MODULAR CONSTRUCTION

It is a building methodology whereby elements of a project are mass produced andassembled to make larger finished products. An entire project can be based onmodularity—think beyond just the modular patient room. Like sustainable projects,make modular a core value of the project, not just an element that can be dropped fromthe program. Identify as many project components as possible including programmaticelements of patient rooms, Operating Rooms, Emergency Departments, exam andtreatment rooms, nurses’ stations, bathrooms, pharmacy and laboratories, and buildingelements such as structure, exterior envelope, and MEP systems (headwalls, bathroomwet walls, and overhead piping and ductwork). With the increased integration of BIM inthe development of projects, incorporating modular building components becomeseasier and more desirable.

NEED OF MODULAR CONSTRUCTION

Construction workers typically are exposed to high levels of noise, dust and airborneparticles, adverse weather conditions, and other factors that can cause fatigue andinjuries and thereby reduce efficiency and productivity. New types of equipment canmake an activity physically easier to perform, easier to control, more precise, and saferfor construction workers. Similarly, changes in materials can reduce the weight ofconstruction components, which in turn can make them easier to handle, move, andinstall. Manufacturing building components off–site provides for more controlledconditions and allows for improved quality and precision in the fabrication of thecomponent.

Prefabrication, preassembly, modularization, and off-site fabrication involve theassembly or fabrication of building systems and/or components at off–site locations andplants. Once completed, the systems or components are shipped to a construction jobsite for installation at the appropriate time. One study that examined the relationshipbetween changes in material technology and construction productivity based on 100construction–related tasks found the following:

• Labor productivity for the same activity increased by 30 percent where lightermaterials were used; and• Labor productivity also improved when construction activities were performed usingmaterials that were easier to install or were pre–fabricated (Goodrum et al., 2009).

Less Material Exposure to Inclement Weather — Many of the indoorair quality issues identifi ed in new construction result from highmoisture levels on the framing materials. Because the modularstructure is substantially completed in a factory-controlled setting usingdry materials, the potential for high levels of moisture being trapped inthe new construction is eliminated.

Less Site Disturbance — The modular structure is constructed off-sitesimultaneously with foundation and other site work, thereby reducingthe time and impact on the surrounding site environment, as well asreducing the number of vehicles and equipment needed at the site.

Safer Construction — Modular construction is a safer alternative.Conventional construction workers regularly work in less-than-idealconditions, dealing with temperature extremes, rain, wind or anycombination of natural conditions. This by its very nature is a muchmore challenging environment for working safely.

BENEFITS OF MODULAR CONSTRUCTIONModular construction techniques have been shown to be inherently advantageous in 7major areas

Less Materials Waste — Pre-fabrication makes it possible to optimize constructionmaterials purchases and usage while minimizing on-site waste and offering a higherquality product to the buyer. Bulk materials are delivered to the manufacturing facilitywhere they are stored in a protected environment, safe from theft and exposure to theenvironmental conditions of a job site.

Additionally, the potential for injury— including falls, the most common work site risk—is muchhigher. In a factory-controlled setting, each worker is typically assigned to a work station supplied withall the appropriate equipment needed to provide the safest work environment possible. Off-siteconstruction also eliminates the hazards associated with materials, equipment and incompleteconstruction processes typical of construction sites that can attract curious and unwelcome “visitors”(e.g. students on a school expansion project).

Flexibility — When the needs change, modular buildings can be disassembled and the modulesrelocated or refurbished for their next use reducing the demand for raw materials and minimizing theamount of energy expended to create a building to meet the new need. In essence, the entire buildingcan be recycled in some cases.

Adaptability — Modular buildings are frequently designed to quickly add or remove one or more“modules”, thereby minimizing disruptions to adjacent buildings and surroundings.

Built to Code With Shorter Build Times — The bottom line is that with modular construction you canget a facility built to the same local codes with construction quality as good as or better than acomparable site built building in much less time. Additionally. the abbreviated construction scheduleallows you to get a return on your investment sooner while minimizing the exposure to the riskscommonly associated with protracted construction schedules.

Source : www.acceleratedconstructiontechnologies.com/...modular.../How%20Are...

DISADVANTAGES

Whilst there are many advantages to all forms of modular buildings, there can be limitations also.Volumetric: Transporting the completed modular building sections take up a lot of space. This isbalanced with the speed of construction once arrived on site.Flexibility: Due to transport and sometimes manufacturing restrictions, module size can be limited,affecting room sizes.Panelised forms and flat pack versions can provide easier shipment, and most manufacturers haveflexibility in their processes to cope with the majority of size requirements.Aesthetics: prefabricated identical units that are later joined together may be viewed as lessaesthetically pleasing and less desirable as a residence than than a traditional home which isindividually built on site.

