RELEVANCE OF PREFABRICATED CONSTRUCTION IN

RESIDENTIAL BUILDINGS OF KERALA

AMITH KRISHNAN

KMEA COLLEGE OF ARCHITECTURE

Guide

Ar. ANJITH AUGUSTINE

Submitted in partial fulfilment of the requirements for the degree of

Bachelor of Architecture

MAHATHMA GANDHI UNIVERSITY

Kottayam

I
 CERTIFICATE

This is to certify that the dissertation work titled “Relevance of prefabricated construction in
residential buildings of kerala” is a Bonafide work of Amith Krishnan(Reg no.15054005),
under my guidance, submitted as Semester VII & VIII subject for the award of “Degree of
Bachelor in Architecture” during the term of 2018 to 2019 through Mahatma Gandhi
University, Kottayam.

Place:
Date:

Ar. Anjith Augustine

II
 Keywords

Architect, ALC Panels, Cost effective, Conventional, Designer, Modular, Fast

construction Gypsum, Pre fabrication, Residence, steel

III
 Abstract

Pre-fabricated construction is now rapidly growing in Kerala’s context. People are attracted
towards steel and pre-fabricated structure mainly because of low budget and fast
construction. This research shows how the aspect of conceptual design is achieved when
using pre-fabricated material. The idea is to study the aspects like space optimization,
aesthetics and visual impacts, flexibility and use of space by using steel and gypsum in
residential building and comparing with the conventional residential buildings of Kerala.
Through this research in looking into only budgeted homes under 2500.00soft.The
construction process is studied through books and internet and two literature case studies
are also conducted to understand why steel and gypsum is rapidly used in construction
industry. The primary and secondary data collected from about literature case studies and
literature review. For the final conclusion of research is done by doing 4 live case studies
which 2 project are under the pre-fabricated construction method and 2 of them for
conventional construction method. Each project for the live case study is taken from the same
location and each having the same design requirement. After doing the live case study I come
to conclusion by doing interviews with designers, contactors and client and users. In interview
I have prepared several questions, for answers of each questions I have rated marks out of 5.
This helped me to conclude answers for my research question.

After visiting the buildings and interviewing the designers and the users of the buildings, I
came to a conclusion that gypsum and steel is a very good option to consider for the
residential buildings along the context of Kerala. For building owners if the construction is
finished as fast as possible it will be cost saving for them.

But when going through the other aspects of steel and gypsum which will be sometime not
feasible to the context of Kerala. The result of this research is only based on the aspects of
space optimization, aesthetics and visual impacts, flexibility and use of space.

IV
 TABLE OF CONTENTS

1.0 INTRODUCTION .......................................................................................................................... 1

1.1 Background and Context ............................................................................................................... 2
1.2 Research Questions ...................................................................................................................... 2
1.2.1 Research Sub questions ......................................................................................................... 2
1.3 Aim and objectives ........................................................................................................................ 3
1.4 Scope, limitations and significance ............................................................................................... 3
2.0 LITERATURE REVIEW .............................................................................................................. 4
Prefabricated construction in Kerala: ............................................................................................. 4
2.1 Literature Review on Gypsum....................................................................................................... 6
2.1.1 Introduction ........................................................................................................................... 6
2.1.1 Glass fibre reinforced gypsum ............................................................................................... 6
2.1.2 An overview of GFRG wall panel systems .............................................................................. 6
2.1.3 Project Details about GFRG .................................................................................................... 7
2.1.4 Applications of GFRG ............................................................................................................. 7
2.1.5 ADVANTAGES OF GFRG .......................................................................................................... 7
2.1.6 Disadvantages of GFRG .......................................................................................................... 8
2.1.7 Conclusion about gypsum ...................................................................................................... 8
2.2 Literature review on steel ............................................................................................................. 9
2.2.2 Disadvantages ........................................................................................................................ 9
2.3 Literature review on ALC panels ................................................................................................. 11
2.3.2 Advantages of steel ALC panels ........................................................................................... 12
3.0 METHODOLOGY ....................................................................................................................... 13
3.1 Data sources and data types ....................................................................................................... 14
Secondary data collection ............................................................................................................. 14
Primary data collection ................................................................................................................. 14
Data sources and Data types ............................................................................................................ 15
Secondary data collection ................................................................................................................. 15
3.2 Data collection ............................................................................................................................ 16
3.2.1 CASE STUDY– LITERATURE .................................................................................................. 16
MATERIALS USED .......................................................................................................................... 17
3.2.2 Outcomes ............................................................................................................................. 18
4.0 RESULT 20
4.1 CASE STUDY – LIVE ...................................................................................................................... 20
1. Preparing questionnaires ......................................................................................................... 20

V
 QUESTIONS FOR DESIGNER........................................................................................................... 20
QUESTIONS FOR OCCUPANT/ USER. ............................................................................................. 21
4.2 Electing appropriate buildings for case study ............................................................................. 22
4.2.1 Prefabricated residential building ........................................................................................ 22
4.2.2 Data collected from case studies. ........................................................................................ 23
1) RESIDENCE FOR MR.RAJAGOPALAN NAMBOOTHIRIPAD @ GURUVAYOOR ........................... 23
2) RESIDENCE FOR MR.SAJEEVAN AT MANJERI ............................................................................ 28
3) RESIDENCE FOR MR.SHAJI AT PERINJANAM ............................................................................. 32
FIGURE 14: On site execution of precast steel and columns ........................................................ 32
4.3.1 Conventional residential building ........................................................................................ 34
4.3.2 Data collected from case studies. ........................................................................................ 34
1) Rsidence for Mr.Sujith at Thrissur ............................................................................................ 34
2) Rsidence for Mr.Shyne at Alappuzha ....................................................................................... 39
5.0 DISCUSSION ................................................................................................................................ 41
5.1 Based on live case study on pre-fabricated residences .............................................................. 41
5.2 Based on live case study on conventional residences ................................................................ 43
5.3 Based on interactions with practicing architects in kerala ......................................................... 44
NO ONE ARE DONE A FULLY-FLEDGED PREFABRICATED BUILDING* ........................ 45
5.4 Inference from live case study .................................................................................................... 46
5.4.1 Prefabricated residences ..................................................................................................... 46
5.4.2 Conventional residences ...................................................................................................... 46
5.4.3 Live interactions ................................................................................................................... 47
6.0 CONCLUSION ............................................................................................................................. 48
7.0 REFERENCES ............................................................................................................................. 49

VI
 LIST OF FIGURES

Figure 1: load carrying capacity of GFRG panels (Photo taken during

interview)…………………………………………………………………………………………………………………………..06
Figure 2:Forces experienced by structures .............................................................................. 10
Figure 3 : Gravity and wind loads taken by steel structures .................................................. 10
Figure 4: ALC panels ready for transportation in plant in Chennai ....................................... 12
Figure 5: Front view from the courtyard ............................................................................... 16
Figure 6: Concept behind the design .................................................................................... 17
Figure 7: The truss is covered with angled louvers, which let in ample amount of light and let
us hot air out ......................................................................................................................... 17
Figure 8: Residence for Mr.Rajagopalan Namboothiripad ................................................... 23
Figure 9: Conventional stair ................................................................................................ 25
Figure 10: Residence for Mr.Rajagopalan Namboothiripad (interior ) ................................ 26
Figure 11: Modular kitchen .................................................................................................. 26
Figure 12: On site execution of precast steel and columns ............................................... 28
Figure 13: At the stage of structure finishing * external walls are made of concrete blocks
and internal prat ion with gypsum boards. (Photo taken during site visit ........................ 29
Figure 14: On site execution of precast steel and columns .............................................. 32
Figure 15: Residence for Mr.Sujith @ Arimboor , Thrissur .............................................. 34
Figure 16: Dining space of Residence for Mr.Sujith @ Arimboor , Thrissur .................... 38
Figure 17: Residence for Mr.Shyne at Alappuzha ........................................................... 39
Figure 17: Residence for Mr.Shyne at Alappuzha ........................................................... 39

VII
 Acknowledgements
First of all, I thank The Almighty God for blessing with this profound grace, without which this
dissertation would not have been a success.

I would like to express my deep sense of gratitude towards my guide Ar. Anjith
Augustine for giving me their valuable suggestions and guiding me, throughout the course of
my research. I would like to extend my heartfelt gratitude to the Faculty members Ar.
Jayadevi Venugopal and Er. Hashim K Abdul Azeez of the Department of Architecture for
their constructive support and cooperation at each and every juncture of the research.

And also extend my gratitude to Ar. Joseph John and Ar. Zenia for her timely suggestions and
supports.

I was fortunate enough to have had the chance to work with Ar.Manuraj CR, who patiently sat with
me in the most critical times to rationalize my thoughts and arrive at the result.

