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Prefabricated construction as a technique to reduce material waste. By: Abhishek V A13567117030 MBA
CEQS 2017-19 Under the guidance of VPS Nihar Nanyam Assistant Professor CAPSTONE PROJECT 2019

RICS SCHOOL OF BUILT ENVIRONMENT SCHOOL OF CONSTRUCTION AMITY UNIVERSITY NOIDA

LIST OF TABLES Contents

Abstract ...................................................................................................................... Error! Bookmark not

defined. Introduction ...............................................................................................................

Error! Bookmark not defined.

Aim ............................................................................................................................................................................5
Objectives ..................................................................................................................................................................5

Methedology ................................................................................................................ Error! Bookmark not

defined. Literature
review .....................................................................................................................................................6

Waste generation:

.....................................................................................................................................................6 Prefabrication:
..........................................................................................................................................................7 Potential

benefits of adopting prefabrication construction method .......................................................................9

Sustainable benefits:............................................................................................................................................9
Economic benefits:

.................................................................................................................................................10

LIST OF FIGURES Fig 1: Waste generation structure in traditional construction

industry .....................................................................................6 Fig 2: waste management

hierarchy .........................................................................................................................................7 Introduction

Waste arising from the construction activity has become a major source of solid waste in many parts of the

countries. Due to this construction industry is treated as a major culprit to the public concern because of its
degrading nature to the environment, so to overcome this issue many construction organizations have

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included waste management as a major function in their project management structure as a result some

different approaches and methodology have been adopted to eliminate the waste that are generating majorly

from the construction activities.

By replacing the traditional conventional method of construction with prefabrication method of construction is

treated as one of the wastes minimizing techniques that can be adopted in many public and private projects.

The various wet trade activities like concrete, steel, masonry work, plastering and formwork which contributes

large quantities of material waste has been identified in the construction projects and strong attention has to

be placed with concern to material waste reduction and environmental safety.

Although, some of the methodology and techniques that are currently following in traditional cast- in-situ

construction to reduce the overall % of construction waste to a marginal effect on overall project. To overcome

and eliminate this cause prefabrication method of construction has been treated as best effective sustainable

construction method that we can adopt with concern to material waste reduction, environmental safety and

solid waste management.

Since past many years some of the countries have been adopted precast modules & prefabrication method of

construction to gain the benefits of prefabrication in particular to lean construction, safer and clean built

environment (Tam et al. 2006 & 2007).by adopting prefabrication technology in the building construction we

can contribute to the construction waste minimization that can be achieved from the various wet trade

activities like brickwork, plastering, concrete works, reinforcement steel etc. (Li et al. 2014). Tam et al.

2007 has revealed that the 100% waste reduction can be achieved in plastering work when compared with

traditional cast -in- situ method of construction. Jaillon (2008) has concluded that best possible way to
minimize the waste is by adopting prefabrication in the early design and construction phase of the project life

cycle. Need for study This research helps to determine the framework of prefabricated impacts and

advantages and recognizes the importance of reducing waste and its effectiveness for current and future
construction industries.

In addition, the study will help identify social, economic and environmental characteristics that support
sustainable building practices in the construction industry. Previous research has focused on the construction

industry as a major source of waste production and demonstrated the need for innovative waste management

technologies instead, (Tam et al) It has been determined in 2005 that although a large amount of waste
reduction is calculated through the use of prefabricated and supportive case studies, there are few obstacles

to the development and practice of prefabrication, namely the lack of skilled and educated workforce and

frontline supervisors.

Given the current expertise and experienced workforce in the prefabricated industry, there is a lack of

framework to identify the importance of prefabrication. Therefore, the results of this study can trigger the

importance of prefabrication and its potential benefits to developers and contractors, especially by helping

them develop conceptual frameworks to reduce waste effectiveness. Aim The main aim of this research is to

encourage the construction industry towards adoption of prefabrication by its various potential benefits and to
develop framework for the significance of prefabrication with concern to material waste reduction.

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For this a clear suitable investigation has to be carried out with respect to material flow and waste generated

from the various wet trade activities like brickwork, concreting, plastering, tiling etc., the wastage levels with
respect to the traditional cast-in-situ and prefabrication construction are also compared to strengthen the

research aim. Objectives To identify the major source of waste generating wet trade items that have been

identified in the traditional cast-in-situ method of construction.

