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PREFABRICATED TECHNOGOLY

- GAWALI VAIBHAV (10)

MORE GAURAV (18)
MOTE PRATIK (19)
NAIK SAMEER (20)
VHORA AMRUTA (29)

PREFABRICATION CONSTRUCTION TECHNOLOGY

INTRODUCTION

Prefabrication is the practice of assembling components of a structure in

a factory or other manufacturing site, and transporting complete assembliesor
sub-assemblies to the construction site where the structure is to be located.
The term is used to distinguish this process from the more conventional
construction practice of transporting the basic materials to theconstruction site
where all assembly is carried out.

The term prefabrication also applies to the manufacturing of things other than

structures at a fixed site. It is frequently used when fabrication of a section of a

machine or any movable structure is shifted from the main manufacturing site
to another location, and the section is supplied assembled and ready to fit. It is
not generally used to refer to electrical or electronic components of a
machine, or mechanical parts such as pumps, gearboxes and compressors
which are usually supplied as separate items, but to sections of the body of the
machine which in the past were fabricatedwith the whole machine.
Prefabricated parts of the body of the machine maybe called 'sub-assemblies'

to distinguish them from the other components.

Prefabrication, the assembly of buildings or their components at a locationother

than the building site. The method controls construction costs by economizing
on time, wages, and materials. Prefabricated units may includedoors, stairs,
window walls, wall panels, floor panels, roof trusses,
room-sized components, and even entire buildings.
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The concept and practice of prefabrication in one form or another has been

part of human experience for centuries; the modern sense of prefabrication,

however, dates from about 1905. Until the invention of the gasoline-powered
truck, prefabricated units—as distinct from precut building materials such as
stones and logs—were of ultralight construction. Since World War I the
prefabrication of more massive building elements has developed in
accordance with the fluctuation of building activity in the United States,
the Soviet Union, and western Europe.USES

OF PREFABRICATION

 Prefabrication is just not used in the construction of huge

buildings, but it has several other uses too:
 The most commonly used form of prefabrication building is the useof
prefab concrete and steel sections in structures where one particular
building element is repeated a number of times.
 Prefabrication eliminates the need to transport concrete to the
construction site and the need to mix and pump wet on a
congested construction site. Also pouring concrete sections infactories
ensure the moulds can be reused time and again.

 Prefabricating steel sections cut cost on on-site cutting/welding

and also lessens the linked hazards.
 These techniques are also being used in the construction of
apartment blocks, housing developments which have repeated
housing units, office blocks, warehouses and factory buildings.
 Prefab glass and steel section are being widely used in the
exteriors of large buildings.
 Prefab bridge systems and elements offer noteworthy benefits in
terms of cost, construction time and safety environmental impact
constructability for bridge designers and contractors.
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 Mobile phone radio towers and other services very often compriseof
numerous prefabricated sections.

 This technology is also being widely used in the assembly of space

crafts and aircraft. Components like fuselage sections and wings
are often manufactured in different countries or states and thenfinally

assembled in the actual site.

PREFABRICATION CONSTRUCTION TECHNIQUES

There are 6 types of construction techniques01

PANELIZED WOOD FRAMING.

02 SANDWICH PANELS.

03 STEEL FRAMING.

04 TIMBER FRAMING.

05 CONCRETE SYSTEMS.

06 MODULAR SYSTEMS.

01 PANELIZED WOOD FRAMING.

Used typically for roofs, these are long pieces offrames

built from laminated timber, covered either by a plywood or some

board roof deck. Panelized frames can be up to 72 feet long, these roof
panels can save construction time
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4 PANELIZED SYSTEMS THAT SAVE TIME AND LABOR

01 ENTEKRA

LP recently invested in this manufacturer, which provides prefabricated wall

panels, floor panels, and roof trusses. Structural elements are delivered to the
jobsite for sequential off-loading to maximize efficiencies, and the framecan be
assembled in three to four days. Entekra says its system reduces theoverall build
cycle by up to 33 percent versus stick framing and reduces theneed for on-site
skilled labor by 40 to 60 percent.

