STUDY OF PREFABRICATION IN INDIA

Rinkesh patel1, Dr.Neeraj Sharma2

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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