Seminar Report On Modular Construction
Seminar Report On Modular Construction
E Society’s
SHRI DHARMASTHALA MANJUNATHESHWARA
COLLEGE OF ENGINEERING AND TECHNOLOGY
DHAVALAGIRI, DHARWAD-580002
(AN AUTONOMOUS INSTITUE AFFILIATED TO VTU)
2019-2020
“MODULAR CONSTRUCTION”
Submitted By:
CERTIFICATE
CONTENT
INTRODUCTION
2. LITERATURE REVIEW
3. CONCLUSION
5. REFERENCES
ABSTRACT :
Modular construction is widely used for single and double storey as well as multi-
story residential buildings. Modular construction technique has played an important role of
producing construction elements quickly and efficiently. The modules are produced in a
factory, and are then transported to the construction site being prepared and then assembled.
Modular construction of houses is an innovation that has potential to tackle issues related to
environmental and sustainability concerns at a rapid rate, mechanizes the construction
process, enabling mass manufacture of affordable houses in a short time period.
The study aims to introduce and to provide more knowledge about modular house to
educate the market and to address the concern of every sector of the society especially the
depressed areas of the society for a beautiful, stable and affordable shelter.
CHAPTER 1
INTRODUCTION
Modular construction can be used for building temporary or permanent building such
as construction of camps, schools and classroom, civilians and also for military facilities as
well as industrial facilities. Modular buildings are a perfect solution in remote and rural areas
where conventional construction may not be possible to be built. Other uses of modular
construction technique include churches buildings, healthcare facilities and retail shops, fast
food joints, etc.
At this time modular construction for buildings or facilities today can be build to any
specification and any size from a simple one to a complex one. Once the building elements
are manufactured, they are then be transported to the site for their final installation. One of
the big advantages of modular construction is that it is very rapid and it can be less expensive
than a site-build structure. Also modular construction cannot be limited by issues like severe
weather and modular buildings are more likely to resist earthquake forces since they are
manufactured under control plant conditions.
As we all know, in building the conventional and traditional buildings, it takes much more
time and the costing is also very high. Also, there will be more wastes and environment will
be polluted; labours are also not safe while construction traditional buildings. If these many
problems are there in following the conventional trend, why should not we look for the easier
and best way for constructional work? Yes. We have to follow the new techniques i.e. Pre-
fabricated Modular and steel structures. This method of building structures will minimize the
constructional cost, time and wastes. But it increases the quality of the building, efficiency of
the work, and the beauty of the buildings. Both Modular and Panel Built fall under the
umbrella term of prefab. Modular house is the culmination of one type of building system.
The building process starts with efficient modern factory assembly line techniques. The
prefabricated components are brought to the site and erected using building block type
construction
1.2 DISADVANTAGES:
1. Smaller Rooms
One of the main drawbacks of modular construction is that the homes can be large, but the
room sizes are usually smaller. The pieces of a modular home can’t be too big to transport by
road, so they can’t generally be more than 14 to 16 feet wide and 60 to 75 feet long.
2. Difficult Financing
Modular homes need to be paid for in advance or finances on a step-by-step basis. In most
cases, owners can’t get a traditional bank loan until construction on the home is complete and
will have to take out a loan from their modular builder. These loans may carry higher interest
rates than regular mortgages.
Despite their advantages, modular homes are difficult to resell due to the assumption that
they are of lower quality. Modern modular structure is seeking to revamp how these homes
are commonly perceived, but it may be awhile before the public sees them as equal to
traditional brick and mortar structures.
4. Land Restrictions
Although they are growing in popularity, some local authorities may not allow you to build a
modular home. Aspiring homeowners will want to confirm that the area where they want to
purchase land and build the home will allow it
1. Modular construction technique can be used to build large modular buildings such as
office complexes, retail shopping centers, churches, temple, mosque, government facilities,
fire stations, schools, medical and health complexes, etc
2. Modular construction technique can also be adopted for building medium residential
buildings as well as high rise buildings, cafeterias, public toilets and other uses that are
usually associated with brick and mortar buildings.
