PREFABRICATION AND MODULAR

CONSTRUCTION
 WHAT IS PREFABRICATION ?

OFF SITE MANUFACTURING/ TRANSPORTATION OF RAW ASSEMBLING THE

OFF SITE CONSTRUCTION MATERIALS TO THE PREFABRICATED
DESIGNATED SITE. COMPONENTS ON SITE.
WHY PREFABRICATED
STRUCTURE?
• Prefabrication is used to effect economy in cost.
•Components manufactured under controlled conditions.
•The speed of construction is increased since no curing period is necessary.
• Prefabrication helps in the use of locally available materials with required
characteristics like light-weight; easy workability, thermal insulation, non-
combustibility etc
DIFFERENT TYPES OF
PRFABRICATION
MATERIALS USED IN
PREFABRICATION
•Concrete
•Steel
•Treated wood
•Aluminum
•Cellular concrete
•Light weight concrete elements
•Ceramic products
CATEGORIES OF
PREFABRICATION SYSTEM
•OPEN PREFAB SYSTEM-This system is based on the use of basic structural
elements to form whole or part of the building.
•The two categories are -
1)PARTIAL PREFAB OPEN SYSTEM
2)FULL PREFAB OPEN SYSTEM
PARTIAL PREFAB OPEN SYSTEM
•This system basically emphasizes the
use of precast roofing and flooring
components and other minor elements
like flooring components and other
minor elements like lintels, chajjas,
kitchen sills in conventional building
construction.
•The structural system could be in the
form of framework or load bearing
walls.
FULL PREFAB OPEN SYSTEM
In this system almost all the structural components are Prefabricated.
The filler walls may be of bricks or any other local material.
LARGE PANEL PREFAB SYSTEM
•This system is based on the use of large
prefab components.
•The components such as Precast
concrete large panels for walls.
•The components such as Precast
concrete large panels for walls, floors,
roofs, balconies, staircase, etc.
•The casting of the components could be
at the site or off the site.
Prefabrication Building Components: BEAMS: – BEAMS CAN VARY IN THEIR
COLUMNS: – A COLUMN IS A VERTICAL MEMBER COMPLEXITY OF DESIGN AND
CARRYING THE BEAM AND FLOOR LOADINGS TO THE
FOUNDATION. IT IS A COMPRESSION MEMBER AND
REINFORCEMENT FROM THE VERY SIMPLE
THEREFORE THE COLUMN CONNECTION IS REQUIRED BEAM FORMED OVER AN ISOLATED OPENING
TO BE PROPER. THE MAIN PRINCIPLE INVOLVED IN TO THE MORE COMMON ENCOUNTERED IN
MAKING COLUMN CONNECTIONS IS TO ENSURE FRAMES WHERE THE BEAMS TRANSFER
CONTINUITY AND THIS CAN BE ACHIEVED BY A
VARIETY OF METHODS.
THEIR LOADINGS TO THE COLUMN.
BEAMS TO COLUMNS
CONNECTION :
Methods of connecting beams and columns
are :
1. A precasting concrete haunch is cast on to
the column with a locating dowel or stud
bolt to fix the beam.
2. A projecting metal corbel is fixed to the
column and the beam is bolted to the
corbel.
3. Column and beam reinforcement,
generally in the form of hooks, are left
exposed. The two members are hooked
together and covered with insitu concrete
to complete the joint. This is as shown in
the figure.
Advantages And Disadvantages :
Advantages: Disadvantages:
Saving in cost, material, time & manpower. Handling and transportation may cause breakages of
Shuttering and scaffolding is not necessary. members during the transit and extra provision is to be
made.
Installation of building services and finishes can be
done immediately. Difficulty in connecting precast units so as to produce
same effect as monolithic. This leads to non-
Independent of weather condition. monolithic construction.
Components produced at close supervision .so quality is They are to be exactly placed in position, otherwise
good the loads coming on them are likely to get changed
Clean and dry work at site. and the member may be affected.
Possibility of alterations and reuse Disadvantages:
Correct shape and dimensions and sharp edges are High transport cost
maintained. Need of erection equipment
Very thin sections can be entirely precast with precision. Skilled labour and supervision is required.
Insta Tower , Mohali.

• Location : Mohali, Chandigarh, India.

