Manufacturers produce prefabricated structures, also referred to as prefab buildings, modular buildings, or pre-engineered buildings (PEBs), in a controlled factory environment to guarantee high quality and efficiency.
Unlike traditional methods, which involve on-site construction of central frames, PEBs simplify the process by designing and manufacturing steel components in the factory. These custom-built components are then easily erected on-site using nuts and bolts. Once limited to industrial buildings and warehouses, prefabricated structures are now finding their way into commercial buildings as well.
Components of Prefabricated structures
Pre-engineered buildings (PEB) consist of structural and non-structural elements connected by bolted joints. Prefabricated structures consist of primary, secondary, sheeting, cladding, and accessories.
Primary Components
The main framing system, comprised of robust steel frames, is the primary component of the building. This modular structure incorporates tapered rafters and columns, all produced at the manufacturing plant. Manufacturers customize the size and shape of these elements according to the application and specific requirements of the end-user.
Secondary Components
The secondary components in PEB are purlins and girts, eave struts, and bracings.
- Purlins and girts support the roof sheeting by running perpendicular to the rafters. Cold-formed C & Z purlins serve as secondary framing systems, connecting rafters and offering extra support. A bending press machine cold-rolls sheet metal strips, creating these components. The steel employed is of high strength, meeting ASTM A 570 standards or equivalent, with a yield strength of 345 MPa.
- Eave struts are at the junction of wall cladding and roof sheeting.
- Bracing is a diagonal element that gives the structure (lateral) stability.
Sheeting or cladding
Sheeting, orcladding,g forms the outer layer of the structure and shields the PEB from the elements.
Accessories
Accessories are additional components of the building. They can include insulation, vents, windows, and doors.
Advantages of prefabricated structure
Speed and efficiency
In construction, time is synonymous with money. Traditional methods face challenges such as weather delays, on-site inefficiencies, and unpredictable deliveries, causing potential delays. Prefabrication acts as a savior, being manufactured in controlled conditions away from nature’s unpredictability.
According to a 2023 McKinsey & Company study, prefabrication can speed up end-to-end project timelines by 20 to 50% and concurrently cut costs by up to 20%.
Cost-effective
Pre-engineered buildings (PEBs) offer a cost-effective choice for greenfield projects. Produced in a controlled environment, they minimize material wastage and boast quicker erection, slashing labour costs. The savings generated can be strategically reinvested in various project aspects.
Prefabricated structures, in general, can yield a 20% cost reduction (source: Dodge Data & Analytics, 2020), making them an efficient and economical choice for construction projects.
Sustainable
The construction sector is a major polluter, primarily due to materials like cement and bricks, causing environmental and noise pollution. Traditional construction, conducted on-site, exacerbates these issues. In contrast, prefab and modular construction in controlled factory environments enhance sustainability by optimising material use, reducing waste, and encouraging recycling.
Prefabrication’s positive environmental impact is especially evident in minimised site disturbance and noise pollution, making it ideal for urban or environmentally sensitive projects. It also champions energy efficiency through sustainable building practices and technologies.
Enhanced quality
Prefabricated structures prioritise quality assurance, eliminating variables such as on-site conditions and skill levels that might affect the final build’s precision. Shifting the manufacturing process to a controlled factory environment with advanced machinery, stringent quality control measures, and skilled craftsmanship ensures the precision and consistency of prefabricated components, meeting or exceeding industry standards. This commitment to quality not only enhances the durability of the builds but also instills confidence in stakeholders about the reliability of the construction method.
- Upfront investment: Initial costs can be higher, requiring careful planning and budgeting.
- Specialised expertise: Transportation and assembly require specialised knowledge and partnerships.
How do you shortlist prefabricated manufacturers?
Define your project requirements
Streamline your prefabricated manufacturer selection by first outlining project specifics like size, complexity, budget, and sustainability goals. This initial step sets the groundwork for identifying compatible prefab partners.
Manufacture research
Identify firms with expertise in managing greenfield projects, adept at addressing their distinct challenges and opportunities. Verify their certifications, such as GRIHA (Green Rating for Integrated Habitat Assessment), IGBC (Indian Green Building Council), or ISO (International Organization for Standards), ensuring compliance with rigorous quality, safety, and sustainability standards.