3. As modular construction technique saves time, it can be used for disaster management
such as earthquakes, hurricanes, and other World calamities that require emergency shelters
and housing for displaced persons as in the case of Refugees crises in some parts of the world
that require emergency shelters, hence modular construction technique is best suited to
address shelter problems as the process is past compare to on-site construction technique.
* Easy availability.
* Light weight for easy handling and transport, and to economies on sections and sizes of
foundation.
* Easy workability.
* Non-combustibility.
* Sound insulation.
A. Structural Insulated Panel (SIP): A structural insulated panel (SIP, also called a
sandwich panel) consists of a pair of oriented strand board (OSB) or plywood panels with a
core of extruded polystyrene (EPS) foam in between, attached with an adhesive. Panels are
available in a variety of thicknesses. They are usually produced in 8-ft-tall panels, but they
can be customized as per the requirement.
Its peculiarity is that the foam in the core is the best insulator and its thickness determine the
value of insulation. The foam core forms a continuous energy barrier, and the smaller number
of studs leaves less opportunity for heat conduction. SIPs are fabricated to very close (1/8
inch) tolerances, and the edge connections, which vary by manufacturer, are designed to fit
snugly together. The best thing 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. De-lamination caused by failure of the adhesive is a major
concern because it would affect the ability of structural SIPs to carry load.
B. Insulating Concrete Panel (ICFs): Insulating concrete forms (ICFs) are a prefab
construction material which consist of hollow EPS foam blocks that are stacked and glued
together onsite, creating a form that is filled with reinforcing bars and concrete. The unique
property of ICFs is that the foam blocks are not removed after the concrete hardens; instead,
they help insulate the building, while the concrete provides structural integrity. Although
ICFs are really a hybrid prefab material, they offer many of the cost and environmental
benefits of pure prefab. In comparison with traditional concrete construction, it is faster to
stack ICF foam blocks than to build a wood form, and since the foam blocks are not removed,
there is much less wastes. It can be also used as sound proof. The concrete must be fluid
enough to fill the foam blocks without leaving air voids, which would severely detract from
the structural integrity of the finished wall, yet must be solid enough not to exert too much
horizontal pressure on the foam, which can cause the forms to fail. Insect can attack this
structure so, insect-resistant additives can be mixed into the polystyrene foam.
Zincalume Steel
Colorbond Steel
Aerocon Panels
CGI sheets
UPVC roof
Asphalt shingles
1) Colour: Coated Galvalume Sheets These sheets are preferred material for roofing and wall
cladding. They combine the strength of steel and corrosion protection of zinc or
zinc/aluminium alloy coatings. These are available in various colours, have appealing
aesthetics, long life, durability and easy installation. Colour coated Galvalume sheets of
AZ150 class (aluminium zinc coating of 150 grams per sq. meter) with coated alloy of 55%
Aluminium, 43.5% Zinc and 1.5% Silicon and of approved colour with top surface coated
with 20-25 microns of polyester coating and bottom service coat with 5-10 microns over and
above epoxy primer, basic steel conforming to IS -513, ASTM A 792 M / AS 1397 –
GALVALUME COATING, ASTM A 924 for mechanical properties and ASTM 755 for
paint coating. Overall width of 1120 mm and laid width of 1060 mm, with six crests of 25
mm, spaced at 206 mm center to centre, and with a stiffening rib (28mm) of 3mm height at
the centre of each valley of the sheet, with two anti–capillary grooves with long return leg on
either side of each crest.
2) Zincalume Steel: This product is high corrosion resistant and thermal efficient hot dipped
zinc-aluminium alloy (55% Al - Zn) coated steel with spangled surface conforming to AS
1397 available in Grade 300 & 550. Thickness of coating conforms to AZ 150 / AZ 200 (AZ
150 - 55% Al-Zn alloy coating of 150 g/m2 minimum).
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. Colorbond steel has good
resistance to accidental spillage of solvents such as methylated spirits, white spirit, mineral
turpentine, toluene, trichloroethylene, dilute mineral acids and alkalis. However, all spillages
should be immediately removed by water washing and drying.