• Built in 48 hours on December 1st 201
• Developerr : Harpal Singh, chairman and
managing director of Synergy Thrislington.
• Insta con -Instant Construction.
• Area : 2,553.60sqm
• Cost : 8-9 crore
• 40 -60 days for units constructions.
• Constructed with the help of the cranes and
200 plus highly skilled technicians and
workers.
Design
Development
Details :
• Light weight structure with unique
bracing system.
• Sustainable, nontoxic and recyclable.
• Reduces the amount of waste ,
carbon footprint and the impact on
green spaces on the site .
• Energy effective structure as it
provides floor insulation using HVAC
technique.
• For fresh air circulation ERV (energy
recovery ventilator ) is used
WHAT IS MODULAR
CONSTRUCTION
MODULAR CONSTRUCTION IS A PRE- ENGINEERED PROCESS OF MAKING
ANY STRUCTURES OR ELEMENTS IN A FACTORY THAT IS OFF-SITE AND
ARE DELIVERED TO THE SITES AND ASSEMBLED AS LARGE VOLUMETRIC
COMPONENTS OR AS SUBSTANTIAL ELEMENTS OF ANY STRUCTURES.

MODULAR DESIGN OR MODULARITY IN DESIGN IS

A DESIGN APPROACH THAT SUBDIVIDES A SYSTEM
INTO SMALLER PARTS CALLED MODULES OR SKIDS
THAT CAN BE INDEPENDENTLY CREATED AND THEN
USED IN DIFFERENT SYSTEMS.
WHY MODULAR CONSTRUCTION
IT SAVES UPTO 35% ON THE INITIAL CONSTRUCTION COSTS LIKE
LABOUR AND MATERIALS .
ONE CAN ATTAIN A SUITABLE QUALITY IN THE ELEMENTS OF ANY
STRUCTURE THAT ARE TO BE PRE-FABRICATED OR PRE-CAST IN THE
CONSTRUCTION FACTORY .
QUICKER AND EFFICIENT FACTORY PROCESSES .

FOR A GOOD RESULT , PROPPER PLANNING , CO ORDINATION AND

COMMUNICATION MUST EXIST BETWEEN VARIOUS RELEVANT PARTIES
INVOLVED FROM EARLY STAGE OF THE PROJECT .
CLASSIFICATION OF MODULES
THERE ARE THREE TYPES OF MODULES :

1. BASIC MODULE
2. MULTI MODULE
3. SUB MODULE
1. BASIC MODULE
IT IS THE FUNDAMENTAL UNIT OF SIZE AND FOR GENERAL
APPLICATION TO BUILDING AND COMPONENTS.
THE SIZE OF BASIC MODULE IS TAKEN AS 100MM DENOTED BY “M”

2. MULTI MODULE
CERTAIN WHOLE MULTIPLES OF BASIC MODULE AS 2M , 3M , 4M ETC ARE
REFFERED TO AS MULTI MODULE.

3. SUB MODULE
CERTAIN SUBMULTIPLES OF BASIC MODULE WHICH ARE WHOLE SIMPLE
FRACTIONS SHALL BE CHOSEN WHEN ABSOLUTELY NECESSARY FOR AN
INCRREMENT SMALLER THAN THE BASIC MODULE .
ADVANTAGES
DISADVANTAGES
1. REDUCED COSTS 1. LIMITED
CUSTOMIZATION

2. QUICKER AND FASTER 2. LIMITED SERVICE

AREA

3. NEW CONSTRUCTION

4. QUALITY
COMPONENTS OF MODULAR
CONSTRUCTION
1) Structural Components
Beams
Columns
Floor Slabs
Walls
Staircases
COMPONENTS OF MODULAR
CONSTRUCTION
2) Non-Structural Components
Cladding
Partitions
Doors
Windows
Bricks and Blocks
COMPONENTS OF MODULAR
CONSTRUCTION
2) Finishes
Ceiling Finishes
Floor Finishes
MATERIALS USED IN MODULAR
CONSTRUCTION
Steel
RCC
Concrete
Bricks
Wood
Case Study: Victoria Hall,
Wolverhampton, UK
Has 3 Blocks from 8 to 25 stories.
824 modules used.
Total floor area 27320 sqm
Avg module size 21sqm and largest is 31sqm
Project completed on 59 weeks (July 2008 to August 2009)
Light weight cladding is used on the exterior.