CASE- STUDY

PRE-FAB
CONSTRUCTION
 PURBANCHAL UNIVERSITY
KANTIPUR INTERNATIONAL COLLEGE
GWARKHO – LALITPUR
DEPARTMENT OF ARCHITECTURE

SUMMITTED BY:
SUBMITTED TO:
ANUSHKA KHATRI (01)
MANISH KARKI (07)
AR. REGAN SINGH
PRADIP BAJRACHARYA (10)
DEPARTMENT OF ARCHITECTURE
UNNATI THAPA (13)

DATE: 2023/09/23
OBJECTIVES

• TO KNOW ABOUT THE PRESENT SITUATION OF THE PRE-FAB CONSTRUCTION IN NATIONAL

& INTERNATIONAL CONTEXT.
• TO KNOW ABOUT THE QUALITY & QUANTITY OF THE CONSTRUCTION.
Table of contents

01 INTRODUCTION

02 NATIONAL CASE STUDY #1

03 NATIONAL CASE STUDY #2

04 INTERNATIONAL CASE STUDY

05 PLASTERING
01
INTRODUCTION
 PRE-FAB HOUSE

• A type of building construction that is built off-site >> transported to

& assembled at a final destination.
• The prefabricated house normally falls into three categories:

MANUFACTURED HOME MODULAR HOME MOBILE HOME

ADVANTAGES OF PREFABRICATED HOUSES OVER
NORMAL HOUSES

• Light Weight
• Budget-Friendly
• Weather Resistant
• Thermal Conductivity
• Earthquake Resistant Construction
• Fire | Water Resistant
• Available in Different Colors
• Customized Size
• Environment Friendly
• Easy Installation,
 CASE- STUDY

02
NATIONAL
CASESTUDY #1
2.1 Introduction
NAME KTM Pre-fab house
LOCATION Handigaon, Kathmandu
USE Construction company
OWNER/ Prabhakar Lama
ENGINEER

Some works:
2.2 Pre-fab Material
1. AAC LIGHTBRICKS BLOCK
• Gaushala, Kathmandu
• Cement, fly ash, limestone, aluminum powder
• 600*200*(75-300) mm AAC BLOCK
CONSTRUCTION

2. GORKHA ECO-PANEL
• Jagati, Bhaktapur
• 50mm, 60mm, 75mm, 90mm, and 120mm
thicknesses.
• LENGTH= 7.5 ft. OR customized length.
• Outside = 4.5 mm non asbestos calcium
silicate board on both side.
• Inside = cement, sand, fiber glass, thermocol. ECO-PANEL
3. SY PANEL
• Tinkune, subidanagar
• EPS SANDWICH WALL: panel length = 2-13m ; width = 1000mm ;
thickness: (50, 75, 100, 125, 150 mm)
• UPVC WINDOW

PANEL BOARD

UPVC window
4. PASHUPATI TRADERS
• I-beam & Metal supplies.
• Teku
• 4” * 8”
Upvc Sheet
5. HULAS H-SPAN I-BEAM

• Corporate office= Sundhara, Kathmandu

• Decking sheet & uPVC sheet
• Available in 0.75 mm - 1.2 mm Thickness
• Available in 8’ Length
• Effective Width 1000 mm

Decking Sheet
 2.3 THE CRUST PIZZA & BREAD

• LOCATION : BATTISPUTALI, KATHMANDU

• USE: RESTAURANT
• STANDARD PREFAB IRON STRUCTURE
• MATERIAL: UNIVERSAL COLUMN, AAC
BLOCK, DECKING SHEET,
uPVC ROOFING SHEET.
• CONNECTION : NUT & BOLT
CONSTRUCTION METHOD
1. According to the floor plan, foundation are excavated to place the columns.
2. I-beams are erected.
3. Steel beam cage is created to support the decking sheet.
4. A single rebar cage is created .
5. 1:2:4 cement mixture is poured. Surface of the slab is then floated for smoothness.
6. AAC are used in walls.
7. For finish, putting & plastering is done.