Finally, I express my heartfelt gratitude towards my parents and friends for the mental
support they had offered me and for their immense encouragement towards the successful
completion of the work.

VIII
1.0 INTRODUCTION
The material cost and the construction costs are increasing in Kerala these days and the
availability of material is reducing. So there is an increasing demand in the construction sector
for an alternate method which solves these currently faced issues to a certain extend.
Modular and prefabricated construction is a new method introduced in Kerala in past 5 years.
Modular construction is commonly known as pre-fabricated construction.
ERIALS RATE ON 2019 RATE ON 2016
Semi Wire cut brick 12.0 per piece 8.0 per piece
9”x 4”x3”
Solid concrete blocks 28.0 per piece 20.0 per piece
16”x8”x4”

Binding wire 16 gauge 66 per kg 55 per kg

Steel TMT Bars 53 per kg 46 per kg

M-Sand 14000.00 for 200 12000.00 for 200 CFT

CFT
Plastering sand river 28000.00 for 500 22000.00 for 500 CFT
sand CFT
Metal 4 mm 11000.00 for 200 6000.00 for 200 CFT
CFT
Cement 406.00 for 50kg 350.00 for 50kg

Table 1: Approximate material cost as per 2019 and2016

(From interview with contactor Mr.Mahesh and Mr.sanju from Thrissur)

MATERIAL COST CAMPARISON OF PAST

4 YEARS
Rate on 2019 Rate on 2016
140
110
70
66

60

55
54

53
46

40
35
30
28
20
12
8

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1.1 Background and Context
Why pre-fabricated construction?
Reduction in construction time: Either the structure can be constructed cast in situ or factory
made. Commonly the pre-fabricated structures are made off site, by this can reduce, and save
large amount of construction time in site.
This result in saving all around from inventory to construction of temporary accommodation,
and factors such as interruptions and dust are eliminated.
With reduce construction the cost is significantly reduced. Pre-fabricated structure have high
level of automation which make cost effective than traditional construction methods.
In case of durability and strength, the buildings are durable and lightweight due to the large
amount of use of steel, which is considered as strong building material.
These structures are against weather which leads to wind storm and rain, and commonly seen
defect cracking also be reduced.

1.2 Research Questions

1) Understanding opportunities and constrains of prefabricated construction in Kerala?
- A feasibility study on residential application in context of Thrissur.
2)
 Space optimization

 Aesthetics and Visual impacts.

 Flexibility and use of space.

How these aspects can be compared with pre-fabricated and conventional construction
method?

1.2.1 Research Sub questions

1) How does steel and gypsum can become a major construction material for the
residential scale?
2) What are the merits and demerits of steel and gypsum over the conventional method?
3) How does these materials help in Space optimization, Aesthetics and Visual impacts,
Flexibility and use of space? In comparison with the conventional method.
4) What will be the difference in cost and time in these construction method? study
through comparing the cost of different materials and time taken for the different
works in these methods of construction

2
1.3 Aim and objectives
By doing a research I am aiming to study and understand how using steel and gypsum as a
major structural element in residential building helps in design flexibility, Space optimization,
Aesthetics and Visual impacts, When compared to the conventional structured residential
buildings. The study will be limited to three factors on conceptual design stage, which is space
optimization, aesthetics and visual impacts and flexibility of use and use of space.
The economical aspect is also a major factor that should be studied, but a brief study on the
economic factors while the construction process is also considered.
Objectives:
1) To find how steel and gypsum become as a major construction material in residential
building over the conventional method.
2) To find the different advantages and disadvantages this method of construction
3) To find the efficient method of construction by looking at the aspects of Space
optimization Aesthetics and Visual impacts. Flexibility and use of space.

1.4 Scope, limitations and significance

Pre-fabricated construction is a vast topic. In this particular type of construction there are
various methods. In addition, various factors affect the particular type of construction.
Here I am studying how to prefabricate residential building with steel gypsum/ALC panels.
The particular type of contraction with steel is now fully fledged in the commercial sector of
Kerala. Gypsum and steel are now widely available in Kerala form manufactures like FACT, so
the availability of material will not be limitation in this method. Here I am looking in to how
these materials can change the typology of traditional construction method. The study will be
much of a qualitative analysis and comparison of buildings, which is constructed, in both
traditional and prefabricated method in all over Kerala.In addition, the study is dealing with
use, types, Quality, time and the importance in future years
I am only looking through three factors, which are space optimisation, aesthetics and visual
impact and flexibility of use and optimisation of space, which are three factors that affect the
conceptual design analysis. In addition, the study will be on buildings, which come under the
residential buildings within the state.
As the limitation to the topic, am not dealing with the structural analysis of the particular
construction type. Few architects in Kerala practice the particular construction methods and
majorly civil engineers and contractors practice the method. Therefore, the data produced is
collected from contractors and civil engineers.
More than live case study I have interacted with 5 architects in kerala to understand their
opinion about the particular type of construction. As limitation to this my result and
conclusion for this interaction will be only based on their opinion.
Even though the major attention of the paper will be on the conceptual design analysis, the
financial aspects during the construction process will also be studied, in a scale, which will
give a brief idea how steel, and gypsum residences differ from conventional typology of

3
residences. The study will be limited to a specific building typology, which are small residences
under 2000.00 sqft within the state.

2.0 LITERATURE REVIEW

Whilst designing a building it's far critical to discover the dimensions of the enclosure and to
expand a structural scheme, with a purpose to offer this functional space deliberating of
considerations which include aesthetics and visual impact, flexibility of use and use of area,
space optimisation and the economic factors. The significance of every of these issues
depends at the characteristic of the constructing. As an instance, the design massive is for a
conventional residential constructing could be one-of-a-kind from a constructing, which has
mixed use including residential and industrial spaces. To broaden an effective idea layout, it
is necessary to review those concerns based totally on their importance, depending on the
form of building. Prefabricated structures – construction and benefits
Prefabricated construction is a system wherein sections of modules of the edifice are
assembled at a faraway area, after which transported to the constructing website online. This
unique construction approach could be very price-effective and regularly makes it viable to
finish a building venture in as a lot as 1/2 the time required for strategies that are more
conventional. Prefabricated construction is usually employed with the construction of recent
homes; the strategy also can be used with other buildings.
At the site, the modules are unloaded, moved into role with the resource of heavy machinery,
and related to form a unmarried building. Along with the fast meeting, prefabricated creation
can frequently store a superb deal of cash on the constructing task. Via the use of general
styles, the constructing materials are pre-reduce at the manufacturing website online. This
removes a first-rate deal of the waste in wooden and other components which can occur all
through the process of constructing. As a end result, a prefabricated house with three
bedrooms is in all likelihood to cost drastically less than a 3-bed room living that is created
from scratch on the constructing website online. One other key benefit of prefabricated
construction is the energy efficient nature of this type of building strategy. Because the
sections of a panelised home are pre-cut, they fit snugly together, making for a tighter edifice.
This means less effort to heat and cool the space, resulting in lower utility bills.
Prefabricated construction in Kerala:
Prefabricated construction is a technique-combining style of additives of systems at
production stage and transporting the ones materials to the web page and assembling from
the web page. However, the website online stage creation could be very much less for this.
These days pre-fabricated construction is becoming extra common and enhancing the quality
of creation inside the finances.
Since the fabric availability and skill complete labour is lowering within the creation area of
Kerala more advanced and budgeted constriction methods desired to be added in the
construction field of Kerala. Flexibility in design:
Modular construction can be easily demolished or relocated to different sites. This will reduce
the demand for raw materials and create energy saving and decreases the construction time.