4) Sandwich Panel: These are used for insulation of roofing and walling in the building. It
consists of 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.
5) Aerocon Panels: Aerocon panels are slim, lightweight wall panels that perfectly substitute
plasterboard, plywood, particleboard and brick wall because of their sheer strength. Their low
weight, ductility, fire and moisture-resistance properties make them hardy survivors of
climatic and accidental disasters. Being pre-fabricated, they are also easy to install and reduce
construction time by 80%. Aerocon panels are certified Green product by Indian Green
Building Council. The Aerocon panels help to conserve natural resources. Fly ash, which is
recycled waste, is utilized in making these panels. No wood is used in the manufacture of this
product and little water is required during construction. These panels are also poor conductors
of heat, therefore making a building energy efficient. Aerocon panels are available in the
following sizes: Size Thickness 600 x 2400 mm 50 and 75 mm 600 x 2700 mm 50 and 75
mm 600 x 3000 mm 50 and 75 mm
a) Thickness Availability: 40 mm, 50 mm, 75 mm, 100 mm, 125 mm, 150 mm, 175 mm, 200
mm.
Flexibility in design and choosing various options on fascia of panels and colours.
All weather proof construction and maintenance free. Long lasting value with
controlled quality, accuracy & speed of construction and caters for better functionality and
application.
8) Dry Wall System: This system is made of durable galvanized steel, which usually uses
gypsum board and calcium silicate board or FCB (Fibre Cement Board) as surface material.
Compared with wooden board, Dry wall system provides safer and resistive wall. Besides
that, compared with bulky brick wall, it can greatly reduce the weight of building. In this
system, thermal and acoustic insulation product can also be filled in partition frame to create
a safe and quiet environment. Thickness availability: 50mm, 60mm, 75mm, 90mm, 120mm,
150mm, 180mm & 210mm.
Solid cement wall systems comprised of a variety of shapes and wall types. We deal with:
Solid wall panel simply refers to walls made of solid concrete. These wall systems require
some form of insulation and an interior wall finishing system to complete the building
enclosures.Cement Sandwich panel is a series of building material with fly ash, different
polymer beads and sand compound as core material along with low alkali sulphoaluminate
cement and calcium silicate board as face panels.
Thickness Availability:
50mm, 60mm, 75mm, 90mm, 100 mm, 120mm,150mm, 180mm & 210mm
D. Roof Options:
CGI sheets
UPVC roof
Asphalt shingles
E. Wall Options:
F. Floor:
Options Generally, cemented solid sheets are used as the flooring materials. Plywood,
wooden planks, Marbles, tiles are also the options of flooring.
G. Door and Window’s Frame: Hollow metal frames are very good replacement for
wooden door/window frames. It can also be provided the looks of a wood frame at a very
economical price and have other advantages over wood. The frames are termite proof and
weather proof and have a better surface finish than wood. It
can be provided with wooden shutters or hollow 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?
3) Better Safety: Steel’s ductility allows it to stretch between 5-7% of its original length;
which makes it more withstanding during earthquakes and also absorb wind turbulence due to
its ductility.
5) Time Savings: Due to the pre-fabricated nature of steel framing; it can be constructed at a
factory and be delivered ready to erect; also no welding required on the site; the structures
can be totally completed with nuts and bolts.
6) Lower Insurance Premium: Due to steel’s insect, wind, and earthquake resistance, home
owner’s insurance premium will be much lower.
7) Versatility: Due to the standard shape of steel container they can be easily customized;
extend upon and taken apart.
8) Eco-Friendly: 50 trees are needed to build the average house. In comparison steel is
extracted, is recyclable in the future and minimizes wastage through customized building.
9) Short-Term Accommodation: Many European countries and military bases are utilizing
the quick to construct and deconstruct nature of such housing, and offering it as affordable
short term housing.
I. Design Procedure
The steel beams, columns, rafter, z-purlins, channel gables, channel walls, etc. are the
components of steel buildings.Following are the steps to construct prefabricated steel
buildings.
