ADDIS ABABA INSTITUTE OF TECHNOLOGY

SCHOOL OF CIVIL AND ENVIRONMENTAL ENGINEERING

CONSTRUCTION TECHNOLOGY AND MANAGMENT

BUILDING INDUSTRIALIZATION AND MAINTENANCE

SEMINAR PAPER

ON

COMPARATIVE STUDY ON PREFABRICATION

CONSTRUCTION WITH CONVENTIONAL CONSTRUCTION.
(A CASE STUDY INDUSTRIAL SHED)

By: - Alemu Regasa .............................GSR/2950/11

Berhanu Bihonegn.......................GSR/7551/11
Mahlet Abebe ...........................GSR/5110/11

Submitted To: - Prof. Dr.-Ing. Abebe Dinku

 January, 2020

CONTENTS PAGE

ACKNOWLEDGMENT.............................................................................................................................2
Abstract.......................................................................................................................................................3
CHAPTER ONE : INTRODUCTION.........................................................................................................4
1.1. BACKGROUND..................................................................................................................4
1.2. STATEMENT OF THE PROBLEM...................................................................................6
1.3. RESEARCH QUESTIONS..................................................................................................7
1.4. OBJECTIVES OF THE STUDY.........................................................................................7
1.4.1. GENERAL OBJECTIVE...........................................................................................................7
1.4.2. SPECIFIC OBJECTIVES..........................................................................................................7
1.5. SCOPE OF THE STUDY....................................................................................................8
1.6. LIMITATIONS....................................................................................................................8
1.7. NEED OF THE STUDY......................................................................................................8
1.8. METHOD OF THE STUDY................................................................................................8
CHAPTER TWO : LITRECTURE REVIEW.............................................................................................9
 ACKNOWLEDGMENT

We would like to express my deepest appreciation to Prof. Dr.-Ing. Abebe Dinku for his
valuable advice, encouragements, constructive advice, and continuous guidance in the whole
process of this courses and helps us to make fruitful paper.

We would like to acknowledge those who had helped us during site visits and those respond our
interviews with patience and collaboration, in giving accurate data for us.

Besides writing of this Seminar paper, We would like to thank those friends who had given us
comments during every step of our work for the success of this paper completion.
 Abstract
Construction is an important activity that has to be done very carefully. In present scenario
there is a large need for Industrial Development. So it has to be completed at some faster rate
without affecting the cost. But with the conventional construction the speed cannot be achieved.
So we opt for some other methods of construction. Prefabrication construction is one of the
method by which the total time of construction can be minimized. Prefabrication construction
has its own advantages such as it reduces the construction time; the erection is easy etc. but still
in countries like Ethiopia there is a hesitation to accept the prefabrication technology. So a
study is done comparing the conventional construction and Pre-Engineered Building
construction based on time and cost. So, various literatures are studied and the scheduling and
estimation is done separately for both the methods of construction and results are obtained
based on this comparison. Pre-Engineering Building is the recently trend for construction of
industrial building, residential building, malls, warehouse, etc. in Ethiopia. Now a days, a large
scope of PEB buildings with many advantages like light weight, short erection time period, easy
maintenance, weather proof, provision of future expansion and also good control over quality.
In this paper, a comparative study of Pre-Engineering Building (PEB) with Conventional one of
two area different area such as 3,000 m2 and 5,000m2 are analyzed.
From the study results, it can induce the relationship between the time and costs evaluation. The
overall construction period for the conventional building construction method was ------- days
while the PEB construction method was ------- days. As compared across the results for the
project construction costs, it shows that PEB construction method with ----------- ETB is more
cost effective with about 19% less than the conventional building method with total amount of
-----------ETB. The results reflect the significance on selection of the construction method,
namely the PEB construction method not only can shorter the construction periods but also
reduce the construction costs since it reduces greatly the expenses on the project direct costs
particularly the machineries costs.
Also a questionnaire is done to analyze the various risks in precast construction and the
analysis is done based on several factors that leads to injury. Further a checklist is also
prepared so that to ensure safety in precast construction by collecting data from precast office.
Key Words: PEB, Conventional, comparison, risks, checklist.
 CHAPTER ONE : INTRODUCTION
1.1. BACKGROUND
Construction industry plays a vital role in any developing country. This is mainly because
developing countries are considerably dependent on the growth and development of their
physical infrastructures and because the linkage of the construction industry to both economic
and social sectors is very significant. A wide range of Industries and construction facilities are
required by our country, including Industrial parks, commercial property, manufacturing
facilities, schools, hospitals, complex transport infrastructure, and so on.

