PREFRABRICATION:
It is a type of construction where the components of a structure are manufactured in a factory or
other controlled environment and transported to construction site for assembly. It is also Known
as Modular construction.
PROCESS OF PRE FRABRICATION:
1. Planning and Design: This is the first and most important step.
a. Engineers and architects prepare detailed drawings of the building.
b. They decide which parts will be made in the factory (walls, slabs, beams, staircases,
etc.).
c. Joints and connections are also planned and designed at this stage.
2. Casting/ Manufacturing in factory: After design approval, the next stage is casting or
manufacturing the components.
a. The decided components are produced in a factory or casting yard using molds.
b. Reinforcement steel (rebar) is placed inside the mold according to the structural
drawing.
c. Then, concrete (with the right mix proportion) is poured into the mold and the
vibrators are used to remove entrapped air in the concrete.
d. Since this is done under controlled conditions, quality is usually better than on-site
work.
3. Curing and storing: Once the concrete is placed in molds, it must be cured properly to gain
strength.
a. The freshly cast components are cured (kept moist) to gain strength after 24 hrs of
casting.
b. Curing is done for at least 3 days
c. Steam curing is often used to speed up the process in factories.
d. After reaching the desired strength, the elements are removed from molds (de-
moulded) carefully and they are stored safely in the yard until needed.
4. Transportation to site: After curing and inspection, the prefabricated parts are transported
from the factory to the construction site.
a. The ready-made components are loaded onto trucks or trailers using cranes and
transported to the construction site.
b. Special care is taken to avoid breakage during transportation by using padding
materials like rubber or straw.
5. Erection/ Assembly at site: At the construction site, all prefabricated elements are lifted
and fixed in position.
a. At the site, cranes or lifting equipment are used to place the prefabricated
components in their correct positions.
b. Components are joined using bolts, welding, or in-situ concrete connections
c. Temporary supports or scaffolds are used until the structure becomes stable
6. Finishing works: Once the structure is erected, the remaining work is done to make the
building functional and attractive.
a. Once all the prefabricated parts are assembled, finishing works like plastering,
painting, flooring, or sealing joints are carried out.
b. Electrical and plumbing fittings are installed.
c. This gives the building a complete look and makes it functional.
ADVANTAGES OF PREFRABRICATION:
i. Speed of construction – Buildings can be completed much faster than conventional
methods (saves time)
ii. Better quality control – Components are made in a factory under controlled
conditions.
iii. Less site disruption – Reduced noise, dust, and labour congestion at the
construction site.
iv. Economical for mass production – Very suitable for large housing projects, schools,
hostels (Saves money)
v. Reduced material wastage – Efficient use of materials in factory setup ( Saves
materials)
vi. All-weather construction – Factory work is not affected by rain or site conditions.
vii. Safer construction – Less on-site labour reduces accidents and safety risks
DISADVANTAGES OF PREFABRICATION:
i. High initial investment – Requires factory setup, heavy machinery, and skilled
workforce.
ii. Transportation issues – Large prefabricated elements can be difficult to transport to
site.
iii. Limited flexibility – Once components are made, design changes are hard to
implement.
iv. Special equipment needed – Cranes and lifting devices are necessary for assembly.
v. Skilled labour requirement – Needs trained workers for precision manufacturing
and installation.
vi. Joints and connections – Weakness may occur at the connection points if not
properly executed.
vii. Not economical for small projects – Best suited for large-scale works, not for
individual houses.