Modular construction is the practice of assembling the components of

a building in factory and then transporting them to the construction site

for installation. Modular prefabricated construction represents a

specific type of prefabrication in which the module building components

are assembled off-site.

Modules are complete box-shaped units, containing walls, floor and roof

with the interior space, which are built in factory, shipped to the site,

installed, and connected into a complete building.

STAGES OF MODULAR CONSTRUCTION

Four stages make up a modular construction project.

1. Design approval by the end user and any regulating authorities.

2. Assembly of module components in a controlled environment .

3. Transportation of modules to a final destination.

4. Erection of modular units to form a finished building.

MODULAR CONSTRUCTION TECHNIQUES

1.MIVAN FORMWORK TECHNIQUE

It is the most advanced formwork systems. It is fast, simple and

adaptable. It produces total quality work which requires minimum

maintenance and when durability is the prime consideration. It is a

totally pre-engineered system where in the complete methodology is

planned to the finest details. In this system the walls, columns and slab

are casted in one continuous pour on concrete. Early removal of forms

can be achieved by the air curing/ curing compounds. These forms are

made strong and sturdy, fabricated with accuracy and easy to handle.

The components are made out of aluminium and hence are very light

weight. They afford large number of repetitions (around 250). The re-

propping is simple hence short cycle time can be achieved.

COMPONENTS OF MIVAN FORMWORK

The basic element of the formwork is the panel, which is an extruded

aluminium rail section, welded to an aluminium sheet. This produces a

lightweight panel with an excellent stiffness to weight ratio, yielding

minimal deflection under concrete loading. Panels are manufactured in

the size and shape to suit the requirements of specific projects. The

panels are made from high strength aluminium alloy with a 4 mm thick

skin plate and 6mm thick ribbing behind to stiffen the panels. Once they

are assembled they are subjected to a trial erection in order to

eliminate any dimensional or on site problems. Following are the

components that are regularly used in the construction:

A. WALL COMPONENTS:-

1) Wall Panel: - It forms the face of the wall. It is an Aluminium sheet

properly cut to fit the exact size of the wall

2) Rocker:-It is a supporting component of wall. It is Lshaped panel having allotment holes for stub pin

3) Kicker:- It forms the wall face at the top of the panels and acts as a ledge to support.

C. DECK COMPONENT:- 1) Deck Panel:- It forms the horizontal surface for casting of slabs. It is built for proper safety of workers.

2) Deck Prop:- It forms a V-shaped prop head. It supports the deck and bears the load coming on the deck panel.

2.TUNNEL FORMWORK TECHNIQUE

Tunnel form is a formwork system that allows construction of cellular walls and slabs in one operation on a daily cycle. It combines the speed, quality and accuracy of offsite production with the flexibility and economy of in-situ construction and is recognised as a modern method of construction. The result is a cellular reinforced concrete structure, the surfaces of which are of sufficiently high quality to require only minimal finishing for direct decoration.

The system creates an efficient load bearing structure for use in a wide variety of applications. It is particularly effective in projects suited to repetitive cellular construction such as residential blocks, hotels, student accommodation, barracks and prisons

METHOD

During the tunnel form construction process, a structural tunnel is created by pouring concrete into steel formwork to make the floors and walls in one monolithic process. Each 24 hours, the formwork is moved so that another tunnel can be formed. When a storey has been completed, the process is repeated on the next floor. A strong, monolithic structure is thus constructed that can reach 40 or more storeys in height.

5.OVERNIGHT- THERMAL CURING

ADVANTAGES OF TUNNEL FORMWORK FINISHING The smooth face of the steel formwork results in a high quality finish that can be decorated directly. This reduces the need for finishing trades thereby providing additional cost savings and speeding the entire process. FLEXIBILITY IN DESIGN The large bays constructed using tunnel form, provide exceptional flexibility in the design and layout of the building and allow a high degree of freedom in the final appearance. QUALITY Quality is enhanced despite the speed of construction. The precise, even steel face of the formwork creates a smooth, high quality finish capable of receiving direct decoration with the minimum of preparation. PRODUCTIVITY AND CONTROL The formwork is specially adapted for each project. The repetitive nature of the system and the use of prefabricated forms and reinforcing mats/cages simplifies the whole construction process, producing a smooth and fast operation HEALTH AND SAFETY Tunnel form has integral working platforms and edge protection systems. In addition, the repetitive, predictable nature of the tasks involved encourages familiarity with operations and productivity improves as construction progresses.

ASSIGNMENT

MODULAR CONSTRUCTION

MAAZ AKBAR KHAN

B.ARCH IV YEAR(SFS)

ADVANTAGES OF MODULAR CONSTRUCTION

1. FAST DELIVERY

A primary benefit of modular construction is its fast delivery. Due to the

simultaneous process of creating modules in a factory at the same time

site work is occurring, modular buildings can be constructed in up to

half the time as buildings built completely onsite. This allows the

buildings to be occupied sooner and allows owners to see a faster

return on investment.

In order to save the most time and money and maximize the efficiency

of the modular construction process, it is important to implement the

modular construction at the beginning of the design-build process.

2. QUALITY

Modular buildings are built with all the same materials and to the same

building codes and architectural specifications as onsite construction,

just completed in an offsite, quality controlled environment. Modular

buildings are also built to be able to withstand travel and installation

requirements, creating a building that can be more durable than

structures built onsite.

3.WASTE MINIMISATION

Modular construction makes it possible to optimize construction materials purchases and usage while minimizing onsite waste and offering a higher quality product to the buyer.

4. LESS SITE DISTURBANCE

The modular structure is constructed off-site simultaneous to foundation and other site work, thereby reducing the time and impact on the surrounding site environment, as well as reducing the number of vehicles and equipment needed at the site.

5.FLEXIBILITY AND REUSE –

When the needs change, modular buildings can be disassembled and the modules relocated or refurbished for their next use reducing the demand for raw materials and minimizing the amount of energy expended to create a building to meet the new need. In some cases, the entire building can be recycled.

6.IMPROVED AIR QUALITY –

Many of the indoor air quality issues identified in new construction result from high moisture levels in the framing materials. Construction occurs primarily indoors away from harsh weather conditions preventing damage to building materials and eliminating the potential for high levels of moisture being trapped in the new construction.

7.SUSTAINABLE

Modular buildings can also contribute to LEED requirements in any category site-built construction can, and can even provide an advantage in the areas of Sustainable Sites, Energy and Atmosphere, Materials and Resources, and Indoor Environmental Quality. Modular construction can also provide an advantage in similar categories in the International Green Construction Code