Comparative study and analyze the waste generation levels of both prefabrication and traditional cast-in- situ

construction with supporting case studies. To identify percentage of material waste generated in projects
where in conventional method of construction has been adopted. To identify and study the percentage of

material waste generated in projects where in prefabrication method of construction has been adopted. To

develop a conceptual framework for minimizing construction waste by adopting prefabricated construction

method.

Methodology Literature review on national and international journals with respect to waste minimization by

adopting prefabrication construction method. Comparative analysis through questionnaire survey, collect data,

analyze the results and draw conclusion. � Comparative study and analyze the waste generation levels of
both prefabrication and traditional cast-in- situ construction with supporting case studies. Literature review

Waste generation: Thousands of tons of construction waste have been produced in every project during

construction and demolition activity, and construction waste is termed as the one of the major sources of

waste in most of the developing and developed countries. (Asmi et al. 2012).

construction waste mainly divided in 2 types 1) physical waste - The waste that is generating during

construction, demolition, renovation activities which comprise of certain various work packages like site
clearance, excavation of ground, all civil construction works etc. 2) non- physical waste -due to some design

mistakes, labor issues and equipment failures waste that can be sorted out during the construction process.

Fig 1: Waste generation structure in traditional construction industry (source:asmi et.al 2012) Cheung et al.

(1993) mainly identified the major causes that is contributing to the material waste generation during on site

production activities: (i) cutting of materials (ii) over ordering, (iii) damage during transportation, (iv) lost during
installation, (v) poor workmanship (vi) change of design. Construction waste management has been evolved in

order to reduce the overall effect on these factors. Poon et al. (2001) describes that in the beginning stage of

project life cycle during design and construction phase on site waste generating activities can be reduced to a
greater extent.

In addition to this, Poon et al (2001) also suggests that source reduction and waste recycling are the two
major techniques which will helps in reducing construction waste, in order to gain the potential benefits from

these techniques we should follow the waste management hierarchy in effective manner. Fig 2: waste

management hierarchy (source: environment performance report, EDP 2003) Prefabrication: Prefabrication is

nothing but it is a process of manufacturing different elements of the building, generally in a specialized

environment area or at a certain manufacturing unit, later being transferred to the construction site through

logistics for final installation process. (Tatum et al. 1986).

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significant changes have been occurring in the modular construction of prefabrication in the past 2-3 decades

(Wong et al. 2003). Thus, prefabrication tends to me the most effective sustainable construction in the

contemporary construction industry with its wide range of practicing different construction technique trends
Wide range of practicing prefabrication tends to the development of sustainable construction and becomes the

most effective construction technique in contemporary construction technique (Cunningham, 2011). The

prefab parts are commonly grouped into three classifications by Tam and Vivian (2007).

Initially, Modular construction � it is likewise called as One-Stop technique as all the building parts are pre-
assembled at offsite fabricating unit and prepared to be handled for onsite installation. Also, Comprehensive

Prefabrication � in this strategy organized pre-assembled parts of the building like slabs, columns, beam
staircase were pre- manufactured in the manufacturing unit and installed onsite.

Thirdly, Semi Prefabricated segments � This technique particularly covers the components like curtain walls,
facades and dry wall systems components of prefab which are said to non-structured prefab elements. From

most recent ten years, a few investigations and examines has been completed to distinguish the potential

advantages of pre-assembling a building, where there is high level of cost cuttings have been come about
because of the construction waste minimization.

Also, this examination shows the decreased waste in amount regarding different construction trades during

manufacturing and installation process of prefabrication. To strength this research study a clear comparative

study to be carried out between traditional cast-in-situ method and prefabricated construction. Therefore,

Jaillon (2008) studied the effectiveness of prefabrication for minimizing waste in the construction market and
concluded that it is one of the potential solutions for minimizing construction waste during project design and

construction.

In addition, Tam (2005) suggested that prefabricated projects can reduce the waste level of wood formwork by

75% to 89% and concrete waste by 60% to 70%. Tam and Vivian (2005) studied the effectiveness of cast-in-
place methods for prefabrication by considering various construction industries in public and private projects.