Technological improvement over the year has contributed immensely to the enhancement of
quality of life through various new products and services. One such revolution was the pre-
engineered buildings. Through its origin can be traced back to 1960’s its potential has been felt
only during the recent years. This was mainly due to the development in technology, which
helped in computerizing the design.
The prefab industry is the backbone for the development of new ideas in construction business of
any country; factory buildings, residential buildings and the industrial township are needed
practically by all the sectors, either to support the manufacturing or services of any industry.
In its steadfast development, the construction industry has discovered, invented and developed a
number of technologies, systems and products, one of them being the concept of Pre-engineered
Buildings (PEBs). As opposed to being on-site fabricated, PEBs are delivered as a complete
finished product to the site from a single supplier with a basic structural steel framework with
attached factory finished cladding and roofing components. The structure is erected on the site
by bolting the various building components together as per specifications.
Pre-Engineered Buildings (PEB) is the future for Ethiopia. Most of the Ethiopians business
community is just started to realize the benefits of PEB's. Where you have been building with
concrete for as long as anyone can remember, it is difficult to change. However Ethiopia's most
progressive companies are seeing the benefits of PEB‟s. The Pre-engineered Building is the
combination of pre-casted and pre-fabricated structures. These are generally ideal for offices,
houses, showrooms, shop fronts etc. Long span, Column free structures are the most essential in
any type of industrial structures and Pre Engineered Buildings (PEB) fulfill this requirement
along with reduced time and cost as compared to conventional structures. This methodology is
versatile not only due to its quality pre- designing and prefabrication, but also due to its light
weight and economical construction.
Industrial building is generally classified as braced and unbraced framed structures. In braced
buildings, the trusses rest on column with hinges and stability is provided by bracings in three
mutually perpendicular planes. The basic function of a bracing is to transfer horizontal loads
from frames i.e. loads like wind or earth quake or horizontal surge due to acceleration and
breaking of travelling cranes over gantry girders to the foundation. The longitudinal bracing
provides stability in longitudinal direction on each longitudinal end provides. The gabble bracing
provides stability in the lateral direction. The tie bracing at the bottom chord level transfers the
lateral loads (due to wind or earthquake) of truss to the end gabble bracings and similarly the
rafter bracing and the bracing system at bottom chords work. Whereas the purlin acts as the
lateral bracings to the compression chords of the roof trusses which increases the compression
chord’s design strength.
The unbraced frames such as portal frames are the most common type of frames used in
industrial building construction because of its simple design, economy, easy and fast erection.
This type of frames provides the large utility area with maximum column free space. In such
type of structures the inner columns are eliminated, requires considerably less Foundation and its
area, the valley gutters and the internal drainage too. The portal frame is a rigid jointed plane
made from hot rolled or cold rolled sections, supporting roofing and side cladding. It's typical
span ranges from 30-40 m and its bay spacing could be 4.5-10 m.
1.2. STATEMENT OF THE PROBLEM
Now days, in world construction sector using prefabricated elements for Industrial Shed
construction has been growing. According to David (2014) prefabricated construction is
preferred in Industrial sector for the reasons that benefits occur right across the value chain to
investor and manufacturer.
The development of Manufacturing industry is becoming a very critical and backbones for the
economic developments of the country. Even though it become critical sector currently there are
so many problems in Ethiopian Manufacturing industry construction industry. Some study states
that delays in construction of manufacturing industry projects are common in Ethiopia and the
project cost for the completion of the project is also high. The other thing is the quality problem
of the works is also under question especially to concrete structural elements
As time is one of the main factors in construction industry, time overrun affects the overall cost
of the project by additional overhead cost, change of material price because of additional time
and inflation. As construction method is playing an important role to eliminate those problems
and satisfying the growing demand of residence in the city. Adopting using PEB is one of the
best methods to minimize the quality problem which occurred by poor workmanship and low-
quality material, minimize the problems occurred by construction delay and to minimize cost of
construction.

1.3. RESEARCH QUESTIONS

 What is the awareness level about prefabrication technology in Addis Ababa real estate
construction industry?
 To what extent prefabricated concrete structural elements are applied in Addis Ababa real
estate construction?
 What are the limitations to use prefabricate concrete structural elements for real estate
construction in Addis Ababa?

1.4. OBJECTIVES OF THE STUDY

1.4.1. GENERAL OBJECTIVE

The main objective of this study is to find out an optimal construction technique which has a
minimal cost and gives a minimum duration of time by doing a comparative study between PEB
and conventional construction.
1.4.2. SPECIFIC OBJECTIVES
 To compare the cost and time of PEB construction versus conventional construction.
 To determine the type of construction that would reduce the construction cost.
 To determine the method of construction that would help to finish the construction
project in shorter duration.
 To study the limitations of PEB technology in Ethiopian context.
 To study whether there are any consequences to the environment with the introduction to
the prefabrication.

1.5. SCOPE OF THE STUDY

The scope of this study is to compare the Prefab construction and conventional construction and
the results arrived based on the cost and duration of the project. This study focused on the current
application status of prefabrication in Ethiopia in manufacturing Industry sector and its potential
to be applied: -awareness to use the method. Geographically the paper focused on manufacturing
industry construction around 100km radius from Addis Ababa city.

1.6. LIMITATIONS
 The study does not include the design aspect.

1.7. NEED OF THE STUDY

Purpose of this study is to determine the constraints in introducing prefabrication method of
construction in our industry. To evaluate the different methodologies in both the construction.
Determine the pros and cons. Suggest improvements to include prefabrication methods.

1.8. METHOD OF THE STUDY

This chapter presents the method of the study on comparison of prefabrication construction with
conventional construction. A Industrial Shed building is taken for comparing and it includes the
first we make a plan with the Federal Industrial parks Cooperation for the visit of the two
Industrial parks this area Bole Lemi Phase I and Adama Industrial Parks for the prefab method
and also we arrange on the same ways Investment Project carried near to Adama Industrial Park
by Individual Investor where they Owned land from government after we visit both site we
collect data such as plan of both shed, estimation of quantities, and determination of project
duration.
Estimation is used to find out the requirement of the materials (resources of labor, material and
machineries) for both the constructions. The details of the materials which are used in the
construction from the companies were collected. By getting these details we can estimate the
quantities of the materials.
Project duration of the each construction was collected from the site offices and compares the
time of completion period by using Critical Path method gives the project duration of prefab and
conventional construction of the Shed.
 CHAPTER TWO : LITRECTURE REVIEW

2.1. THE DEFINITION OF PREFABRICATION

Prefabrication defines as a manufacturing process, generally taking place at a specialized facility,
in which various materials are joined to form a component part of a final installation (Tatum et al
1987).
Prefabrication may be in general terms defined as a continuity of production implying a steady
flow of demands, standardization, integration of the different stages of the whole production
process, a high degree of organization of work, mechanization to replace manual labor wherever
possible, and search and experimentation integrated with production process (UN, 1972).

