TECHNOLOGICAL ADVANCES IN BUILDINGS

Prefabrication and Modular Construction

 Prefabrication and Modular Construction
■ Technological advances in architecture and construction are
influencing the design, delivery, manufacture, assembly and
formation of buildings.
■ Industrialization is taking place in architectural practice and
construction. This industrialization is composed of five degrees.
❑ Prefabrication
❑ Mechanisation
❑ Automation
❑ Robotics
❑ Reproduction
■ Prefabrication is a manufacturing process that takes place in a
specialised facility off-site, where different materials are joined to
form a component part of a building.
■ Mechanisation refers to any process where machinery is used to
ease the workload of the construction workers.
■ Automation relies on the tools and machines to fully take over the
tasks performed by the construction workers.
■ Robotics depends on robots to perform a variety of construction
tasks.
■ Reproduction constitutes future construction methods that are
still in research and development.
Difference between Prefabrication and Modular Construction
Prefabrication and modular construction are the terms used
interchangeably.

Prefabrication refers to the manufacturing of construction elements

away from the construction site and assembly on site. In principle,
these prefabricated elements can be customized for the specific
project.
Modular construction specifically describes instances of prefabrication
where the elements are standardized modules. Each modular unit can
be e.g. a dorm room, a factory-fitted bathroom, or an element in a
facade.
Need of Prefabrication and Modular Construction
Prefabricated construction is needed when:
■ The building needs to have multiple similar units (e.g.
office rooms).
■ The construction site is on very expensive land.
■ The construction site has a short build season, e.g. due
to the climate.
■ The construction site is in a highly dense urban area, or
very remote.
■ The construction site planning is complex due to e.g.
many stakeholders, limited space or time.
Benefits, Challenges and Limitations

Benefits:
▪ Faster construction. (No curing period required)
▪ Greater degree of predictability in cost.
▪ Less dependency of weather and site conditions (leading to higher
productivity of workers).
▪ Reduced material waste and transport carbon emissions.
▪ Increased safety to workers.
▪ Self supporting readymade components- does not need formwork,
shuttering, and scaffolding.
▪ Quality control is easy.
▪ On site congestion can be minimized
▪ Moulds can be reused.
▪ There is less theft material/equipment (and less
property damage due to vandalism).
▪ Materials are protected from exposure to the elements
during construction.
▪ Worker safety and comfort level are higher than in site-built
construction;
Challenges
▪ Design options can to some extent be restricted by the use of
standardised modules.
▪ Very Skilled crew required
▪ Careful handling of components
▪ Limited ability to change the structure through future
renovations.
▪ Leakages at joints
▪ Heavy duty cranes and precision measurement to place in
position
▪ Very costly when the factory is very far away
from the site.
Limitations
▪ Uneconomical for smaller projects
▪ Transportation difficulties
▪ Safety of Crane and other support system has to carefully
considered.
▪ Difficulties in transportation of vary large components
▪ Waterproofing joints
 Types of prefabricated homes

There are several different types of prefab homes.

1. MODULAR HOMES

■ Modular homes consist of one or more modules that are built in a factory and
then transported separately to the building site, where construction is
completed. Each module usually comes fully-outfitted with interior fittings –
plumbing, electrical, doors, closets, and stairs – so there’s little finishing work to
be completed when the home is assembled.
■ Build times from the point of order to move-in are roughly three to four months.
Companies such as Blu Homes and Method Homes offer modular homes.
 2. PANELIZED HOMES

■ Panelized homes are built in panels – a whole wall, for instance – then each
panel is transported to the building site and is constructed into a home.
Typically, panelized homes require more finishing work than modular homes, as
the interior finishing work, such as painting, installing cabinetry and stairs, and
installing flooring, must be completed on-site.
■ Factory build-time is still similar to that of modular homes (about 6 to 12
weeks), but on-site build time is longer. It might take a week to construct the
panels onsite, then it could take an additional month to complete the interior
work, depending on the schedules of the subcontractors. Total build time can be
estimated at three to five months, give or take, depending on subcontractor
schedules
 3. PRE-CUT HOMES

■ Pre-cut homes are “kit” homes, such as log cabin kits or dome homes. The
homes are cut to design specs in-factory, then are shipped as a kit to the
building site to be constructed on-site.
■ One factor that sets apart pre-cut homes from panelized homes is that pre-cut
homes are often designed for the motivated home buyer who wants to construct
the home on-site themselves using the materials and instructions supplied by
the manufacturer. The kits come with a detailed list of instructions and parts,
much like a piece of Ikea furniture. The home buyer then works to piece the
home together, either alone or with the help of a general contractor.
■ For instance, some pre-cut log cabin homes simply provide the pre-cut logs and
framing materials ready to be assembled on-site, these tend to have the longest
on-site build times. Also, not all pre-cut homes come with full walls or ceilings
pre-manufactured. Total build time can be estimated at a minimum of five
months, although it could be much longer.
 4. SHIPPING CONTAINER HOMES

■ Shipping container homes (homes made, quite literally, from industrial steel shipping
containers) have made a splash in the media because of their funky and creative designs.
Much like modular homes, shipping container homes can be stacked and pieced together
like Legos to create homes, offices, and funky eateries, such as Container Bar in Austin,
TX.
■ However, before you settle on shipping container building, is not the same as building a
prefab home. Shipping containers may be sturdy and strong, but they aren’t designed for
residential use. This means you need to check your local building codes to see whether
there are more restrictions for building homes using shipping containers. And unless
you’re quite handy with a welding torch, you’ll likely need to hire an architect and general
contractor to figure out exactly how to construct the home.
■ MEKA Modular Buildings Worldwide is a modular home manufacturer that uses the
standards of a 20-foot shipping container to design its modular structures , who have
redesigned the shipping container specifically for residential and commercial use. For this
reason, the homes are actually built to withstand worldwide shipping.
Machineries used for handling

skids
Gantry girder

Mobile
Fork lifts crane
Precautions for transporting and
storing the components
Stacking – Dos and Don’t s