Compared with traditional methods, the results are favorable for prefabrication, and the percentage of waste

reduction varies greatly. In addition, financial analysis was carried out with a focus on four building materials -
concrete, steel (steel), plaster and tiles.

As a result, up to 85% of clear representations can be saved by prefabrication using traditional methods (Tam
et al. 2007). A similar study by Zheng Dao Li and Geoffrey (2014) has identified the effects of adapting to

prefabrication, resulting in waste generation in various wet trades, such as concrete, tiling, reinforcement,

plastering, and brickwork to a greater extent. Especially in plastering can be reduced to 100%. In addition,
case studies were carried out on buildings built between 2002 and 2004.

The results show that wood formwork is the main source of construction waste, accounting for more than 30%

of the total site production. Similarly, Tam and Vivian (2013) concluded that approximately 8-10% of building

materials will eventually be used as on-site construction waste. Therefore, prefabrication can minimize the

complexity of wet trading in construction and ultimately help minimize construction waste (Zhang et al. 2011).
In addition, Tam and Vivian (2013) also proved that the use of prefabrication is conducive to minimizing

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construction waste, reducing it to more than 74%, and saving 85% of concrete, steel, tiles and plastering.

(Zheng Dao et al.,

2014) quantified the impact of prefabrication on construction waste reduction by using a system dynamics

approach as a research method, and introduced an assessment model that showed tangible and significant

cost savings for building materials through waste minimization. In addition, the model helps stakeholders and

contractors use it as a valuable reference to show the impact of prefabrication. Jaillon and Poon (2008) found

that many developing countries have adopted semi-finished products for their construction techniques through

the effective use of prefabricated structures such as stairs, drywall systems, prefabricated fa�ades,
respectively, at 80%, 55% and 45%.

Prefabricated components in traditional building systems reduce construction waste by 60%. This achieved by

replacing bricklaying by drywall components made of lightweight concrete, while other components such as

stairs and prefabricated panels are a huge waste of traditional methods. Minimizing this construction waste,

minimizing resource conservation and use is an important key feature in sustainable and modern architecture

(Jaillon and Poon, 2008).

Potential benefits of adopting prefabrication construction method Much research has been done to investigate

the effectiveness of using prefabrication rather than traditional structures. This study helps highlight some of

the potential benefits of adopting prefabricated and economical preforms. (Lawson et al., 2012) Sustainable

benefits: ? Waste generated during construction can be reduced from 10-15% in traditional buildings to less

than 5% in prefabrication, while prefabrication also has higher waste recycling opportunities.

? Compared to traditional method, each prefabricated component supply more in quantity to site, so that the
total number of vehicles transported to the site can be reduced by up to 70%. ? When compared to traditional

method of construction noise and disruption from the adjacent buildings can be reduced upto 30% to 50%. ?

By the efficient usage of lightweight materials in the prefabrication very minimal amount of wastage can be
achieved through embodied energy factor. ? Acoustic insulation can be achieved to a greater extent by double

layer construction through prefab elements.

? up to 80% accidents in site activities can be reduced through practicing the prefab technology and it seems

to be a safer method on both onsite and off-site production. Economic benefits: ? Increase in productivity can

be achieved by reducing wastage and usage of materials. ? Overall cost savings in the projects can be
achieved through its speedy installation of prefab elements and parallelly can reduce the overall duration of

the project. ? In order to determine the actual impact of the prefabrication, the importance of each advantage

should be determined (Tam and Vivian, 2005).

William and Zeng (2005) conducted a questionnaire to determine the importance of each advantage by using

prefabrication in the contemporary construction industry. S.

no Title Year Author Work findings Tools used for analysis Future scope 1 Implementation of precast

technology in India opportunities and challenges 22 June 2017 VPS Nihar Nanyam Riddha basu Anil
Sawhney In the Indian construction industry, many projects are lacking in the time and cost overrun due to

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which it affects the end user significantly to overcome this problem industry should adopt the new technology

which can reduce the time overrun. The drawbacks are Transportation cost, production cost, erection cost and

double taxation with respect to the VAT and taxation issues occurred with respect to the different states.