2.2. DEFINITION OF CONVENTIONAL AND PREFAB CONSTRUCTION

2.2.1. PRE-ENGINEERED BUILDINGS
Pre-Engineered Building concept involves the steel building prefabricated systems which are
predesigned. As the name indicates, this concept involves Pre-Engineering of structural elements
using a predetermined registry of building materials and manufacturing techniques that can be
proficiently complied with a wide range of structural and aesthetic design requirements. The
basis of the PEB concept lies in providing the section at a location only according to the
requirement at that spot. The sections can be varying throughout the length according to the
bending moment diagram. This leads to the utilization of non-prismatic rigid frames with slender
elements. Tapered I sections made with built-up thin plates are used to achieve this
configuration. Standard hot-rolled sections, cold-formed sections, profiled roofing sheets, etc. is
also used along with the tapered sections. The use of optimal least section leads to effective
saving of steel and cost reduction. The typical PEB frame of the structure is as shown in the
Figure.

Components of PEB building

Pre Engineered metal buildings use the combination of built-up members, hot rolled, cold form
elements which make the basic steel frame work and other accessories canopy, fascia, clip, trim,
deck sheet for mezzanine floor, ridge vent, bracing, sag rod etc. Build up members are used for
primary members (Rafter and Column) as per optimum requirement with the help of bending
moment diagram, thus reducing wastage of material and self-weight of the structure, due to
reducing self-weight the reaction at support will be reduced and foundation will be light thus
structure become economical. Z & C sections are used as secondary members (Purlin and Girt).
All these components of PEB are fabricated in factories after designing and assemble on site for
erection. Now a days, PEB buildings have become very popular in India because these buildings
are most economical, low cost, short erection time period, light weight, seismic and wind
resistant, water proof & wall covering structure etc. one distinct advantage of PEB buildings
have become bolted is it can be dismantled and relocate. Three types of frames are used in PEB
structure, rigid frame, post end beam and semi rigid frame. Basically, main frame (Column &
Rafter) of PEB structure is rigid steel frame and combination taper column and taper rafter.
These taper sections are fabricated in plant using advanced technology wherein taper flange
welded to the taper web while end wall frame of PEB building may be designed as a main frame
or post end beam frame. While post end beam system framing consists of columns (Post) with
pinned ends and supporting beam known as end-wall. In post beam system consists bracing to
resisting lateral load to maintain longitudinal as well as lateral stability. Generally mezzanine
framing is connected to the main frame column and main
Primary built-up
 Frames in the PEB industry often refer to primary built-up & hot rolled members.
Constant depth or tapered depth built-up members generally account for over 90% of
the weight of frames while hot rolled members generally account for the remaining 10%.
Figures
Secondary Members in the PEB industry refer mostly to longitudinal roof and wall members
that are roll formed from galvanized coils or press broken from narrow galvanized sheets. The
raw material of these members is stocked in five thicknesses: 1.5, 1.75, 2.2, 2.25 and 2.5mm.
The following building components are considered secondary members
 Z” sections acting as longitudinal roof purlins and longitudinal wall girts that connect to
columns & rafters and support exterior roof and wall panels.
 Eave struts located at the building eaves (corner of roof and wall sheeting along
sidewalls also providing bracing for frames and supporting roof and wall panels.
 "C” sections used primarily in framed openings and as a transition member between
partial block walls and wall panels.
 Mezzanine Deck (0.7mm thick) used to support concrete slabs in second level flooring.
 Base angles, gable angles, and mezzanine edge angles.
 Valley gutters (0.9mm thick) in Multi Gable Buildings.
Figures

The Panels & Panel Accessories (PPA)

Panels & Panel Accessories include single skin panels, sandwich panels, trims and flashing,
panels standard buyouts and building accessories. Although all roofs have panels, walls are often
partially or fully open for block wall, precast panels or access.
 Single Skin Panels are trapezoidal ribbed sheets roll formed from thin mill finish or pre
painted aluzinc coated steel and aluminum coils and cut-to-length to meet the
requirements of a specific building.

 Sandwich Panels have a polyurethane foam core sandwiched between two single skin
metal panels (or an exterior single skin metal panel and an interior aluminum faced
laminate). SUNTECH does not produce sandwich panels but has an exclusive
arrangement, with the largest producer of sandwich panels in the UAE, for the purchase
and resale of sandwich panels, to provide its Customers with a single source supply
responsibility. The engineering drawings for the sandwich panels are done by
SUNTECH so are the production of trims and the supply of all sandwich panels
accessories such as fasteners, bead mastic, purlin tape, etc.

 Trims and Flashing include eave trim, eave gutters, downspouts, gable trim, curved
eave panels, flashing around building accessories, etc. which are produced from
 preprinted aluzinc coated steel or aluminum sheets that are bent to the required shape
using roll formers, presses, or folding machines.

Figures
 Building Accessories and special buyouts (SBO’s) include sliding doors, rollup doors,
personnel doors, fiberglass insulation, sandtrap louvers, windows, ridges ventilators.
Some are produced in-house. Some are purchased from suppliers and included in our
single source supply.

figures

 Panel Standard Buyouts are items that are produced by others and stocked as finished
items by the PEB manufacturer. They include sheeting fasteners (carbon steel and
stainless steel), bead mastic, pop rivets, foam closures, skylights, etc. These are packed
by us for a specific building and shipped to the jobsite with the panels.
CONVENTIONAL CONCRETE HOLLOW BUILDINGS

