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STUDY OF PREFABRICATION IN INDIA Rinkesh patel

1, Dr.Neeraj Sharma

2

M.E. Student, Civil Eng. Dept., SNPIT &RC, Umrakh (GTU), Bardoli, Gujarat, India1

HOD & Professor, Civil Eng. Dept., SNPIT &RC, Umrakh (GTU), Bardoli, Gujarat, India2

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

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

any movable structure is shifted from the main manufacturing site to another location, and

the section is supplied assembled and ready to fit. The term prefabrication can apply to any

construction method where a significant part of the construction takes place off-site in a

factory that produces relatively large, complex pieces that are then assembled at the site

into the finished building. Since prefab is such a loosely defined term, it helps to show

where prefab as we define it fits into the spectrum of construction methods ranging from

completely off-site to completely on-site

Keywords: Construction management, prefabrication

1. INTRODUCTION

Prefabrication is the practice of assembling components of a structure in a factory

or other manufacturing site, and transporting complete assemblies or sub-assemblies to

the construction site where the structure is to be located. The term is used to distinguish

this process from the more conventional construction practice of transporting the basic

materials to the construction site where all assembly is carried out. The term

prefabrication also applies to the manufacturing of things other than structures at a

fixed site. It is frequently used when fabrication of a section of a machine or any

movable structure is shifted from the main manufacturing site to another location, and

the section is supplied assembled and ready to fit. It is not generally used to refer to

electrical or electronic components of a machine, or mechanical parts such as pumps,

gearboxes and compressors which are usually supplied as separate items, but to sections

of the body of the machine which in the past were fabricated with the whole machine.

Prefabricated parts of the body of the machine may be called 'sub-assemblies' to

distinguish them from the other components.

The term prefabrication can apply to any construction method where a

significant part of the construction takes place off-site in a factory that produces

relatively large, complex pieces that are then assembled at the site into the finished

building. Since prefab is such a loosely defined term, it helps to show where prefab as

we define it fits into the spectrum of construction methods ranging from completely off-

site to completely on-site.

At the extremes, recreational vehicles are an example of completely off-site

construction, while igloos and straw huts exemplify completely on-site construction. As

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more realistic examples, HUD-compliant manufactured homes (commonly called trailer

homes) are brought to the site almost completely finished, while in traditional wood,

steel or concrete construction, homes are built almost completely on-site from thousands

of basic materials. Prefab fits in the middle of this continuum: it bridges the gap

between manufactured housing and traditionally built homes, offering many of the

advantages and opportunities of each.

Prefabrication is one of the key means of increasing buildability. As the industry

strategies itself to build with less labour and shorter construction time, prefabrication of

concrete structures has become a viable alternative to the traditional way of

construction. Over the last few years, some industry players have effectively adopted the

use of precast concrete components to their advantage by combining it with cast in-situ

concrete elements. Different mix of precast and cast in-situ elements are used to meet

different design requirements for better quality and cost effectiveness. Such

combination enables their projects to achieve higher level of productivity than is

possible with solely cast in-situ construction. By using precast concrete components

predominantly, on-site operations are considerably reduced, providing a safer working

environment. However, it is important to have a good appreciation of its difference in

management from the conventional construction. The benefits of using prefabrication

would not be fully realised by merely adapting the traditional way of design and

construction process. The keys to successful implementation lie in the planning and

understanding of the close relationships between design, construction, detailing,

execution and manufacturing of precast concrete Components. In other words, it is vital

to have a good cooperation between the Architect, the engineer, the builder and the

precaster.

2. ROLE OF PREFABRICATION IN CONSTRUCTION

The role of prefabrication in architecture has been lauded for its potential to increase

productivity and efficiency while not sacrificing quality. The values of better, faster and

cheaper are applicable to developed countries such as the U.S., Japan, and Europe, whose

middle class continues to demand this equation in buildings that range from the remarkable to

the prosaic. Developing countries, including China, India, Africa and many parts of South

America, that are beginning to rely on prefabrication have the potential advantages of

realizing housing quickly and affordably; however, greater reliance on manufactured

production has possibly more disadvantages than advantages for these cultures. With

prefabrication, improved working conditions would seem to be agreeable to everyone: instead

of building in the weather, international fabricators supply controlled environments with

ergonomically considered equipment – and yet in many fabrication environments, reliance on

minimal skills, and a disconnect with the community in which workers live, leaves little room

for continued fostering of personal and collaborative skills, culture, tradition and community

building.

The potential for prefabrication to be used to create a bland, monotonous landscape is

an issue that developed countries’ construction professionals must grapple with. Countries

such as India are undoubtedly suffering a greater banality in the built environment by

embracing prefabrication. Prefabrication is touted as offering a more sustainable solution to

building, but developing counties already rely on vernacular practices for design and

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construction that require relatively low life cycle energy. Developing countries continue to

embrace technology from their developed country allies. This trend does not seem to see a

slowing. The following paper will address this growing trend through the example of India, a

country that is transforming quickly by adopting digital, material, and construction

technologies from around the world and rapidly transforming its landscape. This paper will

illustrate the advantages and disadvantages of prefabrication adoption in this culture and

suggest ways in which developed countries’ architects and local building professionals may

take a leadership role in fostering both culture and technology.

