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Study On Pre-Fabricated Modular and Steel Structures: Prajjwal Paudel, Sagar Dulal, Madan Bhandari, Amit Kumar Tomar
Study On Pre-Fabricated Modular and Steel Structures: Prajjwal Paudel, Sagar Dulal, Madan Bhandari, Amit Kumar Tomar
E. Advantages
The main advantages of prefabricated
structures are assembly of finished elements on site,
self load bearing and quick execution, which have
favoured their use above all in industry.
Self-supporting ready-made components are used, There are other disadvantages too. They are as
so the need for formwork, shuttering and follows:-
scaffolding is greatly reduced.
Prefabricated components speed up Leaks can form at joints in prefabricated
construction time, resulting in lower labor components.
costs. Transportation costs may be higher for
There are less wasted materials than in site- voluminous prefabricated sections.
built construction. The requirement to transport manufactured
Construction time is reduced and buildings homes or modules to their intended site can
are completed sooner, allowing an earlier mean that prefabrication potential may be
return of the capital invested. limited for infill projects in inner city areas.
The mechanization used in prefabricated Increased production volume is required to
construction ensures precise conformity to ensure affordability through prefabrication.
building code standards and greater quality Higher initial construction cost.
assurance. Lack of background research information.
On-site construction and congestion of site is Time consuming in the initial design
minimized. development.
Better quality control can be achieved in a Large prefabricated sections require heavy-
factory assembly line setting than at the duty cranes and precision measurement from
construction site. handling to place in position.
Quality control and factory sealing and Larger groups of buildings from the same type
design can ensure high energy efficiency. of prefabricated elements tend to look drab and
Prefabrication site can be located where monotonous.
skilled labor is more readily available and Local jobs may be lost, if the work done to
the costs of labor, power, materials, space fabricate the components being located in a
and overheads are reduced. place far away from the place of construction.
Time spent due to bad weather or hazardous Prefab structure means that there is less local
environments at the construction site is working on any construction project at any
minimized. time.
Prefabrication allows for year-round Design and construction of modular buildings,
construction, work is not affected by require high levels of collaboration among
weather delays (related to excessive cold, project parties, especially architect, structural
heat, rain, snow, etc.). engineer and manufacturer.
Less wastage of construction material. Prefabricated buildings typically depreciate
Advanced materials such as sandwich- more quickly than traditional site-built housing
structured composite etc. can be easily used, because of its shorter economic life.
improving thermal and sound insulation and
air tightness. II. LITERATURE REVIEW
Independence of climatic condition. The study has successfully established the
Worker safety and comfort level are higher fact that proportion of prefab content has a significant
than in site-built construction. relationship with the cost performance and time
Computerization of the production process performance of the project. The study has quantified
permits a high degree of customization, at an the benefits of employing prefab technology in light
affordable cost. to medium commercial building projects by
concluding that 77% prefab content in light to
F. Disadvantages medium commercial buildings can result in 100% or
Despite these benefits, node discontinuity is more cost performance and similarly 74% prefab
the most critical factor in the event of an earthquake, content can result in 100% or more time performance.
since the risk of losing the support of the horizontal Findings of this study are likely to encourage the
prefabricated structures under seismic activity is what uptake of prefab technology in construction process.
experience has indicated as being the most frequent. However, factors other than prefab content might be
Creating this continuity can also mean losing the responsible for the cost and time performance such as
advantages of the prefabricated structure. In seismic quality of project management, site characteristics,
zones load bearing elements are not allowed where procurement strategies etc. are recommended for
the transmission of horizontal seismic activity is only further investigations (Shahzad, W.M, Mbachu, J.
by friction due to the weight of components. and Domingo, N. (2014).