Cost analysis Questionnaire and brain storming session Quantification of work To overcome this problem as

many projects are doing it by conventional methods, we can adopt the precast construction method or cast in

situ for fast construction and enhanced productivity in projects. The major advantage by adopting precast

construction method is can reduce material waste on site by various materials and reduce the cost on

formwork, scaffolding and high wages on reduce the time on curing the various building elements like walls
and slabs.

2 Analyze time and cost required for conventional and prefabricated building elements Aug 2017 Lakhi m.

Chavan Prof D.B. Desai In Indian construction industry the traditional way of constructing building or any

infrastructure mainly follows the conventional method which is mostly lengthier process compared to

prefabrication construction with respect to the curing, formwork, scaffolding process. In precast similar kind of

elements are produces repeatedly for the better increased productivity in the site with respect to time and
material Quantification of work MS project 2007 When compared to conventional method precast construction

will have better Supply chain management with respect to the predecessor activity in the construction site can

go parallel without time delay in the critical path of the project.

But prefabrication seems to be efficient only in case of mass projects and production of Products with respect

to the time and cost, but we can adopt some of the prefabricated elements in conventional method to reduce
the overall duration of project and material waste in the Indian wastage savings in the project. construction

industry 3 Prefabrication as a mean of minimizing construction waste on site 8 April 2014 Vivian W Y Tam
Jane J.L.hao Hongkong construction industry is adopted prefabrication construction to achieve the waste

minimization in the construction site by achieving sustainable environment.

It mainly identifies the major waste generating activities in the conventional construction with respect to the

cutting of building materials, over ordering of bulk materials, Interview of onsite in charge project managers.

By adopting prefabrication as construction technique 100% of waste reduction is possible in the plastering and
about 73.9 -86.8% waste can be reduced in the traditional formwork and waste with respect to concrete and

steel works items could also be reduced by adopting the prefabricated construction elements with respect to

construction industry with regards to the minimization of solid waste generation in the damage during
transportation, lost during installation and poor workmanship and change of design. next upcoming years with

the rapid urbanization.

4 Designing out waste in high rise residential buildings: analysis of precasting methods and traditional

construction 2009 Andrew Baldwin Chi -sun poon li-yin sheen Simon Austin It mainly talks about that the

design staff and construction expertise required as a part of effective design process at the design stage itself

to reduce the material waste during site execution process by prefabricated construction. This paper tells how

information modelling and design structure matrix techniques Analytical design planning technique (Adept) By

implementing and adopting prefabricated building elements off site in precast design can effectively reduce
the construction waste which is generating on site.

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If suitable effective planning and design management have been implemented at the starting phase of the

project then it is very easy to reduce waste by prefabrication construction also at negligible amount. enable
designers to model and understand the implications of such decisions within detailed design process. 5

Modelling design information to evaluate pre-fabricated and pre- cast design solutions for reducing

construction waste in high rise residential buildings 2008 A.N Baldwin L.Y. Shen C.S. Poon S.A.

Austin How modelling information flows in design process may be used to evaluate design solutions when

seeking to reduce the construction waste in the high-rise residential buildings Interviews were endorsed by
survey of architects and contractors Analytical design planning technique (Adept) To achieve waste

minimization designers must have information relating to all aspects of waste generation in the production

process also with respect to on site material wastage. 6 Best practice of construction waste management and

minimization 2014 Khor jie cheng Azree othuman mydin Factors contributing to the efficiency of material

management process are effective logistic management and supply chain management In order to waste

control Huge difference of waste generated in the conventional method of building compared to prefabricated

construction but the waste generating materials can be recycle and reuse, beside this we can adopt the
prefabricated techniques waste management mainly involves the investment and development in new

technology, products, process and training that can reduce waste.

construction as a technique which would raise the environmental performance for overall site conditions. Its

not the matter of individual to take care of waste generation in site, but i which involves cliants� contractors,
suppliers that each individual should play a important role in each stage to co ordinate with each other to
minimize the waste. 7 Use of prefabrication to minimize construction waste- A case study approach 2005 C.M.

Tam Vivian W.Y. Tam John K.W.

Chan Waste reduction can be minimized at th%construction site if proper design management has been taken

place at the initiation stage. Questionnaire survey with the project managers. By using relative indices with
material ordered and Cost saving can be successful when both contractors and developers can adopt precast

technology. 3 main simulators are important in adopting the precast technology 8 Quantifying the waste

reduction potential of using prefabrication in building construction in hongkong 2008 L. Jailon C.S. Poon Y.H.