4.3. THE DEFINITION OF PREFABRICATION

4.4. DEFINITION OF CONVENTIONAL AND PREFAB RESIDENTIAL

CONSTRUCTION

4.4.1. CONVENTLONAL

4.4.2. MANUFACTURED

 Pre-Cut Manufactured Housing

 Panelized Manufacturer Housing
 Modular Manufactured Housing
 Mobile Homes
Prefabrication Construction
Kariuki (2010) define prefabrication is the practice of assembling elements of a structure in a
factory or other manufacturing site and transporting complete assemblies or subassemblies to the
construction location where the structure is to be placed. Dineshkumar and Kathirvel (2015) also
agreed on that the term prefabrication is used to distinguish the process from more conventional
construction method of transporting the basic materials to the site where the construction is
taking place.
The primary purpose of prefabrication technology is to produce building components in an
efficient work environment with accesses to specialized skills and equipment in order to reduce
cost and time expenses on the site which enhancing quality and consistency (Anderson and
Anderson, 2007).Prefabrication together with increasing use of standardization and
mechanization has brought a rapid change in the development of construction field throughout
the world. Prefabrication techniques lead to increases large scale and high-rise constructions
(Venkateswara, and Sarath, 2013).
Additionally, Ali and Rahinah (2017) cited the work of Kamar (2001) and defined prefabrication
technology as an innovative process of construction using concept of mass-production of
industrialized systems, produced at the factory or onsite within controlled environments, it
includes the logistic and assembly aspect of it, done in proper coordination with thorough
planning and integration.
Prefabricated Concrete Structural Element
History of Prefabrication Construction
Ancient Romans have a practice of pour concrete into molds to build aqueducts, culverts and
tunnels beginning around 100 B.C. (Mikhailov and Susnikov, 1995). In the 1500‘s, the timber
components of house were crafted and painted in Holland, then assembled in London. Later, the
method was widely adopted in Eastern Europe and Scandinavia (Arieff and Burkhart, 2002).
The Crystal Palace (Giant glass-and-iron exhibition hall in Hyde Park, London) was one of the
first prefabrication construction in Britain‘s during great exhibition of 1851.TheCrystal Palace
was constructed in a few months and assembled using a series of prefabricated elements. United
States go into the market in the 1900s however the mass fabrication was first introduced in
World War II when easy to assemble mass accommodation was required for soldiers (Mikhailov
and Susnikov, 1995).
This skill was later utilized by the Europeans and Japanese for quickly rebuild war devastated
areas. In the 1960s and 1970s high rise concrete prefabricated construction was introduced
(Velamati, 2012). Velamati also stated that Hilton Palacio Del Rio Hotel was among the first
concrete high rise prefabricated buildings in the world. The project was during the Texas World's
Exposition of 1968; the 500-room hotel was designed, completed and occupied in an
unpredictable period of 202 working days.
History of Prefabrication Construction in Ethiopia
For the first-time prefabrication plant was established in Ethiopia at 1978 E.C with the help of
former socialist country Yugoslavia. The company called Prefabricated Building Parts
Production Enterprise (PBPPE) and it is the only prefabrication factory in Ethiopia till know.
According to Gutema (1998) the aim was to accommodate the ever-increasing demands of
housing within the shortest possible time, to overcome the shortage of accommodation and meet
the future demands, and to minimize the pressing need of timber for formwork and consequently
conserve the natural forest. The Factory primarily in charge of prefabrication - Prefabricated
Building Parts Production Enterprise (PBPPE) - has produced structural elements for the
construction of office buildings, apartments, hotels and residential buildings for the public and
private sector. According to the information from PBPPE, the building shown in the following
figure 2.2 is one of those buildings. The back-log of housing units in Ethiopia was so vast that all
efforts made by the Government and inhabitants could not wipe out the shortage of housing in
the early 1980s. To promote the building industry and to alleviate the housing shortage
prefabrication technology was introduced. The objectives of the enterprise are to promote the
building industry through mass production of prefabricated concrete elements, to alleviate the
shortage of housing and to reduce the construction cost (Gutema, 1998). As indicated above
establishment of PBPPE in Addis Ababa has brought new techniques for the construction
industry and it was supposed to provide the solution for the vast housing needs at the time.
ADVANTAGES OF PREFABRICATION CONSTRUCTION:
Various literature and researchers have revealed that using prefabrication construction method
have so many advantages than conventional method relative to safety, quality, time and cost.
Tanya Trainee(2010) specify the main benefits of using prefabricated concrete structural
elements – the lower construction cost, the speed of construction and the precision of work.
Nadim (2009) also stated that prefabrication technology can be considered as a business strategy
that transforms the traditional construction process into a manufacturing and assembly process
by embracing new and advanced technologies, engaging people, and translating clients‘ needs
into building requirements. Additionally, Nadim (2012) stated that the advantages of
prefabrication method as follow, improving the overall business efficiency, quality of product,
environmental performance, sustainability, customer satisfaction, and predictability of
timescales. These can be achieved within a controlled production environment, with minimum
waste, in a safer work environment, and with better investment in the long-term economy.
2.5.1. Advantage of Prefabricated Elements Relative to Quality
Prefabricated elements were manufactured in a factory environment with better quality control
(Jaillon and Poon, 2007).Different mix of prefabricated 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 (Dineshkumar, 2015). As prefabricated elements were produced in a factory
under standard control, quality problems occurred by poor work man problem and low material
quality are reduced. In addition, Architect express that with the use of both prefabricated facades
and lost form panels, uniform quality was achieved in the building elevations, and hence
promoting continuity in visual quality and aesthetics (Jaillon and Poon, 2007).
2.5.2. Advantage of Prefabricated Elements Relative to Time
There are various technologies available worldwide for using prefabricated construction
methods, almost all technologies try to reduce costs and time, prefabrication method gives
possibility to the designers for assembling their structures in a short period of time. There are
numerous potential advantages related when delivering and developing building by
prefabrication (Alireza and Omid, 2016). One of the greatest benefits is the ability to
dramatically reduce the time needed for construction. Factory efficiencies allow building
components to be completed quickly and without weather delays. The factory has all of the key
player‘s onsite to handle multiple building requirements and multiple subcontractors are not
always required. This makes prefabrication construction suitable for owners who need buildings
quickly, properties with hard dates for occupancy, and areas where seasonal weather restricts or
even halts construction (Velamati, 2012).
As the industry strategies itself to build with less labor and shorter construction time,
prefabrication of concrete structures has become a viable alternative to the traditional way of
construction.
2.5.3. Advantage of Prefabricated Elements Relative to Cost
The other main benefits of using prefabricated element includes higher financial return due to
less construction interest carry and related time savings through a shortened construction
schedule and potentially reduced hard cost from repeatable and higher efficiency construction
methods, modernized construction process, reduced material waste and higher construction
quality (Velamati,2012).
2.5.4. Advantage of Prefabricated Elements Relative to Safety
Prefabricated construction does not only reduce construction costs, but it also produces a more
stable and fairly rewarded construction industry with improved safety and working conditions,
greater investment in research, design creativity, and product development (Anderson and
Anderson2007). Additionally, by using prefabricated concrete elements mainly, on-site
operations are considerably reduced, providing a safer working environment (Dineshkumarand
Kathirvel,2015).This shows that using prefabricated concrete element have great to minimize
work place hazard by minimizing on – site operation and providing safer working condition.
2.5.5. Advantage of Prefabricated Elements to Work 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 realized by
simply 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 (Dineshkumar and Kathirvel, 2015). In other words, it is vital to have a
good cooperation between the architect, the engineer, the builder and the producer. It also
reduces consumption of energy and material and generally increases the availability of better
designed and high quality-built environments (Anderson and Anderson, 2007).
The adaptation of prefabricated building mainly depends on factors such as labor shortage, labor
cost, housing demand, building process efficiency, weather, as well as reduction of waste
material and energy consumption. Prefabricated building has a relatively inherent economic,
environmental, and social benefits (Khaled and Farid, 2015).
2.6. Limitations of Using Prefabrication
Prefabrication technology has not transferred as easily when compared with other technologies
because it is a production technology knowledge based and not a consumption technology or
product based (Ryan and Shilpa, 2002). It need early decision on design were required in the
building process as precast elements were manufactured before delivered to the site for
assembly. For architect also, the possibility of late change in the design was limited, client
instruction to modification to the design even during construction (Jaillon and Poon, 2007).
Khaled and Farid (2015) also states that the possible barriers to use prefabricated elements as:
lack of research information, higher initial construction cost, limited site space, monotone in
aesthetics, lack of experience, no demand for prefabrication, inflexible for design changes.
Industry practices and techniques, supply chain management and logistics, professionalism of the
industry, and construction market risks.
2.6.1. Limitations of using prefabrication technology in Developing Country
Prefabrication technology has not shifted as easily when compared with other technologies
because it is a production technology or knowledge based and not a consumption technology or
product based. Adapting prefabricated building in these countries is mainly influenced by labor
shortage, labor cost, housing demand, building process efficiency, weather, as well as reduction
of waste material and energy consumption. Prefabricated building has a relatively low uptake in
construction industries worldwide despite its inherent economic, environmental, and social
benefits.
This situation is attributed to prevailing local conditions that vary from country to country.
Although motivations in using prefabricated building help determine its use as an option, the
decision to implement such technology is influenced by the balance between potential benefits
and impediments. The possible barriers to prefabricated building adoption are industry practices
and techniques, supply chain management and logistics, professionalism of the industry, and
construction market risks.
Further studies should be conducted to investigate the measurement strategies on the application
and evolution of prefabricated building. However, addressing prevalent issues in many countries,
benefitting from them in enhancing prefabricated building adoption, and avoiding perceived
barriers require more extensive approach. The similarities and differences among countries
should also be considered. Meanwhile, many other aspects involved in adopting this technology
require attention. Transforming the use of prefabricated building into economic rewards requires
training, organizational changes, and procurement arrangements in the construction industry.
There are several indications of the potential positive benefits of financial and social incentives,
as well as revised national policies and regulations by the government for prefabricated building
uptake. Thus, implementing prefabricated building technology requires a complete restructuring
of the construction industry. The government should encourage and motivate the private sector to
participate in developing such structures (Khaled and Farid, 2015).
2.7. Prefabrication Plant
2.8. Connection Method of Prefabricated Elements of Building