1 2&3 4 5
7
AAC BLOCK

PLASTERING &
PAINTING

PUTTING Metal stairs UPVC sheet

Roof covering Visible pillars.

Aluminum Artificial
windows wood.
 CASE- STUDY

03
NATIONAL
CASESTUDY #2
HIMALAYAN PRE.FAB PVT,LTD
 INDUSTRYCONSTRUCTION

 HEADQUATER KATHMANDU, DHUMBARAHI

 TYPE PRIVATE

 FOUNDED 2010

 SPECIALTIES PREFAB CONSRUCTION, PEB BUILDINGS, PREFAB

MATERIAL SUPPLY
 WHY PREFAB ?

 Short construction period: Steel structure, wall and roof components can be easily and quickly
assembled and disassembled; 4 people can assemble such a house at the size of 150 sqm in 2
days.

 Durable: The house can be disassembled and assembled more than 8 times, and normally used
for more than 20 years.

 These materials are waterproof, fireproof, windproof, sound insulating and heat insulating;
Earthquake proofing grade is 7 grade.

 Its packaging can save much space in transportation, this means much cost is saved for clients.

 A new environment friendly concept, it meets all the requirements of environment protection.
MATERIALS USED

Roof Options:
 PUF Corrugated Panel
 EPS Corrugated Panel
 CGI sheets
 UPVC roof
 Asphalt shingles

Wall Options:
 PUF Sandwich Panel
 EPS Sandwich Panel
 Solid Cement wall Panel
 Dry Wall System
 AAC Blocks
 Different claddings/siding materials.
EPS (Expanded Polystyrene panel)
 Made out of Pre-coated steel sheet on both side
 Lightweight closed cell rigid insulation
 Thermal & moisture Resistant
 Reliable, cost effective & compatible

PUF (POLYURETHANE SANDWICH PANELS)

 New type of multifunctional building material
 The wall panels will have tongue & Groove arrangement and interlocked using cam
lock system.
 PPGI sheet & insulations are bonded with high intension adhesive at high temperature
and pressure through auto forming machine

Thickness available
40mm, 50mm, 75mm, 100mm, 125mm, 150mm,
175mm, 200mm
Advantages
 Pre-engineered and factory made for precision.
 Internationally accepted and meets or exceeds all building code
specifications.
 Higher energy savings.
 Flexibility in design and choosing various option on fascia of panels and
colors.
 All weather proof construction and maintenance free.
 Long lasting value with controlled quality, accuracy & speed of construction
and caters for better functionality and application.
 Easy Relocation.
CEMENT SANDWICH PANEL

 STRONG & HIGHLY DURABLE

 FLYASH, EPS beads & SAND COMPOUND as CORE MATERIAL
 MOISTURE RESISTANT
 PROVIDE DEPENDABLE & PREDICTABLE PERFORMANCE
 THICKNESS 50mm, 60mm, 75mm, 90mm, 120mm, 150mm,
180mm, 210mm

Cement Panel with

EPS Bead
DRY WALL SYSTEM
 This system is made of durable galvanized steel, which usually uses Fiber cement board,
MGO Board calcium silicate board as surface material.

 Compared with wooden board/gypsum board can provides safer and resistive wall.

 Compared with bulky brick wall, it can greatly reduce the weight of building.

 Thermal and acoustic insulation product can also be filled in partition frame to create a safe
and quiet environment.
 Thickness 50mm, 60, 75, 90, 120, 150, 180 &210mm.
ACC BLOCK (Autoclaved Aerated Concrete)
 Lightweight, precast, foam concrete building material suitable for producing concrete masonry
unit (CMU)

 Composed of quartz sand, calcined gypsum, lime, cement, water and aluminum powder.