under controlled conditions using mass production Its peculiarity is that the foam in the core is the best
technology and employing a generally semi skilled insulator and its thickness determine the value of
workforce would result in a product less expensive or insulation. The foam core forms a continuous energy
at least competitively priced to that of conventionally barrier, and the smaller number of studs leaves less
built homes. Indications were appeared to support the opportunity for heat conduction. SIPs are fabricated
contentions made so often by the prefabrication to very close (1/8 inch) tolerances, and the edge
industry that their product is more cost effective than connections, which vary by manufacturer, are
conventional construction (Stefan J. Weidemann, designed to fit snugly together. The best thing about
1990). SIPs is their resistance to insects. While the EPS
foam core provides no nutrition to insects, it offers an
Recycled-content and reused materials are easy way for them to tunnel into the structure. Borate
being used in modular and prefab products to increase additives can be mixed into the foam during
its sustainability; challenges include off-gassing and manufacture, providing some amount of insect
ensuring materials are nontoxic. (BC Housing resistance. De-lamination caused by failure of the
Manufactured Housing Association of BC Real Estate adhesive is a major concern because it would affect
Institute of BC, 2014). the ability of structural SIPs to carry load.
3) Colorbond Steel
The Colorbond steel is comprising of
Zincalumer steel substrate as base material and
coatings of Zn-Al alloy Coating, Conversion Coating ,
Universal Corrosion Inhibitive Primer (Nominal 5μm)
and Finish Coat (Nominal 20μm) on the front side
and similarly with Backing Coat (Nominal 5μm) on
the back side.
Figure: ICFs Colorbond steel has good resistance to accidental
spillage of solvents such as methylated spirits, white
C. Prefab Materials in Marke spirit, mineral turpentine, toluene, trichloroethylene,
Zincalume Steel dilute mineral acids and alkalis. However, all
Colorbond Steel spillages should be immediately removed by water
washing and drying.
Aerocon Panels
FRP Corrugated Sheets
Color Coated Galvalume Sheets
low alkali sulphoaluminate cement and calcium can be provided with wooden shutters or hollow
silicate board as face panels. metal shutter or glass shutter. The shutter can also be
provided with rock wool, mineral wool, PUF,
Ceramic wool or polystyrene insulation.
H. Why Steel?
1) Material Cost Savings: Steel is cheaper in
comparison of weight/strength ratio; and is
ideal for building seismic-activity resistant
housing.
Fig: Aerated Solid Cement Panel 2) Labor Cost Saving: A labor of six men can
construct a steel container house within a
Thickness Availability: day.
50mm, 60mm, 75mm, 90mm, 100 mm, 3) Better Safety: Steel’s ductility allows it to
120mm, 150mm, 180mm & 210mm. stretch between 5-7% of its original length;
which makes it more withstanding during
D. Roof Options earthquakes and also absorb wind turbulence
PUF Corrugated Panel due to its ductility.
EPS Corrugated Panel 4) Low Transport Cost: Steel can even be
CGI sheets transported by people.
UPVC roof 5) Time Savings: Due to the pre-fabricated
Asphalt shingles nature of steel framing; it can be constructed
Color Coated Galvalume Sheets at a factory and be delivered ready to erect;
also no welding required on the site; the
E. Wall Options structures can be totally completed with nuts
PUF Sandwich Panel and bolts.
EPS Sandwich Panel 6) Lower Insurance Premium: Due to steel’s
Solid Cement wall Panel insect, wind, and earthquake resistance,
Dry Wall System using cement boards home owner’s insurance premium will be
Different claddings/siding materials much lower.
7) Versatility: Due to the standard shape of
F. Floor Options steel container they can be easily
Generally, cemented solid sheets are used as customized; extend upon and taken apart.
the flooring materials. Plywood, wooden planks, 8) Eco-Friendly: 50 trees are needed to build
Marbles, tiles are also the options of flooring. the average house. In comparison steel is
extracted, is recyclable in the future and
G. Door and Window’s Frame minimizes wastage through customized
Hollow metal frames are very good building.
replacement for wooden door/window frames. It can 9) Short-Term Accommodation: Many
also be provided the looks of a wood frame at a very European countries and military bases are
economical price and have other advantages over utilizing the quick to construct and de-
wood. The frames are termite proof and weather construct nature of such housing, and
proof and have a better surface finish than wood. It offering it as affordable short term housing.