02 WEYERHAEUSER

NextPhase Site Solutions combines the company’s Trus Joist products with
software and saw technology to create JobPack framing packages for floors,
walls, and roofs. Pre-cut components are bundled and labeled to match
framing layouts for straightforward installation, reducing waste and errors.
Framing members are also pre-drilled for mechanical rough-ins.

03 BMC
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Ready-Frame pre-cut floor, wall, and roof framing packages begin with

software design that optimizes material usage. SmartBundles arrive pre-

cut and pre-labeled for jobsite assembly, requiring less labor and
producing less jobsite waste. The company says the effi ciencies translate
into 30 percent faster build times versus traditional stick framing.

PUReWall panels consist of panelized wood frames, rigid polyiso continuous

insulation that reduces thermal bridging, an integrated weather resistive
barrier that eliminates the need for housewrap, andstructural closed-cell
spray polyurethane foam in the stud cavity. Thepanels are structurally
comparable to traditional wood
stud/OSB-sheathed walls. The company offers three configurations tomeet
every climate zone as well as net-zero applications.

Are Panelized Homes Good?

It’s faster, better, and safer. Faster because materials are pre-cut or
prefabricated, including pre-cut holes, reducing or eliminating measuring and
cutting in the field; better due to improved accuracy, which trickles down to

other trades; and safer because, with most or all cutting already completed,
there aren’t awkward cuts made on site or the associated trippinghazards from
waste.

BMC has been offering pre-cut and pre-built framing products for some time,
officially branding them Ready-Frame about six years ago. Available through 32
of the dealer’s locations around the country, Ready-Frame begins
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with design and optimization through software, which then communicateswith

the dealers’ saws.

All of the parts and pieces typically cut by the labours in the field are cut inour
facilities and bundled by wall section. On the site, the labours combinesthe
precut parts with studs and sheet goods and assembles the wall according to
the instructions, with no measuring or marking required. It reduces waste and
increases cutting accuracy—window and door openings are exactly right . The
labou saves time without having to cut or measure.

Also notes that the system addresses material costs by eliminatingunnecessary

parts.

PUReWall from Covestro takes panelization a step further, offering wall panels
consisting of framing, continuous insulation with an integrated weather resistive
barrier on the exterior, and spray foam on the interior,thereby eliminating
additional steps. Three variations allow for use in allclimate zones.

Like other options, PUReWall helps save jobsite labour, but it improvesaccuracy

and reduces waste.

02 SANDWICH PANELS

Made from 2 thin facings of materials like concrete, plywood, or stainlesssteel.

The facings are then stuck to an insulating core, made typically of materials like
foam, paper, cloth or rubber

Breakthrough innovation from light-weight and durable panels

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Being a composite structure , a sandwich panel consists of two layers of metal

surfaces usually separated by a non-metallic core material. Combiningthe best

benefits of high structural rigity and low weight , sandwich panels offer an
iinnovative enveloping solution mad make for a perfect buildings façade or roof
. EPACK being the leading sandwich panel manufacturer in India offer a
complete range of insulating panel that are compact and application for
varied industries such as agriculture , office building , Healthcare facility , cold
storage unit , warehouses , etc .

Sandwich panels have high insulation properties .

