOME AND RELEVANT ISSUES-Professor, Housing

Research Centre, University Putra Malaysia.

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 Behaviour of Prefabricated Structures in Developed and Developing
Countries-Department of Architecture, Bahcesehir University, Istanbul, Turkey.

 MODULAR FOR ARCHITECTS by Harry William Parker.

 Maïni, S., 2008. Moveable House. Auroville: Auroville Earth Institute.

 McGraw Hill, C., 2011. Prefabrication and Modularization: Increasing Productivity

in the Construction Industry. SmartMarket Report. Bedford

 PREFAB ARCHITECTURE-A Guide to Modular Design and Construction

By Ryan.E.smith
 https://www.designingbuildings.co.uk/wiki/Modular_vs_traditional_construction
 https://www.clearviewmodularbuildings.co.uk/about/why-build-modular

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