3. PRESENT SCENARIO:

Prefabrication in India began with the emergence of the Hindustan Housing Factory.

The company was developed by the first Prime Minister of India, Pandit Jawaharlal Nehru, as

a solution to the housing crisis that resulted from the influx of refugees from West Pakistan in

the 1950s. The Hindustan Housing Factory pioneered the production of pre-stressed concrete

railway sleepers to replace dilapidated wooden sleepers on Indian Railways. The company

changed its name shortly thereafter to reflect the diversity of its operations. It is now known

as the Hindustan Prefab Limited or HPL. Located in Delhi, today the government run

company prefabricates primarily precast concrete for architectural and civil projects

throughout greater India. When HPL began it was intended to produce low-income housing

solutions for the deficit in India. Precast wall panels and frame members such as beams and

columns provided a much needed set of tools to erect quick structures for mass housing. The

most difficult technology transfer obstacle for the HPL has been the cost of machinery and

materials for production. Since the government could not recoup the return on investment for

the factory through housing production, prefabrication from HPL began to service other

markets including higher dollar civil and larger public and hotel buildings. The quality of

construction is much higher when components are manufactured in a stable environment such

as the factory. This is especially true in India where today, prefabrication has become

synonymous with durable, modern, and western construction methods. Materials are used

more efficiently, are safer from climatic damage, and can be reused in the material stream.

Because of these benefits, a general consensus in India is to move prefabricated building

systems beyond precast concrete for large-scale construction to additional market sectors

including a resurgent interest in applying prefabrication technology to housing. Traditional

construction techniques involve the use of timber molds or shuttering for roof spans and other

structural systems. These temporary timber structures have a short lifespan and due to the

volume of construction in the peak seasons of spring and summer for larger well-funded

projects are often unavailable. This hinders construction schedules and does not allow

projects to be completed before cooler or rainy seasons begin.

4. CHARACTERISTICS OF PREFABRICATION

Light weight

Thermal insulation property

Easy workability

Durability in all weather conditions

Non combustibility

Economy in cost

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Easy availability

Sound insulation

5. ADVANTAGES OF PREFABRICATION

High capacity - enabling the realization of important projects

Factory made products

Shorter construction time - less than half of conventional cast in site construction

Independent of adverse weather conditions during construction

Continuing erection in winter time until -20 °C

Quality surveillance system

Opportunities for good architecture

Healthy buildings

Reduced energy consumption

Environmentally friendly way of building with optimum use of materials,

recycling of waste products, less noise and dust, etc.

Cost effective solutions

Safety in construction

Increase in the quality of construction

Reduction of construction waste

6. LIMITATION OF PREFABRICATION

Large prefabricated sections require heavy-duty cranes and precision measurement

and handling to place in position.

Larger groups of buildings from the same type of prefabricated elements tend to look

drab and monotonous.

Careful handling of prefabricated components such as concrete panels or steel and

glass panels is required.

Attention has to be paid to the strength and corrosion- resistance of the joining of

prefabricated sections to avoid failure at the joint.

Similarly, leaks can form at joints in prefabricated components.

Transportation costs may be higher for voluminous prefabricated section than the

materials of which they are made, which can often be packed more compactly

7. VARIOUS PREFABRICATION SYSTEM

OPEN PREFABRICATION SYSTEM

1) Partial prefab open system

2) Full prefab open system

LARGE PANEL PREFABRICATION SYSTEM

1) Wall System

2) Precast floors

3) Staircase systems

4) Box type construction

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8. COMPARISION of conventional method vs prefabrication method

Duration:

COST:

CONCLUSION

The total cost and total duration for the double storey residential building have been

determined for both prefab and conventional construction. And also we had known about the

advantages and disadvantages of both prefabrication and conventional construction by the

survey conducted in similar companies. The comparison showed there is enormous cost

difference between the methods, which the prefab is very high when compared to

conventional on this type of individual houses. The main advantages for prefab construction

and also it helps when there is labor shortage. This is main drawback for prefab construction

which is not economical to construct in this case.

ACKNOWLEDGMENT

The author thankfully acknowledge to Mr. J.N.Patel, Chairman Vidyabharti Trust, Mr.

K.N.Patel, Hon. Secretary, Vidyabharti Trust, Dr. H.R.Patel, Director, Dr.J.A.Shah,

Principal, Dr. Neeraj Sharma, Head of Civil Engineering Department, Our Guide,

S.N.P.I.T.&R.C.,Umrakh, Bardoli, Gujarat, India for their motivational & infrastructural

supports to carry out this research.

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