Flexible designing and wide application range makes the manufacturing ofthe
best sandwich panels possible to have them installed vertically or horizontally ,
These panels are easy to installand durable construction

Ensures that they serve without a fault for lifetime .Offering breakthrough
innovation in composite paneling solution , EPACK has earned a favorable
market reputation and has developed a strong client network with a complete
range of sandwich panels that suit every commercial and industrialrequirement
. The highlight features of prefabricated sandwich panels which offer it vast
benefits have been listed as follows :

● Sandwich panels offer excellent thermal insulation and acoustic

insulation properties
● Offering a leak proof construction and isolating properties , sandwich
panels are very energy efficient and isolating properties , sandwich
panels are very energy efficient
● The top sandwich partion supplier EPACK offer and effective
alternative to masonry with its Structural Insulation panel (SIP)
● The sandwich panels are resisitant to flames , corrosion , termites ,
physical impact and fungus
● These composite panels are easy to install and have very low
maintenance requirements
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● Low thermal conductivity helps in high energy saving and maintains a

desired temperature

Manufacture in compliance with the highest industrial norms and guidelines , the
sandwich panels on offer provides Uncomprised quality and satisfy vast commercial
applications . The high quality raw material used in the making , gives the panels a
commercial application . The high quality raw materials used in the making , gives the
panel a commendable structure , superior strength and extraordinarily long life
.

03 STEEL FRAMING

For ages, steel has been one popular and trusted building material for
commercial and residential construction. Steel framing uses this strong and
durable material to create prefab panels which can be used to construct
buildings.

LGSF or Prefabricated Light Gauge Steel Framed

This based construction method uses the latest technology to create structures
that are strong yet beautiful. Buildings can be designed in any form, style and
height, to be suitable for conditions against earthquake andstrong wind gusts
(up to 300 km/h). It is an extremely versatile method of building and offers several
advantages over conventional methods.

ADVANTAGES

01 ENERGY SAVINGS
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Prefab buildings have superior thermoregulation compared to conventional

buildings. This makes fans and air conditioners much more efficient, and saves
power and the environment.

02 SPEED

In 12 weeks what it takes a conventional project 6-12 months to do.

Depending on the size and complexity of the project, it can be even faster.

03 CUSTOMIZATION

One of the greatest advantages of this technology is the ease of

customizations compared to conventional. Build your project in any style, onany

type of terrain, even difficult to access locations.

04 AESTHETICS

Prefab buildings don’t need thick columns and beams. The computer-aided
nature of the manufacturing also allows the architect to be more creative.
From the outside, it looks no different from conventional buildings. Looks
better because of the precise angles and straight lines.
05 COST

The best part is that it costs the same (or even less) as conventional, despite
being better in almost every way! If you factor in the amount of time you save,
you can see why prefab construction using Esthete’s LGS system works out more
economical.
06 LABOUR

Apart from the lesser labour needed for a prefab project, our employees are
trained well and dedicated to finishing things on time. The LGS technology
encourages hassle free construction.

04 TIMBER FRAMING
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Not very common in India, timber framing panels are quite popular in other

countries where timber homes are common. These framings are built in
factories and then used in erecting timber homes.

05 CONCRETE SYSTEM

Having concrete fragments of a prefabricated building cast in the factory

provides more versatility and also saves time. Even though architectural elements
like concrete panels are heavier than other building components,they are
typically sturdier and can improve a building’s aesthetics.

06 MODULAR SYSTEM
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These systems use all prefab styles and create a whole building structure typically
made from factory-constructed units. The buildings are transported to the final
construction site and then simply connected to a preparedfoundation.

Overview of the Prefabricated construction in India & abroad

Prefabricated construction is the assembly of pre-made components for

construction of structures required for industrial use, and then transportingthese
complete assemblies to the final location.

● The prefabricated construction system has been identified as one ofthe

replacement to altering the speed of conventional construction
methods at a rapid rate.
● These modules are then transported and installed on-site as
load-bearing structural blocks of the structure.
● This type of prefabricated structure also provides environmental
benefits, such as the decline of construction waste and CO2 emissions,
and less interruption to the building site’s neighbours byminimizing on-
site noise and dust.
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● These advantages are the driving force within the European building
industry for the expansion of prefabricated building systems.
● Moreover, due to increase in population, other countries (i.e. US,
Canada, Japan, etc.) also use modular construction technology to
construct houses, apartments, offices, etc.