4
Modular construction is creating flexibility in architectural design and structural design. In
addition, creating a limitless opportunities.
Consistent quality:
The first-class will trade according to distinctive contractors. These all relies upon up on all
artisanship and normal quality of materials that turned into given for construction. With pre-
fabricated creation maximum of the works are done form the manufacturing facility and only
the execution is executed from the web page. Gadget equipment’s do maximum of the works
so it is ensuring a uniform quality within the construction. The pre-fabricated substances are
present process various exceptional exams from the manufacturing unit itself and can
maintain the regular first-class.
Reduce site disruption:
For the reason that many additives of a constructing are completed in the manufacturing unit,
there's appreciably much less truck site visitors, equipment and fabric suppliers around the
final creation website online. This limits the disruption of traditional jobsites that suffer from
noise, pollution, waste and other common irritants. This streamlined technique to creation
offers a miles greater green ecosystem for productiveness, and gets rid of needless
distractions and interference which can be ordinary of creation websites. Shorter
construction time:
For the reason that creation substances and the pre-fabricated materials are transportable, it
can reduce the construction time. In all topics, the pre-fabricated production takes 1/2 the
time of traditional construction techniques. This because of higher making plans, removal of
site weather factors, quicker fabrication as multiple gadgets.
Safety in construction:
Since most of the works are achieved from manufacturing facility as dry substances, there's
much less threat from moisture environmental dangers and dust. An indoor construction
surroundings gives considerably fewer risks for accidents and other liabilities. There are strict
manufacturing unit strategies and processes that guard the employee from on-the-task injury.
At a construction website online, even though protection is of utmost importance, people are
subjected to weather-associated situations, changing floor situations, wind and other
crewmembers which can be on the web site.
(Factory Design for Modular Homebuilding. Smith, R. E. (11 Jan 2011). Prefabricated
Architecture: A Guide to Modular Design and Construction. )

5
2.1 Literature Review on Gypsum
2.1.1 Introduction
The abbreviation for glass fibre reinforced gypsum is GFRG. It’s far the name of a brand new
building panel product manufactured from gypsum plaster bolstered with glass fibres and it's
also referred to as fast wall in the industry. This product is suitable for speedy mass-scale
building creation, became at first evolved, and was used in view that 1990 in Australia. GFRG
is of precise relevance to India. There is a first rate need for value-effective mass-scale low-
priced housing, and gypsum is amply available as an industrial spinoff waste. The product isn't
best ecofriendly or inexperienced, however is likewise proof against water and fireplace.
2.1.1 Glass fibre reinforced gypsum
GFRG panels are currently manufactured with a thickness of 124 mm, a length of 12m and a
top of 3m. Although its important application is in the construction of wall, it could
additionally be used in ground, and roof slabs in mixture with the bolstered concrete. The
panel includes cavities that can be packed with concrete and reinforced with steel bars to
provide electricity and ductility. The panels can be unfilled and partly filled or fully full of
reinforced concrete.
The principle distinction among dewatered and non-dewatered GRC is the difference in
density and it has effects. First of all, even though the fibre content by way of weight is the
identical and higher density of the dewatered board gives a higher fibre extent fraction giving
better strengths. Secondly, the dewatered board has higher compaction and reduced
porosity, which offers higher fibre/matrix bond electricity.
2.1.2 An overview of GFRG wall panel systems
Glass fibre reinforced gypsum, abbreviated as GFRG, which is better referred to as rapid wall
inside the enterprise, is the name given to a new constructing panel product that is fabricated
from gypsum plaster and strengthened with glass fibres. GFRG is of specific relevance to India.
There’s a extraordinary need for price-effective mass-scale low-priced housing wherein
gypsum is amply available as an industrial derivative waste. The product is not most effective
green or inexperienced, however additionally resistant to water and fireplace.
( https://www.allacronyms.com/GFRG/Glass_Fibre_Reinforced_Gypsum )

6
Figure 1: load carrying capacity of GFRG panels

2.1.3 Project Details about GFRG

A storey building in Kochi is chosen, carried out by using a Kerala based enterprise Sheghram
Nirman Pt. Ltd. the construction approaches and strategies are determined, that are getting
used for GFRG panel’s construction, the complete cost and estimation of constructing,
applicable techniques used for panel manufacturing, analysis, and duration of the each detail
of building. A detailed case study of contrast among the traditional constructing and GFRG
panel constructing in the most important factors is made..1. Cost
2. Time
3. Quality
4. Quantity
B. Type of Building: two Storey Building
C. Type of Construction: Rapid wall construction with GFRG panels
D. Area: 1500 Sq.ft

2.1.4 Applications of GFRG

GFRG building panels are generally used in the following ways.
1. As load bearing walls in buildings, to resist the gravity load.
2. As partition or infill walls in multi-storeyed framed RC structures.
3. as compound walls in combination with minimum quantity of concrete.
4. As shear walls, resist both gravity load and lateral load from earthquakes and wind as walls
of lift well and parapet walls.
5. As floor slabs / roof slabs, pitched roof slabs and staircase waist slabs and mid-landing slabs.
2.1.5 ADVANTAGES OF GFRG
1. High speed of construction.
2. More carpet area for the same built-up area- thickness of wall panels is only 124mm.
3. Less embodied energy and carbon footprint has significant reduction in use of steel,
cement, sand, and water.
4. Less cost of construction and savings in materials and no cement plastering.
5. Less building weight, thereby reduction in design for seismic forces and savings in
foundation in multi-storeyed buildings.
6. 8 to 10 storied buildings can be designed using GFRG panels and without the need of
conventional RC beams and columns.

7
7. Very good finishes of GFRG buildings: use of factory made panels for all the walls, floors,
and staircases.
8. Less CO2 is emitted compared to other conventional building materials.
9. Better thermal comfort inside GFRG building than conventional buildings.
10. Since gypsum is a hard material, there is no creep in the GFRG panel, so it is major asset
of this type of construction.
11. In this Rapid wall system, there is no volume change even at high temperature.
12. The movement of moisture through concrete structures is dampness. There is no
dampness problem in GFRG panel wall system.
13. The durability of this rapid wall system is same as the RCC construction.
2.1.6 Disadvantages of GFRG
1. You do need some expertise in order to make a house using this technology. The handing,
fixing and equipment required for these panels is different from conventional style. Although
it is not very difficult to learn, the right techniques and it will eventually take time for
becoming and industry trend
2. The Panels are customized according to the design and drawings of your house when
manufactured. Unfortunately, you cannot make many changes during the fixing stage. Hence
planning is important. In addition, the doors, windows and other openings are made by
cutting through the panels, hence the planning for placing doors and windows need to be
extensive.
3. In India, if you are looking to do a construction in a normal populated area, it is very likely
that your plot is already surrounded by built house. The GFRG technique needs empty spaces
around the plot so that cranes can be placed while fixing panels. In addition, the panels need
special care while storing them and need more space as compared to cement/blocks. These
two factors make it difficult for a full-scale implementation in India Empty space to store and
move Panels is needed.
4. The fact that panels are specifically made for a design and is transported from factory, the
price of each type of panel goes done significantly only when used on a large scale.
Comparatively you can save 25–30% compared to that of conventional building method and
more if used on large scale. (https://www.scribd.com/document/371764803/GFRG-jorn)
2.1.7 Conclusion about gypsum
From this, we finish that conventional buildings are extra high-priced when as compared to
panel gadget. The panels has properly existence span as identical as concrete systems.
Nowadays using panels for creation is evolving regularly. Still most people aren't privy to this
form of creation practices for residential homes. From this assignment, we are able to deliver
some attention approximately the construction of panel systems approximately the price,
time control, useful resource allocation and exceptional and amount of GFRG. The main
motto of this assignment is to create focus among human beings approximately the
development at low-priced rate.
GFRG can be efficaciously used for the whole superstructure of buildings, such as all walls,
slabs, staircases, parapets, and many others. This constructing system has many benefits over

8
traditional buildings. GFRG buildings have the ability to satisfy the challenges of presenting
fast cheap mass housing. This is an green and sustainable constructing device, which uses
recycled business waste gypsum or natural gypsum and minimising using cement, steel, sand,
water and labour enter. This technology is now gaining reputation in India and all over other
Asian nations.

2.2 Literature review on steel

This is the maximum seen shape of creation for steel buildings. it is so named for the reason
that the profile of the metallic beam appear to be a letter "I", solid out of steel like a railroad
music rail (only tons bigger). This tool is likewise known as "inflexible frame" or "pink iron"
metallic building. A metal main body truss is the help for the constructing. each truss includes
four sections: sidewall sections and roof sections. After assembly on the ground, every solid
metallic "I" beam truss is raised after which added down (or bolted) to the concrete basis. An
everyday spacing among trusses is usually 25-30 ft (6-10 meters).2.2.1 Advantages of steel i
beam buildings
* Common type of building system, generally readily available.
* A common building system to most in the construction/contracting/steel building business.
* Quick assembly and erection
* Wide variety of colours available
* Few width limitations, that is, you can do huge "monster" type buildings with clear span
widths of 100 to 200+ feet (30-60 meters).
* Can be cost effective
* Can accommodate higher load requirements
* Generally no interior support posts or columns needed.
* Low roof slope makes the profile less obstructive
* Does not need a slab floor, can be installed on foundation piers (for example, a riding ring
that would not have a interior concrete slab floor)
2.2.2 Disadvantages
* Usually limited to a simple "box" shape with little or no roof pitch (slope) or unique
configurations beyond a square or rectangle, and usually with no exterior options other than
steel sheeting (usually what we see around.)
* Usually requires a crane or heavy apparatus, and sometimes on-site welding, depending on
the size of the building and the degree of pre-engineering done by the builder.
* Some systems need that insulation be done only at the time the building is erected. If
fiberglass bat insulation is used (this is the most common method) then some of R-value of
the insulation is lost at all the compression points since the fiberglass insulation is sandwiched
between the trusses and the outside sheeting.