 Used for both interior and exterior construction, and painted or coated with a stucco or plaster

 Quick and easy installation

 ACC materials can be routed, sanded, cut to size on site using standard power tools with
carbon steel cutters

 Size of Block are 600×200mm and Thickness varies 75 to 300 mm

 CASE- STUDY

04
INTERNATIONAL
CASESTUDY #1
Single family house,
Schönkirchen, Lower Austria

International case study

Single family house, Schönkirchen, Lower Austria
● built by Ing. Graf Zimmerei und Holzbau GmbH, is a single family
house
● The building is located in the small village of Schönkirchen, about
40 km north-east of Vienna and about 160 m above sea level.
● The building has no basement, but 30% area is used as a garage and
storage room.
● The remaining 70% is used as living area.
● The garage and the living area are connected and accessible via a
central porch.
● The living area of the building was built as a solid wood
construction. Stone wool is used as insulation material.
● The garage is a brick construction of only one floor and not
conditioned.
Section and plan
KEY FIGURES

● Gross floor area: 290 m2

● Living area: 161 m2
● Gross volume: 885 m3
● Net volume: 760 m3
● Nr of occupants: 4 persons
● Planned service life: 50 years
 STRUCTURES AND CONSTRUCTION METHODS

● Foundation and floors: The construction of the

foundation consists of reinforced concrete with
XPS and EPS insulation. In the residential
building, wood parquet is used as flooring in
almost all rooms. In the garage, tiles are laid.
● External walls: built as a solid wood
construction with stone wool insulation.
EPS XPS
The thickness of the construction is 42 cm. (expanded) (extruded)
The U-value is 0.13 W/m²K.
The external walls of the garage consist of 16
cm of bricks.
Standard thermal transmittance of wall

● Solid brick wall: 2 W/ (m²K)

● Cavity wall with no insulation: 1.5 W/ (m²K).
● Insulated wall: 0.18 W/ (m²K).
● Single glazing: 4.8 to 5.8 W/ (m²K).
● Double glazing: 1.2 to 3.7 W/ (m²K) depending on type.
● Triple glazing below: 1 W/ (m²K).
● Solid timber door: 3 W/ (m²K).
Roof
● The roof consists of timber rafters and stone wool.
● The flat roof has a thickness of 42 cm and a U-value of 0.12 W/M²k
● The roof of the garage consists of concrete (18 cm) and EPS insulation
(10 cm).
 Other structural features
● The internal walls built as lightweight timber
constructions and as solid brick construction in
the garage.
● The rendering of the internal walls consists of
loam on reed matting.
● The inner ceiling is made of cross laminated
timber panels. CLT (cross laminated timber )
● The stairs and door and window frames are also
made out of wood.
● Windows are equipped with 3-layer thermal
insulation glazing. The windows have a U-value
of about 0.7 W/m²K (depending on the area and
orientation).
● Construction work: The construction works were carried out by a
small-sized carpenter company with major input from the building
owners.
● Prefabrication: All essential structural parts of the external building
shell (walls including windows, roof) are made of prefabricated cross-
laminated timber. They were delivered to the site where they have
been completed with a special focus on airtightness.
● On-site work: Because of the high of prefabrication, on-site works are
reduced to completion and connecting prefabricated components. The
internal walls have been built directly on site, adding the reed matting
and loam rendering. Also the garage was brought up directly on the
site.
 RESEARCH

05
PLASTERING
 PLASTERING

 Plastering is a construction and finishing

technique used to create a smooth, even,
and decorative surface on the interior and
exterior walls and ceilings of buildings.

 Involves the application of a mixture

called plaster, >>> composed of gypsum,
lime, or cement, along with sand and
water, to a substrate such as masonry,
drywall, or lath.
 TYPES OF MOTAR USED IN PLASTERING

 Choice of mortar depends on factors such as the

type of surface, the desired finish, and local
building practices.
Cement Mortar:
 Widely used for plastering
 Consist of cement, sand, and water.
 ratio of cement to sand can vary, depending on the desired
strength and finish.
 Durable and suitable for both interior and exterior plastering