2.10. Current Application of prefabricated elements in Construction

2.11. Current Application of prefabricated Structural Element in

Ethiopia

2.12. The Current Construction Method in Ethiopian

2.13. An Overview of the current Status of Industrial Park Development in

Ethiopia
The Industrial Parks proclamation 886/2015 provides that industrial parks can be developed by
any profit-making public, public-private or private enterprise. Three mechanisms are in place for
the establishment of IPs/SEZs: (a) fully developed by the federal or regional government; (b)
developed by PPPs with the IPDC; and (c) by private developers only. Industrial parks in
Ethiopia can also be categorized based on their focus sector including textile and garment;
leather and shoes; agro-processing, pharmaceutical and IT parks. In the following section, we
will discuss each paths of industrial parks development with practical examples. The GTP I
envisioned the establishment of five industrial parks in the country: two in the Addis Ababa area
(Bole Lemi and Kilinto Industrial Parks), one in Hawassa, one in Dire Dawa and one in
 Kombolcha. The country is targeting US$ 1 billion of annual investment in industrial parks over
the next decade to boost exports and make it Africa's top manufacturer. Bole Lemi Phase I
(covering 156 hectares) is the first IP operating under the IP development strategy. It was
established in 2012 with the help of a World Bank loan, and started its operations in 2014. It now
consists of some 20 pre-erected factories (of 185,000 square meters of factory space) rented-out
to more than 10 foreign-owned manufacturing companies producing and exporting leather and
apparel goods (see Table below). Bole Lemi Phase 2 (covering 186 hectares) is currently under
construction with the financial support of the World Bank. The World Bank also supports the
development of the new industrial hub in Kilinto, 20 miles south of the capital. (Dollar, 2016)
Kilinto aims to be a mixed-use park and the top destination for manufacturers in agro-processing,
pharmaceuticals, electric and electronics products, wood and furniture, both for export and to
serve local consumers.