9
* Some steel I-beam building systems aren't really designed for the "do-it-yourself" market
(especially large buildings), but are presented as such
* May be required to pre-drill all the holes in the exterior steel sheeting for the attachment
of the steel panels to the side girts and roof purlins
* Many are sold through broker (which is perfectly OK -- just make sure you know who you
are dealing with and exactly what you are buying.)

Figure 2:Forces experienced by structures

(CRITERIA FOR SELECTION OF PREFAB IN INDIA- BY P.K.ADHLAKHA & H.C.PURI)

Figure 3 : Gravity and wind loads taken by steel structures

(CRITERIA FOR SELECTION OF PREFAB IN INDIA- BY P.K.ADHLAKHA & H.C.PURI)

10
2.3 Literature review on ALC panels
ALC Panel – Autoclaved lightweight Concrete Panel is the following technology flexible
inexperienced constructing material of desire for constructing community, which comes with
a number of Technical and useful blessings that trigger a love for this cloth among the creation
specialists and workers. The fabric is appropriate and proved to be a tremendous
constructing fabric for structures consisting of residential, commercial, and business and
warehouse buildings, inns, faculties and hospitals, and so on. In any terrain and all climatic
situations. it is used for each outside and internal partitions, load bearing and non-load
bearing partitions, basement walls, infill partitions to framed structures, celebration
partitions, fire break partitions, etc. It’s also used as a precast ground/ decking / roof.

ALC Panel Product kinds: ALC, unlike traditional concrete masonry units (“CMU”), is a solid
panel /cloth gadget with integrated insulation and structural components, and is to be had in
a selection of products that can be utilized in each load and non-load-bearing programs.
complete load bearing applications, however, are confined to low-upward thrust creation,
although cladding and large panels are to be had to take advantage of ALC’s insulate, fireplace
proofing, and other advantages on mid- and excessive-upward thrust initiatives. Moreover,
the big wall, ground, and roof panels, measuring up to ten feet lengthy, 2 toes extensive, and
in diverse thicknesses, are also utilized in load-bearing capacities and are commonplace in
commercial and industrial applications. ALC Panels, additionally known as “units” are stacked
the use of skinny-set mortar, as opposed to the conventional cement-based mortar used in
CMU construction.
2.3.1 ALC Panels
Due to ALC’s layout flexibility and mixed structural and insulation additives, a whole shape
can be constructed the usage of the only fabric. outside surfaces can be finished with skim
coat, conventional veneers or siding, while interior partitions may be skim coated, painted,
or left unfinished, similarly to conventional sheet rock finishes.
Further, ALC is easy to use and can be cut and manipulated with ordinary wooden-working
tools. ALC panels are made With cement, lime, Silica Sand as raw materials, adopting -manner
and welded metallic reinforcement mesh (reinforcing bar) processed through special anti-rust
liquid, produced in high temperature, high stress and steam curing, it’s a type of porous
silicate plate of high performance, and has many incomparable performances of good fire-

11
resistance, fire prevention, sound insulation, heat insulation, thermal insulation and so forth.

Figure 4: ALC panels ready for transportation in plant in Chennai (DLC Limited site)

2.3.2 Advantages of steel ALC panels

The usage of the ALC, the construction work may be elevated to obtain a more quantity of
time performance. By using the proper tools the construction can be mechanized to growth
the labour efficiency and faster creation.
A higher hearth score of three-four hours can be done for the buildings constructed using
ALC. (The R cost is 1.2 in keeping with inch and as a result a four inch or 100mm thick ALC
Panel wall could gain an R fee of four. Eight whereas the identical 4inch Concrete wall has an
R value of simplest 2. which results in an ideal thermal insulation, that is 6 to 10 times better
than normal concrete. This enables keep on the strength fee notably.
Forty-forty eight dB of sounds are filtered by means of the ALC panels, which makes it
certainly acoustic. Perfect for resorts, hospitals, classified ads and multifamily.
The lightweight nature of this product helps reduce the dead load of the building
considerably. The density of this material is 1/4th of Concrete.
No Air Cracks inside the completed homes, which reduces the general protection costs for the
constructing in the long run.
The products are tested and authorized through the renowned laboratories like SGS, TUV,
and SETSCO….and so on, which isn't the case in the traditional constructing fabric.
Accelerated comfort and capability
Massive size of the panels assist do away the construction with much less quantity of joints.
Due to the mild weight nature, much less manpower and their attempt is required for
construction.
True Workability – approach operating on conduits and fixing service lines etc becomes easier
with this product.

12
The reinforcement with Galvanized steel mesh gives additional power to the panels
Long sturdiness: proof against rot or pest, and this material has been in use for over eighty
years
As this cloth has a high load-bearing electricity – it becomes the selection for all sort of
partitions: external and internal, load bearing and non-load-bearing, basement, and fireplace
ruin walls … and many others.
This is an environmental pleasant constructing material as it's miles non-poisonous. The
wastage is minimal and negligible and the whole fabric is reusable and recyclable.
As this fabric has a excessive load-bearing strength – it becomes the selection for all kind of
walls: outside and internal, load bearing and non-load-bearing, basement, and fire break walls
… and so on.
(http://www.parivarta.com/alc-panel/)

3.0 METHODOLOGY
The method I followed during this process is explained in this chapter. Firstly I started
with getting a brief idea on how steel and gypsum/ALC structures are designed, fabricated
and erected, and also various methods in constructing these structure. This study was to build
a base knowledge about my topic so that all his homework will help me for further study and
interviews. This base study was done from reading books, eBooks and construction videos on
internet. The second stage is doing case studies, in which literature case studies comes first,
I opted to finish the literature case studies first because all these work helped me to build a
basic knowledge on the construction techniques of steel structures, which later helped me
for easy communication with designers and labours. After finishing the literature case studies
comes the live case studies. For that, first I identified the buildings which came under my
scope and shortlisted it into three buildings. A questionnaire was prepared for both the
designers and the occupants for the structure which will ease the data collection. And by
schematically analysing and comparing the data collected from the designers, occupants and
my personal observation I came to a concluded the study.

Overview:
1. Secondary data collection
 Literature case study about steel and gypsum residential building.
 Finding how does the steel and gypsum work as a major construction material
and its advantages and disadvantages over conventional method.
2. Primary data collection
 Questionnaire preparation from the inferences of literature review.
 Interactive section with contractors and engineers.
 Live case studies of selected on both conventional and prefabricated
method.

13
  Online interaction with company managers of particular companies and
practicing engineers.
 Interactions with occupants of these case studies.

Table 2: Methodology

3.1 Data sources and data types

Secondary data collection
 Literature cases studies

 One literature case study is done on gypsum and steel residence.

SHUNYA, Sec-107, NOIDA
 SHUNYA well maintained energy efficient building with structure made
of steel and internal and external partitions with gypsum

Primary data collection

 Questionnaire preparation from the inferences of literature review and

literature case studies.

 Live case studies.

 Five live case studies were done, three case study for pre-fabricated in which
one is a renovation project and two case study for conventional method
1) Residence for Mr.Rajagopalan Namboothiripad @ Guruvayoor
2) Residence for Mr.sajeevan at Thrissur
3) Residence for Mr.shaji at Perinjanam ,Thrissur (Renovation )
4) THE HOUSE OF NIVRITI THRISSUR(Conventional method )
5) BREEZE HOUSE ALAPUZHA (Conventional method )

14
  Interactive section with contractors and engineers and architect of the
selected projects.

- Conducted Interview with two contractors in Kerala with more than

20 years of experience, with two engineers and one young architect
in Kerala.
- Conducted telephonic interview with a managing directors and
engineers of the particular products.
- The primary data was collected for the research is from interviews
with to contractors from Trissur who have more than 20 yrs. of
experience and two young engineers.

Table 3.: Data sources and data types

Data sources and Data types
 From interviews with to contractors from Thrissur who
have more than 20 yrs. of experience and two young
engineers .
Secondary
data collection  Literature review

 CRITERIA FOR SELECTION OF PREFAB IN INDIA- BY

P.K.ADHLAKHA & H.C.PURI

 PREFABRICATION IN DEVELOPING COUNTRIES: A CASE

STUDY OF INDIA, by Ryan E. Smith

 Literature case studies

 SHUNYA, Sec-107, NOIDA

 Questionnaire preparation
-For the interactive section with architects and structural
engineers and contractors.
-Conducted telephonic interview with managing directors
and engineers of the particular products.
 Live case studies

 Residence for Mr.Rajagopalan Namboothiripad @

Guruvayoor

15
 Primary data  Residence for Mr.sajeevan at Manjeri
collection
 Residence for Mr.shaji at Perinjanam ,Thrissur
(Renovation )

 THE HOUSE OF NIVRITI THRISSUR(Conventional method )

 BREEZE HOUSE ALAPUZHA (Conventional method )

 Interactive section
-with young architects in Kerala, with two young
engineers in Kerala and two contractors.