2. Transportation of materials
3. Site clearance
4. Marking
6. General excavation
7. Preparation of foundation base
8. Concreting of foundation
9. Curing
10. Erection
11. Flooring
12. Roofing
16. Finishing
Fig (elements of building)
CHAPTER 2
LITERATURE RIVEW
2.2 LITERATURE;- BY [Prajjwal Paudel, Sagar Dulal, Madan Bhandari, Amit Kumar
Tomar ]
The prefabricated house is constructed by light steel frame to sandwich panels for the
building envelope materials, as a standard module for space series combination of
components, the bolt connection, and the new concept of environmental protection economic
activities in prefabricated house. The prefabricated components are brought to the site and
erected using building block type construction. Work is never delayed by curing time or
missing materials and can be completed for 30 to 45 working days. Further study shows that
it can also lower the total cost of the project by 12 percent as compare to the traditionally
build house using traditional materials such as CHB (Concrete Hollow Blocks). This paper
includes the study on steel structures and pre-fabricated structures. In a general survey, many
people were asked about the types of houses they prefer; one common reply was earthquake
resistant and economical houses. This paper also includes analysis and research on the
quality, strength, environment friendly, costing and the comparison between the traditional
buildings and pre-fabricated buildings. The study aims to introduce and to provide more
knowledge about modular house to educate the market and to address the concern of every
sector of the society especially the depressed areas of the society for a beautiful, stable and
affordable shelter.
As we all know, in building the conventional and traditional buildings, it takes much more
time and the costing is also very high. Also, there will be more wastes and environment will
be polluted; labours are also not safe while construction traditional buildings. If these many
problems are there in following the conventional trend, why should not we look for the easier
and best way for constructional work? Yes. We have to follow the new techniques i.e. Pre-
fabricated Modular and steel structures. This method of building structures will minimize the
constructional cost, time and wastes. But it increases the quality of the building, efficiency of
the work, and the beauty of the buildings. Both Modular and Panel Built fall under the
umbrella term of prefab. Modular house is the culmination of one type of building system.
The building process starts with efficient modern factory assembly line techniques. The
prefabricated components are brought to the site and erected using building block type
construction. According to McGraw-Hill construction’s report, 76% of respondents indicate
that prefabrication/modular construction reduces site waste—with 44% indicating that it
reduced site waste by 5% or more. In addition, 62% of respondents believe that these
processes reduce the amount of materials used—with 27% indicating
prefabrication/modularization reduced materials used by 5% or more
> The use of prefabrication and preassembly is estimated to have almost doubled in the last
15 years, increasing by 86%.
> Earthquake resistant structures can be constructed with low investment and less time.
> The use prefab materials obviously reduce the waste produced in sites.
> Environmental risks are reduced.
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.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.
CHAPTER 3
CONCLUSIONS;
`From the studies and research performed in the prefabricated materials and prefabricated
structures, it is found that these prefabricated structures are very much effective in developing
as well as developed countries. The construction of these types of structures saves time,
money and assures the safety of the people as well. Since, these structures are light weight,
earthquake resistant, and aesthetic, we can accept these structures without any hesitation.`
REFERENCES
[3] Osama M Mohson, Paul J Knytl, Basel Addulaal, Jack Olearezyk and Mohammed Ali
Hussein, “Simulation Of Modular Building Construction”,University Of Alberta Edmonton
Journal.
[6] Shahzad, W.M, Mbachu, J. and Domingo, N. (2014). ―Prefab content versus cost and
time savings in construction projects: Aregression analysis‖. Proceedings of the 4th New
Zealand Built Environment Research Symposium (NZBERS). 14 November. ISBN 2324-
1829 (Online)
[9] Milovanovic et al, ―The Sustainable Prefabricated Wall Panel System Made of
Recycled Aggregates‖, Croatia
[10] Hampson, K.D. & Brandon, P., (2004). Construction 2020A Vision for Australia's
Property and Construction Industry. Brisbane: CRC Construction Innovation.
[12] Abhyuday Titiksh, Dr. M.K. Gupta, (2015), ―A Study of the Various Structural
Framing Systems Subjected to Seismic Loads‖, SSRG International Journal of Civil
Engineering (SSRG-IJCE), India