FORMWORKFormwork is the term given to either temporary or permanent molds into which concrete or similarmaterials are poured. In the context of concrete construction, the falsework supports the shutteringmoulds.

MIVAN FORMWORK

The panels of Aluminium formwork are made from high strength aluminium alloy, with the face orcontact surface of the panel, made up of 4mm thick plate, which is welded to a formwork ofspecially designed extruded sections, to form a robust component. The panels are held in positionby a simple pin and wedge arrangement system that passes through holes in the outside rib of eachpanel. The panel fits precisely, securely and requires no bracing. The walls are held together withhigh strength wall ties, while the decks are supported by beams and props. Since the equipment ismade of aluminium, it has sections that are large enough to be effective, yet light enough in theweight to be handled by a single worker. Individual workers can handle all the elements necessaryfor forming the system with no requirement for heavy lifting equipment or skilled labor. By ensuringrepetition of work tasks on daily basis it is possible for the system to bring assembly line techniquesto construction site and to ensure quality work, by unskilled or semi-skilled workers. Trial erection ofthe formwork is carried out in factory conditions which ensure that all components are correctlymanufactured and no components are missed out. Also, they are numbered and packed in such amanner so as to enable easy site erection and dismantling

MERITS OF ALUMINIUM FORMWORK i. In contrast to most of the modern construction systems, which are machine andequipment oriented, the formwork does not depend upon heavy lifting equipment and canbe handled by unskilled labors.ii. Fast construction is assured and is particularly suitable for large magnitude constructionof respective nature at one project site.iii. Construction carried out by this system has exceptionally good quality with accuratedimensions for all openings to receive windows and doors, right angles at meeting points ofwall to wall, wall to floor, wall to ceiling, etc, concrete surface finishes are good to receivepainting directly without plaster,iv. System components are durable and can be used several times without sacrificing thequality or correctness of dimensions and surface. v. Monolithic construction of load bearing walls and slabs in concrete produces structurallysuperior quality with very few constructions joined compared to the conventional columnand beam slabs construction combined with filter brick work or block work subsequentlycovered by plaster.vi. In view of the four - day cycle of casting the floor together with all slabs as against 14 to20-- day cycle in the conventional method, completed RCC structure is available forsubsequent finish trades much faster, resulting in a saving of' 10 to 15 days per floor in theoverall completion period.vii. As all the walls are cast monolithic and simultaneously with floor slabs requiring nofurther plasters finish. Therefore the time required in the conventional method forconstruction of walls and plastering is saved. As fully completed structural frame is madeavailable in one stretch for subsequent - finishing items, uninterrupted progress can beplanned ensuring, continuity in each trade, thereby providing as cope for employingincreased labor force on finishing item.

Source : www.researchgate.net/...tunnelform.../9fcfd5115944f9d9f0.pdf

MIVAN aims in using modern construction techniques and equipment in all its projects. On leaving the MIVAN factory all panels are clearly labeled to ensure that they are easily identifiable on site andcan be smoothly fitted together using the formwork modulation drawings. All formwork begins at a corner and proceeds from there.

TUNNEL FORM WORK

Tunnel form is a formwork system that allows construction of cellular walls and slabs inoneoperation on a daily cycle. It combines the speed, quality and accuracy of offsite production withthe flexibility and economy of in-situ construction and is recognised as a modern method ofconstruction. The result is a cellular reinforced concrete structure, the surfaces of which are ofsufficiently high quality to require only minimal finishing for direct decoration. The system creates anefficient load bearing structure for use in a wide variety of applications. It is particularly effective inprojects suited to repetitive cellular construction such as residential blocks, hotels, studentaccommodation, barracks and prisons.

•Tunnel form is a fast-track method of construction that is well suited to repetitive cellular projectssuch as hotels, social housing and student accommodation.•Recognised as being a modern method of construction, tunnel form simplifies the wholeconstruction process by enabling a smooth and fast operation that can result in frame costs beingreduced by up to 15 percent and provide frame programme time savings of up to 25 percent.•During the tunnel form construction process, a structural tunnel is created by pouring concrete intosteel formwork to make the floors and walls in one monolithic process.•Each 24 hours, the formwork is moved so that another tunnel can be formed. When a storey hasbeen completed, the process is repeated on the next floor.• A strong, monolithic structure is thus constructed that can reach 40 or more storeys in height.

Source : www.1floor1day.com/.../Tunnel%20Formwork%20for%20Modern%20... avighnagroup.com/.../01.07.11-Architecture-Update-Mivan-Technology...