Project references
To evaluate quality, reliability, and client satisfaction, ask for and carefully check references. Speak with previous customers and find out about their experience with the manufacturer; pay particular attention to things like timely delivery, communication, and build quality.
Asses site logistics expertise
There are special logistical challenges associated with greenfield projects. Verify the manufacturer has experience and tools to address transportation and erection challenges unique to your site. This could be remote locations, challenging terrain, or poor infrastructure. Ask them how they will overcome these challenges and what their contingency plan is.
Establish open communication
Open communication is a must for the successful execution of any project but more so with prefabricated structures because they have off-site construction elements. Establish an open communication protocol from the beginning, including expectations, reporting guidelines, and dispute resolution, if any. Proactive communication and frequent updates promote confidence and avoid unpleasant shocks or delays.
Venwiz: Your One-Stop Solution for Prefabricated Structures in Greenfield Projects
Tired of juggling multiple vendors and battling logistical nightmares in your greenfield project? Venwiz, India’s only digital platform dedicated to industrial services, is here to revolutionise your experience. Venwiz has over 20,000 vendors in 52 categories.
Verified vendors: Venwiz has over 20,000 vendors in 52 categories. All vendors on our platform are verified. Use our intelligent search engine to find your ideal vendor.
- Time and Cost Savings: Reduce project timelines with prefabrication and optimise your budget with competitive quotes from multiple vendors in 2 weeks. Venwiz’s transparent pricing and efficient processes ensure you get the best value for your money.
Expertise at Your Fingertips: Our team of industry experts is readily available to answer your questions, provide guidance, and connect you with the right vendors. Leverage their knowledge to make informed decisions and navigate the prefabrication process with confidence.
Some of Venwiz’s top prefabricated structures
Blue Ladder Construction and Fabrication
Since 2022, Blue Ladder Construction And Fabrication in Ranchi has been a verified vendor, specialising in Pre-Engineered Buildings, Warehouses, and Industrial Sheds. Under the leadership of Director Jaykant Pandit, they provide comprehensive services including design, fabrication, installation, commissioning, and construction. Recognized as an OEM authorised supplier and channel partner with industry giants such as SAIL, Jindal Steel, Tata Steel, ArcelorMittal, and Apollo Steel Pipes, their esteemed clientele includes Unilever, ILFS, Afcons, Flipkart, Amazon, Gati, and ABIS.
Established in Bharuch in 1999, Bright Construction And Co., led by Partner Altaf Patel, excels in steel structures, RCC structures, equipment foundations, and pre-engineered building structures. Providing EPC services for power and civil infrastructure, they’ve earned the trust of clients like BHEL and Megha Engineering. With 23 years of experience, Bright Construction is known for quality, safety, and on-time project execution in Gujarat, Maharashtra, Punjab, Odisha, Jharkhand, and Chhattisgarh.
Infinity Fabtech Private Limited
Established in 2016, Infinity Fabtech Private Limited, located in Indore, is a certified vendor with a robust profile. Led by Business Development Manager Pankaj Shrivastava Sankhla, they excel in providing services such as design, fabrication, and supply of PEB structures, reflective insulation, and air ventilators. With ISO 9001:2015 certification, they offer an array of products, including pre-engineered building structures, prefabricated buildings, warehouse solutions, and more. Their diverse clientele includes Shyam Tata Showroom, BHEL, Essar Steel, Mahindra First Choice, and many others. With 100 dedicated professionals, Infinity Fabtech ensures quality and innovation in every project.
Conclusion
The prefabricated construction revolution is transforming the landscape of greenfield development, offering a future characterised by efficiency, sustainability, and cost-effectiveness. By embracing prefabrication with a strategic and informed approach, project leaders can unlock a world of possibilities, expedite projects, optimise costs, and build a more sustainable future.
Ready to turn your vision into reality?
- Connect with Venwiz: Let our team of experts guide you through the prefabrication journey. Contact us: contact@venwiz.com
- Register or log in to our platform for all your capex procurement requirements.
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