PREFABRICATION ADOPTION IN INDIA

● The prefab production was pioneered by Hindustan Housing Factory. The
corporation transformed its name due to the diversity of its operations
and is now recognized as Hindustan Prefab Limited or HPL.
● The government-run corporation prefabricates mainly precast concrete
for architectural and civil projects and is located in Delhi.
● In the last few decades, Indian Infrastructure and Construction sectorhas
grown exponentially. It is main driving factor for the economic growth.
● On 25th June 2015 The Pradhan Mantri Awas Yojna (PMAY) was
launched which involve manufacture of about 20 million houses by
2022 for urban poor while rural housing which envisages 10 million
houses in next three years was launched on 1st April, 2016. In orderto
attain this enormous task, Ministry of Housing and Urban
Development, GOI has adopted numerous innovative pre-fab
construction systems, developed within the country.

SANGATH VAULT TECHNOLOGY

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TYPE OF VAULT – BARREL VAULT

The complex is an ensemble of vaulted . The architectural ensemble is

harmonious unity of the spatial composition of vaults The design studios are
housed in a double height volume surmounted by two vaults; between them
lies a flat roofed area that permits light to enter the end-walls of eacn vault.
Perpendicular to this wing is a block of four vaulted units. The two units facing
the entrance court rise to a triple height and house an architect's office,
conference room, lounge, and service area on the ground floor. First and
second floors house the Vastu-Shilpa Foundation and guest area. The barrel
vaults had glass and grill on their vertical faces and looking down through those
I could see the underground studio spaces. Construction of this vault is done
firsty they have prepaired a form work in fabrication of particulatar height and
span and then they have laid a wooden planks in semi circular manner over
that formwork which has done in
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fabrication and then they have poured a motar over it and small pieces of

mosac tiles are laid over it.

CASE STUDY

Tata new heaven housing , Banglore India

 This Project consists of a total of 3,000,000 sq. ft., including approximately

1,750,000 sq. ft. of residential area, distributed amongst 35 towers. The project
includes seven types of residential units, with each tower having a different
configuration. The towers have G+10, G+12, and G+14 foors, and stand over a
cast-in-situ concrete podium and parking garage. ABKJ provided
consultancy forour client, Shapoorji Pallonji, in providing engineering and
developing detailed information for Precast Concrete fabrication and erection
purposes. The scope of work includes Building Information Modeling (BIM)
using Revit software, and providing erection drawings and Precast Concrete
fabrication shop drawings based on the Revit model.
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SITE PLAN –

FLOOR PLANS
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CONCLUSION

To establish IBS( Industrial building system ), MMC ( Modern method of construction ) ,

and OSM ( Off –site Manufacturing ) in the construction industry, all participants
must acquire knowledge on the current technology in the construction industry.
This is necessary for India to compete globally and adjust to the current
economic changes. The industry should also respond and cooperate with the
government initiative encouraging OSMs, and embark on research work to
increase the standards of the construction industry. The experience and problems
faced in setting up OSMs should be shared. An exchange of knowledge to
motivate and educate the country to move to a higher level of development for
the construction industry must also be pursued. Thus, IBS have the similarity drive
and challenge with the United Kingdom (UK) and Australia; and among the factors
are skilled craft worker, fast track completion, cost and transportation. The three
factors that determine the ability of construction industries to enter the
international market are technological advantages that are associated with…
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possessing formidable construction technologies; sophisticated management

systems for scheduling, material tracking, organized sub-contractors; and financing
capability that enables a company to arrange for project financing schedules from
international financiers. Technology is an important tool to push the construction
industry to achieve the international level. This will help construction companies to
achieve long-term profitability and acquire a balance growth in the future. The
trend in the prefabrication construction industry pattern has gone through a few
transitions from the conventional method to the prefabrication stages. This research
manages to determine the pattern prefabrication construction, physical and social
factors for implementation IBS, MMC and OSM.