3.2 Data collection

3.2.1 CASE STUDY– LITERATURE

 3.2.1A SHUNYA, Sec-107, NOIDA

Figure 5: Front view from the courtyard (Behera, P. (2017). Presentation on Prefabricated
Structures & Prefabrication – Concept, Components & Advantages.)

SHUNYA is a 0 power prefab residence by means of the organization 3C. Its miles an internet-
0 power domestic is that which works on the principle of making use of maximum renewable
strength, and is independent of any strength grid, and preserves the energy that it consumes.
SHUNYA is broadly speaking constructed with old refurbished substances like antique
shipment packing containers, antique metallic sections, GFRG panels packaged timber, and
vintage furniture. It achieves extra than 70% financial savings in electric energy in comparison
to a conventional building of the same climatic area; nearly forty% financial savings in electric
energy is thru passive power conservation strategies. It has additionally included a courtyard

16
that serves as a number one source of (electricity) mild and herbal ventilation and has sun
shades with louvers designed optimally for summer and wintry weather climate.

Figure 6: Concept behind the design

It is constructed using four cargo containers, which are welded and bolted to each other .The
doors, windows have been cut through these containers.

Figure 7: The truss is covered with angled louvers, which let in ample amount of light and let
us hot air out (Behera, P. (2017). Presentation on Prefabricated Structures & Prefabrication
– Concept, Components & Advantages.)

MATERIALS USED
 Local materials used including locally available materials and maximum materials are
reused.
 steel and wood and GFRG Panels as main materials
 columns
 frame

17
  truss
 finishing material
• WOOD

 interior walls
 finishing material
 beams
 GFRG Panels are used as main material for partition of walls

3.2.2 Outcomes
Prefabrication era has no longer transferred as without problems whilst as compared with
different technologies because it's miles a manufacturing technology or information
primarily based and not a intake era or product primarily based. Technology switch of
prefabrication isn't always as pertinent to architects as it is far to producers of constructing
products, however we're caretakers of way of life inside the AEC industry. in many cases,
have been requested to help with among the transfers that are happening by using way of
worldwide exercise or running for multi-countrywide companies which are generating
prefabricated additives and complete buildings for India and elsewhere. Even though
transfers will retain to occur, especially in the place of prefabrication in building, we need to
be well aware of how the selections of U.S. and western architects may also have a62effect
on the moral dilemmas regarding less evolved international locations’ development and
subculture.
the usage of prefab can help to achieve outcomes for the society’s immediately needs due
to the fact the fast changing surroundings, commercial enterprise, economics,
industrialization, residential desires, settlements and lots of different factors of
transportation like bridges, towers, railways calls for fast settlement and requirement for
buildings, places of work and industries, for this reason prefabrication is the solution for
immediate and time saving production
Table 3. Comparison between prefabricated (GFRG) and conventional building
Materials/items Prefabricated building Conventional
building

Cement 16 tons 32.55 tons

Steel 1800 kg 2779 kg

Sand 20 cum 83.87 cum

Granite 38 cum 52.46 cum

Brick - 57200

18
 GFRG panel 500 sum

Water 50000 liter 200000 liter

Labour 389 man days 1200 man days

Construction time 21 days 120 days

Wt. of superstructure 170 tons 490 ton

Construction cost

Rs. 13.25 lakhs 18.27 lakhs

Table 4: Comparison of construction time

S. No Item of work RCC (in days) GFRG(In
days)
1 EARTH WORK EXCAVATION 2-4 2-4
2 PCC 2-3 2-3

3 BRICK WORK IN FOUNDATION 5-7 5-7

4 DPC 2-4 2-4

5 COLOUMN 9-10 -

6 WALL 10-15 2-4

7 BEAMS 15-18 -
8 LINTEL /SUNSHADE 4-5 2-3

9 SLAB 28 14

10 PLASTERING 10-12 --

11 WHITE WASH 3-4 -

12 COLOUR WASH 2-3 2-3

13 FLOORING 3 3

TOTAL DURATION 98-120 35-45

19
The idea is to study the following aspects in steel and gypsum residential buildings and
compare it with the conventional residential buildings, keeping the following areas as key
aspects.
• Space optimization. – Land values are increasing at alarming rates each day in every
city undergoing the process of development and Kerala is no exception. Thus in this present
scenario, optimization of whatever little space available is of clear importance to save space,
money as well as resources. This can be achieved in various ways like; inducing design
strategies by minimalizing waste of space in the design or even by thoughtful use of materials/
finishes/ furniture etc. In this time of decreasing land availability and the increasing demand
for it, space optimization is now an essential tool for designing in whatever limited spaces
available. A conventional method of construction may not always fulfil the space
requirements of the users/ designers, which demands for newer technologies/ materials/
installations that can withstand the crisis of space limitation.
• Aesthetics and Visual impacts – Although the visual interests can vary from person
to person , as to what they prefer to see through their eyes, the general finish of the type of
construction matters; whether it is neat , eye pleasing, availability of colours and textures etc.
• Flexibility and use of space - A same space can be interpreted/ used in different ways,
depending on its users. The intended use, at the time of designing/construction, of a
particular space can change over the years based on user demands, especially in today’s fast
growing era. Thus it is important for spaces to be open to changes over time or anytime in
future. Construction techniques supporting these provision of future changes, by reducing
the demolition need / ease in installation etc., are recommended in today’s construction by
many designers as well as clients.

4.0 RESULT
4.1 CASE STUDY – LIVE

1. Preparing questionnaires
Individual questionnaires were prepared for architects / designers and occupants. case
studies will be done , on from pre-fabricated building and other from conventional building
typology which will help me to compare the typologies in same locality and can come to a
better result. Two type of questionnaires are prepared for the designer. One is normal
interview questions and the other is for them to rate, this will ease in reviewing the results
too.
Occupants will be having the ratting and yes or no questions. Their opinion for the same
questions is also noted.
QUESTIONS FOR DESIGNER.
1. Can you give a brief idea on the project?
2. Why did you choose steel & ALC over conventional RCC framed structure?
3. What are the advantages of these materials over the conventional method?
4. Can you please explain the quality of spaces in this residence?

20
 5. How did using of steel & ALC helped you in optimisation of space?
6. How did using these materials affect the elevation or aesthetics of the building?
7. How does the use of these materials affect the flexibility in use of space?
8. Would you choose again for further of your projects?
9. Can you please explain about the usability and about client satisfaction?

Table : Rating Table

DESIGNER

QUESTIONS
1. Did the use of steel help you in space
optimisation?
2. How would you rate the use of steel and
ALC in achieving the visual impact of your
building in others?

3. How would you rate the flexibility of use

of space you have created?
4.Advantage over conventional method

5. usability and client satisfaction

6. Quality of spaces provided

7. overall aesthetics of residence

*Noted opinion if any.

QUESTIONS FOR OCCUPANT/ USER.

Table 6: Rating Table / user
1. User 1

2. User 2

21
 3. User 3

NO:

QUESTIONS
1 2 3
1. How will you rate the quality of
space of this building in 5 ?

2. How will you rate the building in

terms of aesthetics and visual
impact?

3. Have you felt any discomfort in

terms of discomfort and flexibility of
use of space?

4. Have you felt any kind of

discomfort because of the material
used for construction?

5. Would you recommend this

construction method and technology
to others?

6. What is the main objective for

choosing the particular construction?

4.2 Electing appropriate buildings for case study

By this reserch I am aiming to study and analyse the conceptual design factors and comparing
the prefabricated residential building with the conventional building of steel and ALC
structures in kerala , and unerstand how these materials can solve the present problems in
residential building construction . As I am only looking to 3 factors that influence the
conceptual design which is space optimisation, aesthetics and visual impact and flexibility of
use of space, and for comparing the building I hav shortlisted 2 buildings which is in thrissur
and which has all three factors satisfied.
4.2.1 Prefabricated residential building
1) Residence for Mr.Rajagopalan Namboothiripad at Guruvayoor
2) Residence for Mr.sajeevan at Manjeri

3) Residence for Mr.shaji at Perinjanam ,Thrissur (Renovation )

22
4.2.2 Data collected from case studies.
1) RESIDENCE FOR MR.RAJAGOPALAN NAMBOOTHIRIPAD @ GURUVAYOOR

Figure 8: Residence for Mr.Rajagopalan Namboothiripad

DESIGNER/ BUILDER
Er.Pradeep Nair (GREEN LIFESTYLE CREATOR P.LTD CHENNAI )
OCCUPANTS
1. Mr.Rajagopalan Namboothiripad (Owner)
2. Mrs.Reeja Rajagopalan (wife)
3. Rajeev (son)

Interview with designer (Pradeep Nair)

Q1. Can you give a brief idea on the project?