Table 3 Federal developed parks

No Name Location Main Industry Progress Size

1 Bole Lemi Industrial Park I Addis Ababa Garment Operational 157ha
2 Hawassa Industrial Park SNNPR Garment Operational (100ha in phase
400ha I)
3 Mekele Industrial Park Tigray Garment Construction 1000ha (75ha in
Under phase I)
4 Kombolcha Industrial Park Amhara Garment Under 750ha (75ha in
construction phase I)
5 Jima Industrial Park Oromia Garment Decided 1000ha (75ha in
contractor phase I)
6 Adama Industrial Park Oromia Assembling, Under 2000ha(365ha
garment, food construction in phase I)
7 Bole Lami Industrial Park II Addis Ababa Garment Decided 170ha
 contractor
8 Kilinto Industrial Park Addis Ababa Pharmaceutical, Decided 279ha
medical equipment contractor
9 Dire Dawa Industrial Park Dire Dawa Assembling, Decided 4000ha (150ha
garment, food contractor in phase I)
10 Bahir Dar Industrial Park Amhara Garment Planning 1000ha (75ha in
stage phase I
11 DebreBirhan Industrial Park Amhara - Planning
stage
12 Aysha Industrial Park Somali - Planning
stage
13 Airline and logistics Park4 Addis Ababa Transportation Planning
stage
14 Addis Industrial Village5 Addis Ababa 80ha
15 Modjo Leather City Leather Oromia Planning
stage
16 Arerti Industrial Park, home Amhara Construction Planning 100 ha
productsappliance stage

Table 4 Regional developed parks

No Name Location Main Industry Progress Size

Bure Integrated Agro-Industrial Amhara Agro-processing Under construction 260.35ha
Park
Bulbula Integrated Agro- Oromia Agro-processing Under construction 263.09ha
Industrial Park
Yirgalem Integrated Agro- SNNPR Agro-processing Under construction 214.86ha
Industrial Park
Baeker Integrated Agro- Tigray Agro-processing Under construction 258.62ha
Industrial Park

Table 5 Private parks

No Name Location Main Industry Progress Size

Eastern Industrial Zone Oromia Various Operational 500ha
Huajian Light Industry City Addis Shoes Garment Operational 138ha
Ababa Partly
Modjo George Shoe Industrial Oromia Leather 50ha
Park
Kingdom Linen Industry Zone - Dire Linen Signed MOU
Dawa

2.14. Industrial Development in Ethiopia

2.15. Current Application of Prefabricated Elements for Industrial Building

Construction
1. Self-supporting ready-made components are used, so the need for formwork, shuttering and
scaffolding is greatly reduced.
2. Construction time is reduced and buildings are completed sooner, allowing an earlier return of
the capital invested.
3. On-site construction and congestion of site is minimized.
4. Better quality control can be achieved in a factory assembly line setting than at the
construction site.
5. Prefabrication site can be located where skilled labour is more readily available and the costs
of labour, power, materials, space and overheads are reduced.
6. Time spent due to bad weather or hazardous environments at the construction site is
minimized.
7. Less wastage of construction material.
8. Advanced materials such as sandwich-structured composite etc. can be easily used, improving
thermal and sound insulation and air tightness
Disadvantages of prefabrication:
1. Leaks can form at joints in prefabricated components.
2. Transportation costs may be higher for voluminous prefabricated sections.
3. Large prefabricated sections require heavy-duty cranes and precision measurement from
handling to place in position.
4. Larger groups of buildings from the same type of prefabricated elements tend to look drab and
monotonous.
5. Local jobs may be lost, if the work done to fabricate the components being located in a place
far away from the place of construction. This means that there are less locals working on any
construction project at any time, because fabrication is outsourced.

IDENTIFYING THE COMPONENT-STRUCTURAL/NON STRUCTURAL

1.STRUCTURAL
 ROOF AND FLOOR SLABS
 COLUMNS:
2.NON-STRUCTURAL

3.METHODS OF CONNECTION
 Foundations
 Columns to base Connection (Anchorage bolts)
 Columns to Columns connection
 Columns with beam connection
PREFAB MATERIALS AVAILABLE IN THE MARKETS:
Structural Insulated Panels: These are composite building material consisting of an insulating
layer of rigid polymer foam sandwiched between two layers of structural board. One of the main
advantages of SIPs is their insulating value, which depends on the thickness of the foam core.
The foam core forms a continuous energy barrier, and the smaller number of studs leaves less
opportunity for heat conduction. One of the biggest concerns about SIPs is their resistance to
insects. While the EPS foam core provides no nutrition to insects, it offers an easy way for them
to tunnel into the structure. Borate additives can be mixed into the foam during manufacture,
providing some amount of insect resistance.