■ Stacking method and packers for support spacers vary according to the type of precast elements.
■ Horizontal stacking – beams , slabs and columns
■ The storage support position for beams and slabs – within 300 mm from the lifting points
■ Do not use more than two support points in particular pack for prestress elements like
hollow core slab
Stacking – Dos and Don’t s

The packers or support spacers should not be misaligned as shown

 Stacking – Dos and Don’t s

Wall panels should always be stored vertically and braced in position by

A - frames or racking systems
Different storage and stacking
examples
Transportation
Precautions during transport
Erection and Installation of components on site: Requires proper
attention and skill to prevent the elements from developing erection
and handling stresses

Erection
Temporary strengthening of panels with opening is necessary
➢ The lifting points should be designed and located to limit the bending moments
within the beam element.
➢ As a general guide , they should be located at about one fifth of the beam length
measured from the edge.
II

I 1 m1 r 1
Wherever necessary multiple lifting points can be designed and located to
minimize undue stresses within the slab elements, in particular for slender
panels such as precast planks.
Columns are usually
first handled in
horizontal position.
Slings are attached to
the inserts at the top
to facilitate the
rotation of the
elements to vertical
position before
hoisting and placing to
their designated
location
 Machines used for hoisting
Guyed Derrick Crane

- A derrick is a lifting device composed at minimum of

one guyed mast, as in a gin pole, which may be
articulated over a load by adjusting its guys. Most
derricks have at least two components, either a guyed
mast or self-supporting tower, and a boom hinged at its
base to provide articulation.
The most basic type of derrick is controlled by three or
four lines connected to the top of the mast, which allow
it both to move laterally and up and down. To lift a load,
a separate line runs up and over the mast with a hook
on its free end, as with a crane.
 Cranes

Climbing cranes

Portal cranes

Tower cranes
Mobile cranes
4 PREFAB HOMES YOU CAN
BUILD IN UNDER 24 HOURS
 M.A.Di, Assembled in 6 hours
Starting from €32,800 (excluding
delivery)
■ Not only can this A-frame cabin be
constructed anywhere in the world,
but it only takes 6 hours to put
together.
■ Architect Renato Vidal designed
the tiny M.A.Di homes – available
in five sizes, from 27sqm to 84
sqm – as modules that can be
unfolded and built without the
need for foundations, making the
prefab home a good choice for
homeowners in a hurry. Take a
closer look.
 KODA by Kodasema, assembled in 7 hours

Starting from €90,000

■ Those after the simple life will
appreciate this tiny minimal
cabin. Its glazed wall makes the
prefab home perfect for making
the most of remote landscapes,
while a mezzanine sleeping
area offers just enough space
for its owners to bed down in.
Nomadic owners take note – it
can be assembled and
disassembled in under seven
hours. Take a closer look.
 ÖÖD House, assembled in 8 hours

From $65,000 (excluding land,

installation and set-up, shipping
and taxes)
■ ÖÖD House owners can enjoy
their privacy behind this tiny
home’s mirrored exterior, which
helps it disappear into the
landscape. There’s only one
room to squeeze into, but what
this prefab home lacks in
square-footage it more than
makes up for in views through
its wraparound glass windows.
 Kasita, assembled in 24 hours
From $139,000 (excluding land,
installation, shipping and taxes)
■ Simple living is the
philosophy of Kasita – a
micro home inspired by its
founder’s year-long voluntary
stay in a dumpster. Thankfully
there’s nothing dumpster-like
about the cabin’s light-filled
interiors – spanning 374 sq.
ft. – which are kitted out with
minimalist storage units and
wooden floors. It’s positioned
as a solution to the housing
crisis, and can be installed
within 24 hours of delivery.
 PREFABRICATED HOUSES IN PAKISTAN
■ Karmod Prefab Home is the largest and most diverse manufacturer of factory-
built accommodation in Pakistan. The company has been building a wide
variety of units for more than 30 years to many parts of Pakistan, supplying
customers in the industrial, commercial and government sectors.
■ The Leading Manufacturer of Prefabricated Homes & Offices in Pakistan they
are specialized in designing, manufacturing and construction of the
prefabricated house, steel structure. Prefab Home is a leading manufacturer of
prefabricated/ mobile homes, offices, labor camps, temporary site offices,
guard rooms Etc.
■ Excellence in Quality, across all aspects from raw material to final product,
including packing is our basis to manufacture.
■ Their commitment is to server their customers’ needs while maintaining a
reputation for quality, integrity and employee satisfaction, which propels them
forward.
 PROJECTS
1. New York City Beach Restoration Modules
2. School of Business Building,University at Albany, SUNY, New York, USA, 2013.
3. Metro Arkitekter, Hyllie Train Station, Malmö, Sweden, 2010.
4. Studiotrope, Morgan Library, Colorado State University, Fort Collins, CO, USA, 2012.
5. Strategie Architecten, HEMA building, Oosterbeek, the Netherlands, 2009.
6. FAAB Architektura, PGE GiEK Corporate Headquarters, Bełchatów, Poland, 2013.
7. Consarc Architects, iCon Innovation Centre, Daventry, Northamptonshire, UK, 2011.
8. the Royal Melbourne Institute of Technology (RMIT) Design Hub, Melbourne,
Australia, 2012.
9. Dico si Tiganas, Multifunctional Sports Hall, Cluj-Napoca, Romania, 2014.