Ans: This was the first prefabricated residential building with ALC and Steel, in Kerala.
So my objective was to make it as unique as possible in a budget that the owner would take.
As it was the first residence in Kerala we had to face many queries and ensure clarity of the

23
methods to be followed, before actually starting the construction. But despite those
challenges, we were able to successfully complete the project within the intended schedule.
Q2. Why did you choose steel ALC over conventional RCC framed structure?
Ans: Ours is an established company in India, which mainly focused on the
construction of commercial buildings with steel gypsum and ALC. The design requirements
of this project and its space availability, lead me to choosing steel gypsum and ALC type of
construction. Also, prefabricated construction is fully fledged in the commercial sector of
Kerala and not so much in the residential sector, so I consider this project as a stepping
stone for more designers and users to opt for alternate practices rather than sticking on to
the conventional methods of construction anytime and anywhere.
Q3. Did using steel and ALC help you in optimisation of space?
Ans: In conventional method, the wall sizes are normally 25 cm thick while using steel
and ALC it is only 15 cm thick, thus overall there will be a considerable increase in usable
space of the building. Also in prefabricated structures, the columns used are less and this
too helps in optimising the space available.
Q4. How did using these materials affect the elevation or aesthetics of the building?
Ans: Aesthetics is a subjective matter and there is no “correct” way of presenting it.
In this design steel and ALC have given the external façade a simple look without much
experimentation or ornamentation which satisfies the client as well. In general the use steel
and ALC may bring in a touch of typicality in terms of visual appearance, which could be
corrected through the choice of colours or textures used for finishes.
Q5. How does the use of these affect the flexibility in use of space?
Ans: In steel & ALC construction the walls are installed as panels and can be removed
or demolished easily compared to conventional methods of construction. So a space can be
reinterpreted in the future years by making slight alterations in the structure without
creating much havoc or structural instability. Also, there are very minimal amount of
columns and beams running inside the residence. So the flexibility of use of space is ensured
to a great extent.
Q6. Would you choose these construction again for further of your projects?

Ans: Sure yeah, if the site conditions and the project requirements are favourable. But
since transportation of prefabricated structures to the site are involved the budget
controlling was a problem. In my experience for a single dwelling house, this type of
construction is a little bit expensive. It is more suitable for large scale projects. Also the time
of construction and completion of the project was very less compared to conventional
methods of construction.
Q7. Are there any long term goals for using steel & ALC construction?

24
 Ans: Changing the use of space over time is a challenge that needs to be addressed in
today’s designs and this type of construction provides room for future alterations. In steel
& ALC construction the walls are installed as panels and can be removed or demolished
easily compared to conventional methods of construction. So a space can be reinterpreted
in the future years by making slight alterations in the structure without creating much
havoc or structural instability.
Q.8. Do you feel using steel & ALC helped in considerably reducing the overall cost of
construction?
Ans: The wall sizes in this type of construction are just 15 cm and thus there will be a
considerable amount of reduction in the materials required for construction, compared to
conventional methods. That being said, while considering the overall picture there isn’t
much of a difference in cost as the transportation and installation charges adds up as extra
in the end. Thus for large scale projects where a bulk amount of materials can be reduced,
this type of construction is cost effective, but not so much for small scale residential
projects.
Q.9. Does the use of Steel & ALC influenced the design of the building, during the primary
design stages?
Ans: Steel & ALC type of construction was fixed in the primary stages of design itself. This
helped in creating more room for usable spaces while keeping the total floor area intact.
Thus helping in reducing the waste of spaces and crating more spacious interiors.
Q.10.Are there any challenges/limitations you faced during the construction time?
Ans: The materials and prefabricated units used in this project are from our industry in
Chennai, so they had to be transported to the site in Kerala, which was one of the major
challenges faced in the project. Also reducing the budget cost low was a big challenge for this
scale of a building. In this project, one thing that could have been bettered are the details in
the finishes which would have improved the overall aesthetics of the building.

Figure 9: Conventional stair (interior )

PHOTO TAKEN DURING SITE VISIT

25
Figure 10: Residence for Mr.Rajagopalan Namboothiripad (interior )
PHOTO TAKEN DURING SITE VISIT

Figure 11: Modular kitchen

PHOTO TAKEN DURING SITE VISIT

Table 7:RATING TABLE (DESIGNER)

Er.Pradeep Nair (GREEN LIFESTYLE CREATOR P.LTD CHENNAI )

DESIGNER

QUESTIONS

1. Did the use of steel help you in space 3

optimisation?

26
 2. How would you rate the use of steel and 4
ALC in achieving the visual impact of your
building in others?

3. How would you rate the flexibility of use 4

of space you have created?

4.Advantage over conventional method 4

5. usability and client satisfaction 5

6. Quality of spaces provided 3

7. overall aesthetics of residence 3

* The detail is poor, some of the design elements have very less perfection. I propably
should have took the factor perfection more seriously.

Table 8: RATING TABLE (OCCUPANTS/ USERS)

Occupants
1. Mr.Rajagopalan Namboothiripad (Owner)
2. Mrs.Reeja Rajagopalan (wife)
3. Rajeev (son)
NO:

QUESTIONS
1 2 3
1. How will you rate the quality of 3 3 2
space of this building in 5 ?

2. How will you rate the building in 3 3 2

terms of aesthetics and visual
impact?

27
 3. Have you felt any discomfort in NO NO NO
terms of discomfort and flexibility of
use of space?

4. Have you felt any kind of YES YES YES

discomfort because of the material *bescause of the
used for construction? using of steel tress
in first floor ,
feeling hot in first
floor
5. Would you recommend this YES YES NO
construction method and technology
to others?

6. What is the main objective for Cost effective and Cost effective
choosing the particular faster construction and faster
construction? time construction
time

*No Air condition are used , although there is no problem in ground floor ,but feeling hot in first floor
because of the using of trussed roof. More compromises are done in the filed Aesthetics.

2) RESIDENCE FOR MR.SAJEEVAN AT MANJERI

Figure 12: On site execution of precast steel and columns

PHOTO TAKEN DURING SITE VISIT

28
FIGURE 13: At the stage of structure finishing * external walls are made of concrete blocks and
internal pration with gypsum boards. (Photo taken during site visit
DESIGNER/ BUILDER/ ENGINEER
Er. Anand P( MECHANICAL )
Er.Najeeb ( CIVIL )
An engineering consortium Manjeri
OCCUPANTS
1. Mr. Sajeevan (Owner)
2. Mrs.Seema (wife)
3. sooryanath (son)

Interview with designer

Q1. Can you give a brief idea on the project?

Ans: Actually the project is a budgeted home .so we decide to use these prefabricated
materials as main material. Were we can reduce so much of cost?
Q2. Why did you choose steel ALC over conventional RCC framed structure?
Ans: As the client wanted to finish the project as fast as possible. And also steel can
load more weight than that of concrete for large scale.
Q3. Did using steel and gypsum help you in optimisation of space?
Ans: Actually we are used gypsum panels for internal walls and concrete blocks for the
external walls. Internals walls have less thickness compared with the normal brick walls so
maximum carpet area can be utilized.
Q4. How did using these materials affect the elevation or aesthetics of the building?

29
 Ans: Actually we are using concrete blocks for the external walls. so the elevation can
be designed as normal as conventional method
Q5. How does the use of these affect the flexibility in use of space?
Ans: all the structure elements are made from our factory and only site level execution
is done from site and which take only 2 days for the execution in site. Each columns and
beams are individual blocks and each can be easily dismantled
Q6. Would you choose these construction again for further of your projects?

Ans: Sure yeah, we are promoting this method to other areas also. As cost of materials
are increasing day by day this will be a good method for people whose looking into budgeted
homes.
Q7. Are there any long term goals for using steel & gypsum construction?
Ans: the renovation in future years will be more easy in this method because each walls
and columns are modules and con easily modified . Also at time of renovation the waste
will be less compared to the conventional method
.
Q.8. Do you feel using steel & gypsum helped in considerably reducing the overall cost of
construction?
Ans: almost 5 lacks we saved in the structural stage when comparing with conventional
method. When coming to finishing stage it is dependable accordingly to the products we are
using.
Q.9. Does the use of Steel & gypsum influenced the design of the building, during the
primary design stages?
Ans: No. At first stage discussion itself we are fixed with this method.
Q.10.Are there any challenges/limitations you faced during the construction time?
Ans: security was the main concern for the client so we are used concrete blocks for the
external walls.

Table 9:RATING TABLE (DESIGNER)

DESIGNER/ BUILDER/ ENGINEER
Er. Anand P( MECHANICAL )
Er.Najeeb ( CIVIL )
An engineering consortium Manjeri

30
 DESIGNER

QUESTIONS

1. Did the use of steel help you in space 4

optimisation?

2. How would you rate the use of steel and 4

gypsum in achieving the visual impact of your
building in others?