Sandwich Panel:
These are used for insulation of roofing and walling in the building. It has one or both side metal
Galvalume sheet and PUF insulation in between. These have high thermal efficiency and
significant mechanical strength, which makes it possible to go for larger spans as well as large
partition walls.
FRP Corrugated Sheets:
Fibre-reinforced plastic (FRP) (also fibre-reinforced polymer) is a composite material made of a
polymer matrix reinforced with fibres. The fibres are usually glass, carbon, basalt or asbestos.
The polymer is usually an epoxy or a polyester thermosetting plastic. FRPs are commonly used
as roofing material as it is light weight, strong and resistive to deforming forces. They are usually
rust and termite proof. They have good impact resistance, possess fire retardant properties and
resistant to external weather conditions.
RESULTS AND DISCUSSION

FOR THREE DIFFERENT STAGES

Comparison of total project duration for both prefab and conventional construction of Industrial
Shed with area of 5,500m2
1. Project Duration
S. No DESCRIPTION DURATION
1 Sub Structure -(Site cleaning, Earthwork, Foundation, Basement, 30 days
Soil filling & Consolidation.)
2 Super Structure – (Wall panels framing and Roofing slabs.) 74 days
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and 76 days
Windows, Extra items.)
Table 1: Total Duration for Prefabrication Construction
The duration of the prefab construction was calculated through the data collected from precast
company, which help to find the duration of erection for the super structure of prefabrication
construction. The duration of the project is shown in three different stages. The duration of
substructure was the same as conventional construction because of same method is used to
construct in the prefab. But the super-structures in the prefab were completed earlier when
compared to conventional construction. The project duration of super-structure has a huge
variation and it’s an advantage of prefab construction. The walls and slabs are manufactured in
factory and installed in site, which reduces the duration of the super-structure. The prefab
construction takes less time duration in finishing works when compared to conventional
construction, because of the electrical piping work was fitted already in precast walls and slabs.
The plastering work is no need for precast elements, which is good in appearance and finishing.
The total duration of the double storey residential building for prefabrication construction is 65
days which is shown in table 4.1.

S. No DESCRIPTION DURATION
1 Sub Structure-(Site cleaning, Earth work, Foundation, Basement,
Soil filling & Consolidation.)
2 Super Structure (Columns, Lintel & sunshade, Beams, Roof
slabs, Brick work, Plastering.)
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and
Installation of doors & Windows, Extra items.)

Table 2: Total Duration for Conventional Construction

The duration of the conventional construction was calculated through the data collected from
conventional company and CPWD engineering data, which help to find the duration for the
conventional construction. The duration of the project is shown in three different stages. The
duration of sub-structure was same for both constructions which used same method to construct.
But the super-structures in the conventional takes long time to complete when compared to
prefab construction. The project duration of super-structure has a huge variation and it is a main
delay to the project in conventional construction. And finishing work also the conventional
construction takes more time duration when compared to prefab construction, because of the
electrical and plastering work is done only in site condition. The total duration of the double
storey residential building for conventional construction is 128 days which is shown in table 4.2
In this analysis, we had known about the total project duration of both prefab and conventional
constructions. The figure (5.1) shows the comparison of project duration for the both prefab and
conventional construction in three different stages. As in the figure the sub-structure has taken
the same duration for complete the project for both construction of double storey residential
building, because of the sub- structure was done by the traditional method.

chart

Figures Comparison of total project duration for both prefab and conventional construction of
Industrial Building
The total project duration were calculated for both construction and shown in the Figure (5.2).
The figure represents the duration of the prefabrication construction is lower than the
conventional construction. The time duration of the project difference is 63 days between the
prefabrication and conventional construction. This contains very low time duration compared to
the conventional method for the individual double storey building.

Comparison of total project cost for both prefab and conventional construction of Industrial Shed
with area of 5,500m2
2. Cost Analysis
S. No DESCRIPTION Cost
1 Sub Structure -(Site cleaning, Earthwork, Foundation, Basement, 16,539,000
Soil filling & Consolidation.)
2 Super Structure – (Wall panels framing and Roofing slabs.) 46,041,000
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and 26,820,000
Windows, Extra items.)
Table 3: Total Cost for Prefabrication Construction
The cost of the prefab construction was calculated through the data collected from precast
company, which help to find the cost of the super structure of prefabrication construction. The
sub-structure and finishing work cost was the same as conventional construction because of same
method is used to construct in the prefab. The cost of the project is shown in three different
stages. The total cost of the double storey residential building for prefabrication construction is
73, 00,000.00 (Sixty nine lakes and nineteen thousand rupees only).

S. No DESCRIPTION Cost
1 Sub Structure-(Site cleaning, Earth work, Foundation, Basement,
Soil filling & Consolidation.)
2 Super Structure (Columns, Lintel & sunshade, Beams, Roof
slabs, Brick work, Plastering.)
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and
Installation of doors & Windows, Extra items.)
Table 4: Total Cost for Conventional Construction

The cost of the conventional construction was calculated through the data collected from
conventional construction company, which help to find the cost of the total project. The sub-
structure and finishing work cost was taken to the prefab construction from the conventional. So
there are no cost variations in both constructions for these stages. But the cost variation was in
the super-structure and which is low when compared to the prefab construction for double storey
residential building. Total cost of the double storey residential building for conventional
construction is 60, 19,000.00 (Sixty lakes and nineteen thousand rupees only).

Chart

Figure Comparison cost for prefab and conventional in three different stages

In this analysis, we had known about the cost of both prefab and conventional constructions. And
also the comparison cost for different stages as sub-structure, super-structure and finishing
works. The figure (5.3) shows the cost difference for the both prefab and conventional
construction in three different stages. As in the figure the sub-structure and finishing works has
the similar cost for both construction of double storey residential building, because of the sub-
structure and the finishing works was done by the traditional method. But the category of super-
structure has more variations, which the prefabrication construction is very high cost compare to
the conventional construction, because of the superstructure was done in two different methods
as prefab and conventional. The total project cost were calculated for both construction and
shown in the Figure (5.4). The figure represents the cost of the prefabrication construction is
higher than the conventional construction. The cost difference is 12, 91,000.00 rupees between
the prefabrication and conventional construction.

