PREFABRICATED TECHNOGOLY

- BHARGAVI TALEKAR

PREFABRICATION CONSTRUCTION TECHNOLOGY

INTRODUCTION
Prefabrication is the practice of assembling components of a structure in
a factory or other manufacturing site, and transporting complete assemblies
or 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 the
construction 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 fabricated
with the whole machine. Prefabricated parts of the body of the machine may
be called 'sub-assemblies' to distinguish them from the other components.
Prefabrication, the assembly of buildings or their components at a location
other than the building site. The method controls construction costs by
economizing on time, wages, and materials. Prefabricated units may include
doors, stairs, window walls, wall panels, floor panels, roof trusses,
room-sized components, and even entire buildings.
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 use
of 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 in
factories 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.
 ⚫ Mobile phone radio towers and other services very often comprise
of 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 then
finally assembled in the actual site.

PREFABRICATION CONSTRUCTION TECHNIQUES

There are 6 types of construction techniques
01 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 of

frames 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
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 frame
can be assembled in three to four days. Entekra says its system reduces the
overall build cycle by up to 33 percent versus stick framing and reduces the
need 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
 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.

04 COVESTRO
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, and
structural closed-cell spray polyurethane foam in the stud cavity. The
panels are structurally comparable to traditional wood
stud/OSB-sheathed walls. The company offers three configurations to
meet 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 tripping
hazards 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
with design and optimization through software, which then communicates
with the dealers’ saws.
All of the parts and pieces typically cut by the labours in the field are cut in
our facilities and bundled by wall section. On the site, the labours combines
the 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 eliminating
unnecessary 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 all
climate zones.
Like other options, PUReWall helps save jobsite labour, but it improves
accuracy and reduces waste.
02 SANDWICH PANELS

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

steel. 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
Being a composite structure , a sandwich panel consists of two layers of
metal surfaces usually separated by a non-metallic core material. Combining
the 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 , Health
care facility , cold storage unit , warehouses , etc .
Sandwich panels have high insulation properties .
Flexible designing and wide application range makes the manufacturing of
the 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 industrial
requirement . 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
 ● 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 and
strong 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
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, on
any 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
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
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 prepared
foundation.
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 transporting
these complete assemblies to the final location.

● The prefabricated construction system has been identified as one of

the 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 by
minimizing on-site noise and dust.
 ● 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 sector
has 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 order
to 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

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
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 for
our 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.

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 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.
ACKNOWLEDGMENT
The authors wish to thank the Construction Industry Development Board
(CIDB), M.N.A. Azman1 , M.S.S. Ahamad2 and W.M.A. Wan Hussin3
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