3. How would you rate the flexibility of use of 4

space you have created?

4.Advantage over conventional method 4

5. usability and client satisfaction 5

6. Quality of spaces provided 3

7. overall aesthetics of residence 3

Table 10:RATING TABLE (OCCUPANTS/ USERS)

OCCUPANTS
1. Mr. Sajeevan (Owner)
2. Mrs.Seema (wife)
3. sooryanath (son

NO:

1 2 3

QUESTIONS

1. How will you rate the quality 5 5 4

of space of this building in 5 ?

2. How will you rate the 4 4 3

building in terms of aesthetics
and visual impact?

31
 3. Have you felt any discomfort NO NO NO
in terms of discomfort and
flexibility of use of space?

4. Have you felt any kind of NO NO NO

discomfort because of the
material used for
construction?

5. Would you recommend this YES YES NO

construction method and
technology to others?

6. What is the main objective We wanted to

for choosing the particular complete the
construction? project as fast as
possible

3) RESIDENCE FOR MR.SHAJI AT PERINJANAM

PREFABRICATED RESIDENTIAL BUILDING/ RENOVATION

FIGURE 14: On site execution of precast steel and columns

PHOTO TAKEN DURING SITE VISIT

Table 11 :RATING TABLE (DESIGNER)

BUILDER/ ENGINEER
Er. Jos Kattukkaran Er.Najeeb ( CIVIL )
Kattukkaran Architectural Solutions Thrissur

32
 DESIGNER

QUESTIONS

1. Did the use of steel help you in space 4

optimisation?

2. How would you rate the use of steel and 4

gypsum in achieving the visual impact of
your building in others?

3. How would you rate the flexibility of use 4

of space you have created?

4.Advantage over conventional method 4

5. usability and client satisfaction 5

6. Quality of spaces provided 4

7. overall aesthetics of residence 4

Table 12:RATING TABLE (OCCUPANTS/ USERS)

OCCUPANTS
1. Mr. Shaji (Owner)
2. Mrs.Mini (wife)

NO:

1 2

QUESTIONS

1. How will you rate the quality 4 4

of space of this building in 5 ?

2. How will you rate the 4 4

building in terms of aesthetics
and visual impact?

33
 3. Have you felt any discomfort NO NO
in terms of discomfort and
flexibility of use of space?

4. Have you felt any kind of NO NO

discomfort because of the
material used for
construction?

5. Would you recommend this YES YES

construction method and
technology to others?

6. What is the main objective As we are

for choosing the particular renovating the old
construction? house we have
concern about the
structural stability

4.3.1 Conventional residential building

 1) Rsidence for Mr.Sujith at Thrissur

 2) Rsidence for Mr.Shyne at Alappuzha

4.3.2 Data collected from case studies.

1) Rsidence for Mr.Sujith at Thrissur

34
Figure 15: Residence for Mr.Sujith @ Arimboor , Thrissur
Architect
Ar. Manuraj CR (i2a Architects Studio)
Occupants
1. Mr.Venu (Owner)
2. Mrs.Hema (wife)
3. Mr.Sujith ( son)
Interview with designer (Ar. Manuraj CR)

Q1. Can you give a brief idea on the project?

Ans: “HOUSE OF NIVRITI” means the house of bliss, which was designed to provide joy and
happiness for its residents. The main concept was to create a connection between the
building and nature .So it is designed in such a way that it responds to the aspects of site
context and climate.. The abundance of natural light inside & proper ventilation brings in fresh
flow of air and enhance living experience of the habitat. The design was approached to
incorporate traditional aspects as much as possible, as per the client’s requirements.
Q2. Why did you choose conventional RCC framed structure?
Ans: The design was an attempt to bring in maximum traditional elements possible, as per
the client’s requirements. Thus conventional RCC structure was the best option which
would easily blend in with the building’s concepts. Any other alternative ways like
prefabricated structures would’ve been a misfit to the theme of design.
Q3. How did this affect the optimisation of space inside the house?
Ans: All the walls are load bearing walls and hence are 25 cm thick. There were challenges
while designing certain spaces inside the house, to increase the usable space. But by
designing spaces linked to one another, without completely dividing them with a wall,
openness was achieved in the design.
Q4. How did using this conventional method affect the elevation or aesthetics of the
building?
Ans: The concept of the building rooted back to the traditional Kerala construction and the
conventional method of construction was the ideal option for the project. The mixture of
exposed bricks and cement finished walls in the exterior , together blended with the
traditional clay tiles on the roof pulled of a rustic traditional look for the house.
Q5. Was flexibility in use of space considered while designing the project?
Ans: As the walls are all load bearing, future alterations or extensions in the design may
affect the structural stability of the building and would be a great risk to do so. Only
adaptive reuses of space like the change in interior furniture or partition walls may can be
made to make the spaces flexible.

35
 Q6. Would you choose this approach again for further of your projects?
Ans: It will depend on its locality context, project requirements and its scale. For
constructing a normal residence in Kerala context, conventional RCC framed structures
would be ideal, considering the transportation and labour charges required for other
alternative methods like steel & ALC construction.
Q7. Are there any long term goals for using conventional method of construction?
Ans: The building will have a strong life expectancy for many years and many columns and
RCC framed structures are used in this conventional method of construction. Although
future building alterations would be a difficult task as it can affect the building’s structural
stability.
Q.8. Has this method in any way helped in considerably reducing the overall cost of
construction?
Ans: The project was completed within the client’s targeted budget and no extra expenses
were made. Transportation charges and other installation charges associated with
prefabricated type of construction were reduced here, as most of the construction
materials and labour came from nearby distance of the site.
Q.9. Have this method affected the design of the building, during primary design stages?
Ans: During the design stages, increasing usable spaces in the design with minimum wall
partitions was a challenge, as the structural stability was to be taken care as well. The
spaces were designed keeping the wall thickness 25 cm everywhere and was able to
successfully render the client’s requirements.
Q.10.Are there any challenges/limitations you faced during the construction time?
Ans: There weren’t any big challenges, but preserving the existing vegetation of the site
was an essential challenge which I was able to overcome successfully.

Table 13:RATING TABLE (ARCHITECT)

ARCHITECT
Ar. Manuraj CR (i2a Architects Studio )
QUESTIONS DESIGNER

1. How you zoned residence to this small plot? 2

2. What about the space optimisation in this project 3

?

3. How would you rate the flexibility of use of space 3

you have created?

36
 4. Why don’t you recommend other methods? 2

Advantage over prefabricated method

5. usability and client satisfaction 4

6. Quality of spaces provided 4

7. overall aesthetics of residence 4

RATING TABLE (OCCUPANTS/ USERS)

OCCUPANTS

1. Mr.Venugopalan (Owner)

2. Mrs.Hema (wife)

3. Mr.Sujith (son)

Interview with users

Occupants
1. Mr.Venu (Owner)
2. Mrs.Hema (wife)
3. Mr.Sujith ( son)
Q1. Was there any demands from your side on space optimisation while discussing with the
designer?
Ans: We wanted spaces that could enhance the family bonding like in traditional buildings
and we are happy be the design of the house – keeping the central courtyard connected to
the dining as the energy core of house.
Q2. Now that the project is complete, do you feel your needs have been fulfilled in a
thoughtful way?
Ans: Absolutely. We wanted a house that would help us connect with nature and the older
generations, keeping the traditions intact and that is exactly what we got.
Q3. Does this method of construction chosen by the designer affect your desired aesthetical
quality of the building in any way?
Ans: The conventional style of construction have added to the beauty of the traditional
themed elevation and design of the building, which the designer has successfully rendered.

37
Q4. Do you feel the spaces of your home are capable of adaptive reuse?
Ans: We haven’t planned of any future alterations or extensions as of now, although if needed
an extra room could be added in the present open terrace area of the house.
Q5. Are there any challenges/ discomfort you face as dwellers?
Ans: we don’t face any challenges/ discomfort, in fact we feel living a step closer to the nature
now.

Figure 16: Dining space of Residence for Mr.Sujith @ Arimboor , Thrissur

Table 14:RATING TABLE (OCCUPANTS/ USERS)

QUESTIONS USER1 USER2 USER3

1. How will you rate the quality of 4 5 5

space of this building in 5?

2. How will you rate the building in 5 5 5

terms of aesthetics and visual
impact?

3. Have you felt any discomfort in NO NO NO

terms of discomfort and flexibility
of use of space?

4. Have you felt any kind of NO* NO NO

discomfort because of the material
used for construction?

38
2) Rsidence for Mr.Shyne at Alappuzha

Figure 17: Residence for Mr.Shyne at Alappuzha

Architect
Ar. Arjun KJ (i2a Architects Studio )

Occupants
1. Mr.Shyne (Owner)
2. Mrs.Soniya (wife)
3. Father
4. Mother
Table 15:RATING TABLE (DESIGNER)
ARCHITECT
Ar. Arjun KJ (i2a Architects Studio

DESIGNER

QUESTIONS

1. How you zoned residence to this small plot? 3

39
 2. What about the space optimisation in this 3
project ?