Chart

Figures: Comparison of total project cost for both prefab and conventional construction of
Comparison of total project duration for both prefab and conventional construction of Industrial
Shed with area of 3,000m2
1. Project Duration
S. No DESCRIPTION DURATION
1 Sub Structure -(Site cleaning, Earthwork, Foundation, Basement, 30 days
Soil filling & Consolidation.)
2 Super Structure – (Wall panels framing and Roofing slabs.) 74 days
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and 76 days
Windows, Extra items.)
Table 5: Total Duration for Prefabrication Construction

S. No DESCRIPTION DURATION
1 Sub Structure-(Site cleaning, Earth work, Foundation, Basement,
Soil filling & Consolidation.)
2 Super Structure (Columns, Lintel & sunshade, Beams, Roof
slabs, Brick work, Plastering.)
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and
Installation of doors & Windows, Extra items.)
Table 6: Total Duration for Conventional Construction
Comparison of total project cost for both prefab and conventional construction of Industrial Shed
with area of 3,000m2
2. Cost Analysis
S. No DESCRIPTION Cost
1 Sub Structure -(Site cleaning, Earthwork, Foundation, Basement, 13,782,500
Soil filling & Consolidation.)
2 Super Structure – (Wall panels framing and Roofing slabs.) 38,367,500
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and 22,350,000
Windows, Extra items.)
Table 7: Total Duration for Prefabrication Construction
S. No DESCRIPTION Cost
1 Sub Structure-(Site cleaning, Earth work, Foundation, Basement,
Soil filling & Consolidation.)
2 Super Structure (Columns, Lintel & sunshade, Beams, Roof
slabs, Brick work, Plastering.)
3 Finishing Works–(Electrical, Plumbing Painting, Tiling, and
Installation of doors & Windows, Extra items.)
Table 8: Total Duration for Conventional Construction

In this Study, we compare the cost and time taken for convention as well as prefabricated
construction show them through graphical representation and network diagram

Comparison Graphs of Cost and Time for Conventional and Prefabricated Structures
Cost for substructure is lesser in prefabricated structures. The cost for superstructure is almost
equal in both cases. Finishes shows a difference of about 6 lakhs lesser in prefabricated. The time
for the sub structure is almost equal in both prefab and conventional construction. The
superstructure in the conventional methods takes 241 days more than prefabricated structure,
which helps to reduce the total duration in prefabrication by large extent. Finishes in
conventional takes 114 more days than prefabricated structure.
CONCLUSION
The main goals of the work have been achieved. 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 prefab construction for individual double storey residential building cost is 13% more than
the conventional construction. This is main drawback for prefab construction which is not
economical to construct in this case. At the same time the prefab construction is easy to work and
reduces the project duration, is reduced by 63 days when compared to the conventional. It’s the
main advantages for prefab construction and also it helps when there is labour shortage. As a
result of survey we had known that the prefab construction have more advantages and
procurement in industrialized, heavy infrastructures. But in individual houses there are lot of
constraints and lack of knowledge its get struggling to implement in our country. At this stage
conventional construction is economical and comfortable when compared to the prefabrication
construction.
Even if the general theoretical idea of prefabrication technology is known by
professionals involved in real estate construction in Addis Ababa, majority of them
have no information about the existing prefabrication plant in Addis Ababa.
Majority, 72.5%, of the professionals involved in Addis Ababa real estate
construction are preferred using prefabrication construction method to conventional
method. But it is believed that there is no capability to use the technology in
construction industry of Ethiopia.
There is no sufficient supply of prefabrication elements in Addis Ababa, as a result
the attitudes towards use it for real estate construction is also limited. The study
shows that, currently there is no practice of using prefabricated concrete structural
elements in Addis Ababa real estate construction.
The major challenges to use prefabrication technology are: - shortage of supply of
prefabrication elements, lack of information about the existing potential, shortage of
skilled man power on the area, lack of consideration of the existing dimension during
design and low motivation of designers to adjust their work with it.
 PEBs needs a huge initial investment

RECOMMENDATION

Based on the findings of the study and the discussions above a summary of some general
recommendations are offered to support the improvement of application of prefabrication
technology for real estate construction in Addis Ababa and to recommend some area for
further investigation. These are listed below:
Great effort should be done by government to distribute technical information for
professionals and other stakeholders to raise public information about the existing
potential of the technology.
Acceptance and preference of the technology by professionals is great potential to
apply a given technology, so that the government and other stakeholders should use
this resource as an input.
To minimize the shortage of supply of prefabricated elements in addition to
improving the existing plant, government should encourage the investors who have
potential to establish modern prefabricating plant in Addis Ababa.
 The government should pay due attention to develop prefabrication construction as a
viable solution to improve the quality, speed, and economy of upcoming real estate
construction.

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APPENDIX
Interview Questions
Section I: -Interview Questions to Industrial Parks Development Cooperation staff ,
Employer Representative and Contractor for Comparison of prefabricated PEB Industrial
Building than Conventional method.
1. What is the benefits of using prefabricated structural elements than Conventional method in
minimizing of quality problems?
2. What is the benefits of using prefabricated structural elements than Conventional method in
minimizing of work place hazard?
3. What is the Advantage of using prefabricated structural elements than Conventional method
takes shorter time?
4. Minimizing of material wastage
5. Minimizing of overhead cost
6. Low maintenance cost
7.It need less work place
8.Easy HR management
9.No false work needed
10.It need less supervision
What are shortcomings of using prefabricated structural elements?
1. Not easily transported
2. It may face connection problem
3. It is not flexible with design
4. It need more expensive machinery
Challenges to Use Prefabricated Concrete Structural Elements
1. Shortage of skilled man power on the area
2. Shortage of supply of prefabricated elements
3. Lack of information about the existing potential.
4. Lack of awareness about the technology
5. Lack willingness of professionals