Lime Mortar:
 Contain lime, sand, and water
 Known for their breathability and
flexibility>>suitable for historic or older
buildings.
 Used for traditional and heritage restoration
projects.
Lime-Cement Mortar:
 Known as lime-cement plaster
 Lime and cement as key components.
 Combine the qualities of both lime and cement-based mortars
 Mixture offers a balance between the properties of pure lime
mortar and pure cement mortar>> better adhesion and
durability
 Used in Exterior, Plastering, Restoration, Bricklaying, Repair
Work, Stucco
 COATS OF PLASTER

 Two or three coats

 Brick work and stone masonry >> min. two
coats
 Wood or metal >> min. three coats

Scratch Coat (First Coat):

 First coat of plaster>>"scratch coat" or "base
coat.“
 Thickness 10 mm- 15 mm
 Provide a strong bond with the substrate (such
as masonry, drywall, or lath) >>> create a level
surface for subsequent coats.
 Usually thicker than the other coats >>contain
coarser sand for better adhesion.
 After application, the surface is scratched or
scored to create a rough texture, which helps
the next coat adhere securely
Brown Coat (Second Coat):
 Second coat of plaster >>"brown coat.“
 Thickness 6mm- 9mm
 Applied over the scratch coat >> provide
additional thickness and further level the
surface
 Typically thinner than the scratch coat
>>contains finer sand for a smoother
finish.
 Depending on the desired finish and the
surface condition, >>trowelled to a
relatively smooth surface or left slightly
textured to receive the final coat.
Finish Coat (Third Coat):
 Final coat of plaster >> "finish coat" or
"topcoat.
 Thickness 2mm-3mm
 Provide the desired texture, appearance,
and smoothness to the plastered surface.
 More thinly than the previous coats
>>>adjusted to achieve a smooth, textured,
or decorative finish, depending on the
desired aesthetic.
 Composed of a finer mix of plaster>>>>to
achieve the desired surface quality
 Plastering on brick work
Plastering on wood work
 METHODS OF PLASTERING
SN. LIME PLASTER CEMENT LIME-CEMENT
STEPS PLASTER PLASTER
1 Surface  Ensure that the substrate is clean, free from loose debris, and slightly
Preparatio damp.
n  If plastering on laths, secure them firmly to the wall or ceiling, leaving a
2 Mixing the  small gaphydrated
Mix the betweenlime
themandfor the plaster to grip.  Mix cement and sand in
 Mix cement and
Plaster sand in the desired ratio. sand in the the desired ratio.
 Common ratios are 1:3 or desired ratio.  Add hydrated lime to the
1:2 depending on the  Common ratios mix amount of lime added
are 1:3 or 1:4 >>around 10% to 20% of
application.
the cement weight.
3 Applicatio  Apply a "scratch coat" as the first layer >>> use a scratcher to create a rough
n surface on this coat.
 Allow the scratch coat to partially dry (but not fully) before applying additional
coats>>> take a few hours or more.
 Apply additional coats (usually two or three) of lime plaster
 Trowel the final coat to achieve the desired finish, whether smooth, textured, or
decorative.
4  Requires proper curing to achieve maximum strength and durability.
Curing
 Moist the surface with water and cover it with damp cloths or plastic sheets to
slow down the drying process.
 Keep it moist for at least several days or longer, depending on the environment.
5 Finishing  Enhance the plaster's appearance by burnishing it with a trowel or applying lime
wash or paint for color and protection
 Leave the plaster as is for a textured look or apply paint or other decorative
finishes
 DEFECTS IN PLASTERING
 Defects in plastering refer to imperfections or issues that can occur during or after the
plastering process, which negatively impact the appearance, structural integrity, or
durability of the plastered surface.
 Result from various factors, including poor workmanship, incorrect materials, and
environmental conditions.
 Cracks: improper mixing of plaster,
inadequate curing, or structural
movement.
 Hollows or Blisters: gaps or bubbles
between the plaster and the wall
 Crazing: fine, interconnected cracks on
the surface of the plaster>>plaster dries too
quickly
 Bulging or Slumping: uneven distribution
of plaster, resulting in areas that protrude
or sink compared to the surrounding
surface.
 Efflorescence: appearance of white,
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