3. How would you rate the flexibility of use of 3

space you have created?

4.Why don’t you recommend other methods? 4

Advantage over prefabricated method

5. usability and client satisfaction 3

6. Quality of spaces provided 4

7. overall aesthetics of residence 4

Table 16:RATING TABLE (OCCUPANTS/ USERS)

OCCUPANTS

1. Mr.Shyne (Owner)

2. Mrs.Soniya (wife)

3. Father

4. Mother

NO:

1 2

QUESTIONS

1. How will you rate the quality of space of 4 4

this building in 5 ?

2. How will you rate the building in terms of 4 4

aesthetics and visual impact?

40
3. Have you felt any discomfort in terms of YES YES
discomfort and flexibility of use of space?

4. Have you felt any kind of discomfort YES YES

because of the material used for
construction?

5. Would you recommend this construction YES YES

method and technology to others?

5.0 DISCUSSION
5.1 Based on live case study on pre-fabricated residences
DESIGNER 1 DESIGNER 2 DESIGNER 3 TOTAL( 15)

QUESTIONS

1. Did the use of steel help you in space 3 4 4 11

optimisation?

2. How would you rate the use of steel and 4 4 4 12

gypsum in achieving the visual impact of your
building in others?

3. How would you rate the flexibility of use of 4 4 4 12

space you have created?

4.Advantage over conventional method 4 4 4 12

5. usability and client satisfaction 5 5 5 15

6. Quality of spaces provided 3 3 3 9

7. overall aesthetics of residence 3 3 3 9

41
Table 17: Comparison

CASESTUDY 01
Space
optimization 3 4
Aesthetics

Flexibility
4 3
use of space

CASESTUDY 02
Space
optimization 5 4
Aesthetics

Flexibility

3
use of space 4

CASESTUDY 03
Space
optimization 4 4
Aesthetics

Flexibility

use of space 4 3

42
 • Flexibility
and use of
OVERALL CONCLUSION
space AGE ABOVE 50
40% 14%
AGE BELOW
30
14%

Aesthetics
• Space 20%
optimization
36%
• Space optimization • Flexibility and use of space
• Aesthetics and Visual impacts. AGE ABOVE 50
AGE BELOW 30

5.2 Based on live case study on conventional residences

CASESTUDY 01
Space
optimization 4
3
Aesthetics

Flexibility

3
use of space 2

43
 CASESTUDY 02
Space 5
optimization 3
Aesthetics

Flexibility
2
use of space 4

OVERALL CONCLUSION
AGE ABOVE 50
• Space optimization
40%
• Flexibility and
use of space • Flexibility and use of
20% space
• Aesthetics and Visual
impacts.
Aesthetics AGE ABOVE 50
• Space 60%
optimization
20% AGE BELOW 30
AGE BELOW 30
20%

5.3 Based on interactions with practicing architects in kerala

1. Ar. Manuraj CR (i2a Architects Studio )

2. Ar. Arjun KJ (i2a Architects Studio )

3. Ar. Levin P Joy (Finder studio )

4. Ar. Josaph Josaph Chalisery (Dream infinite studio)

44
 5. Ar. CS Menon ( CS MENON Associates )

QUESTIONS 1 2 3 4 5

1. Have you done any project with pre NO YES NO NO NO

fabricated construction method ? If NO why
don’t you prefer these types methods.

2. Your opinion about the construction with pre 2 3 2 2 3

fabricated method ?

3. Is this method have more advantages with 2 2 2 2 3

the conventional method ?

4.When we looking into aspects like 3 3 2 3 3

• Space optimization

• Aesthetics and Visual impacts.

• Flexibility and use of space.

Which method is more suitable to the context

of kerala?

No one are done a fully-fledged Prefabricated building*

Looking into space optimisation and flexibility it is ok
But aspects like aesthetics visual impacts and use of spaces conventional method is more
feasible to the context of kerala. *

45
 • Drastic increase in cost of
BACKGROUND construction materials
STUDY FROM • An alternative method want to be
INTERVIEW introduced in the construction sector
of residence.

• Steel, gypsum and ALC panels have

LITERATURE more advantages as compared with
REVIEW the conventional method.
• There is drastic difference in time and
cost

• The energy efficiency of these

LITERATURE CASE buildings are high.
STUDY • Building is more flexible
• Increase in carpet and thereby have
more space inside.

5.4 Inference from live case study

5.4.1 Prefabricated residences
 Have more advantages when looking into the aspects of space optimization and flexibility
 Visual interests can vary from person to person.
 Construction techniques supporting these provision of future changes, by reducing the
demolition need / ease in installation etc.,
 Time and cost are the other aspects attracting to the technology of prefabricated
construction
 When looking into clients they are more satisfied about the quality of space inside, usability
and living atmosphere inside

5.4.2 Conventional residences

When looking into aspect of aesthetics this method is more aesthetically pleasing. Although the idea
of aesthetics can vary from person to person, as to what they prefer to see through their eyes,

46
the general finish of the type of construction matters; whether it is neat, eye pleasing,
availability of colours and textures etc.
5.4.3 Live interactions
Most of the architects not interested with the method of prefabrication. It all about the lack of
understanding about the particular method of construction. Architects wanted promote more about
these method and also want to put forward more design ideas with these methods.

47
6.0 CONCLUSION
From the above live casestudies certain conclusions can be drawn, based on the three key
factors for comparison : Space optimization, Aesthetics and Visual impacts, Flexibility and
use of space, all in the Kerala context.
Space optimization: From the case studies it is clear that the use of steel gypsum & ALC
construction provides room for optimising whatever the space available, over conventional
RCC framed structure. : In conventional method, the wall sizes are normally 25 cm thick
while using steel and ALC it is only 15 cm thick, thus overall there will be a considerable
increase in usable space of the building. Also in prefabricated structures, the columns used
are less and this too helps in optimising the space available. This helps in creating more
room for usable spaces while keeping the total floor area intact. Thus helping in reducing
the waste of spaces and creating more spacious interiors.
So to conclude, in this present scenario of increasing land value and decreasing land
availability, optimization of whatever little space available is of clear importance to save
space, money as well as resources. A conventional method of construction may not always
fulfil the space requirements of the users/ designers which demands for newer methods,
like prefabricated construction, that can withstand the crisis of space limitation.
Aesthetics and Visual impacts: As we all know, aesthetics is a very subjective matter and
there is no “correct” way of presenting it. That being said, from the above case studies as
well as from discussions with the architects and designers, it is evident that prefabricated
structures create a touch of typicality in designs especially in external facades. There is very
less to experiment with, in this type of construction. But conventional RCC framed method
of construction provides more room for experimentation by allowing the use of different
materials, finishes etc.
Flexibility and use of space: In steel & gypsum/ ALC construction the walls are
installed as panels and can be removed or demolished easily compared to conventional
methods of construction. So a space can be reinterpreted in the future years by making
slight alterations in the structure without creating much havoc or structural instability. Also,
there are very minimal amount of columns and beams running inside the residence. So the
flexibility in use of space is ensured to a great extent. In conventional method, as the walls
are all load bearing, future alterations or extensions in the design may affect the structural
stability of the building and would be a great risk to do so. Only adaptive reuses of space like
the change in interior furniture or partition walls may can be made to make the spaces
flexible.
The intended use, at the time of designing/construction, of a particular space can
change over the years based on user demands, especially in today’s fast growing era. Thus
to conclude, steel & ALC method of construction would be more successful in achieving
flexibility in design for the future.

48
7.0 References
1. Alatza, D. R. (1 Jan 2014). Pre fabricated structures. sree kamalamani publications.
kirby building system. (2015).
2. Technical handbook. kirby building systems.
Mark Lawson, R. O. (24 Feb 2014).
3. Design in Modular Construction. CRC press.
Mullens, M. A. (1 Mar 2011)
4. Factory Design for Modular Homebuilding.
Smith, R. E. (11 Jan 2011). Prefabricated Architecture: A Guide to Modular Design
and Construction.

Modular construction - Steelconstruction.info. 2011. Retrieved January 2, 2014, from

http://www.steelconstruction.info/Modular_constructi on truncated.
MBI.
5. Why Build Modular. 2013. Retrieved October 10, 2013, from
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6. Behera, P. (2017). Presentation on Prefabricated Structures & Prefabrication –

Concept, Components & Advantages.
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MODULAR CONSTRUCTION AND. ARPN Journal of Engineering and Applied Sciences.
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Steel. SSRG International Journal of Civil Engineering (SSRG-IJCE), 5.
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