Chiang Gavalin and Bern old states that most of the construction wastes are mainly arises from the

Construction waste is mainly a mixture of both inert and non-inert materials arising from construction,
demolition, renovation, excavation etc. Government incentives on GFA for buildings who are adopted green,

sustainable and innovative material used for the works. Questionnaire survey with the professionals working

on the particular high-rise public and private projects.

Case study on recently completed building projects Environmental issues Construction costs Govt incentives.

Only the way the construction waste can be reduced in design and construction phase is by adopting the

prefabrication techniques rather than going for traditional cast insitu construction. Waste generation in timber

formwork can be reduced which is one of the major wastes generating activity in the conventional construction

building technologies and prefabrication.

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9 Cutting construction waste by prefabrication 2006 Tam Vivian Material wastage specified by any building or

in any construction activity is mainly defined as the difference value between the quantity of materials

delivered and accepted on site and those properly used with respect to the particular drawings. (shen et
al.2002b) These economic benefits include the possibilities of selling specific waste materials and their

removal from site at no charge or reduced cost, In order to assess its effectiveness, an interview survey was

conducted in 2002 which collected thirty-one construction senior p ractioners� observations and opinions on
wastage levels when comparing prefabrication with the traditional wet trade approach.

The practitioners included senior project managers, project managers, architects, This paper also

demonstrates that �cutt�ove - order�, ge during transportati �lost instal lation�, �poor workmanship�

and �changn� can be greatly reduced after adopting prefabrication. Wastage minimization should be
integrated into the construction processes and planned at the tender stage. RESEARCH METHODOLOGY:

Objective -1 � Literature review on national and international journals with respect to waste minimization by
adopting prefabrication construction method. Objective-2 � Comparative analysis through questionnaire
survey, collect data, analyze the results and draw conclusion.

with a subsequent reduction in materials going to landfill at a higher cost (Snook et al. 1995) senior quantity

surveyors and engineers, with around 15 to 25 years on-site experiences. Objective-3: � Comparative study
and analyze the waste generation levels of both prefabrication and traditional cast-in- situ construction with

supporting case studies. Case study- USE OF PREFABRICATION TO MINIMIZE CONSTRUCTION WASTE

A CASE STUDY APPROACH In this paper, (Tam et al.

2005) studied the potential benefits and effects of prefabrication, which is considered to be one of the best

examples of comparative studies in this study. (Tam et al. 2005) selected four private construction projects - a
hotel reconstruction project, a residential development project, and two commercial projects, reviewing the

prefabrication with conventional method of construction and determine the level of wastage occurred in

various materials and wet trade items.

Structured interview has been carried out to various project managers to collect the data regarding the

prefabrication levels applied on the respective projects. To support the data from the interview all site
observation data and recordings are collected and analyzed with respect to in addition to this, all the site

observations and recordings were also collected. The study mainly includes the 4 major activities with respect

to plastering, cement, reinforcement and wood formwork. Staircase and facades are commonly used prefab
elements in all the projects.

Details of the project In all the buildings to minimize the leakage of water through joints window which is made
up of aluminum is casted integrally during the construction of facade. For the residential project balcony which

is made up of precast and external walls which is bearing whole load in the permanent form have been

adopted as major items of prefabrication elements.

Projects 2, 3 and 4 use drywall systems as internal partitions to reduce on-site construction waste, which is

caused by traditional on-site production. For the project -4, approximately 95% of building service components
are manufactured off-site, including integrated lighting, low glare fluorescent lights, air volume systems, solar

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reflective double-glazed curtain walls, semi-spray nozzles and suspended sound absorbing ceilings. The main

major outcomes that predict the level of waste in the four projects are determined by percentage and

comparison charts, which are explicitly mentioned in the results of the current study.

Wastage levels of building materials can be defined as the remains of the materials delivered on site after

being used in the built work. This can be described in Equation (1) and Equation (2) for projects with

prefabrication and projects using conventional cast-in-situ approach: Wp = Mdp - Mup/Mdp. 100% equation (1)

Wc=Mdc-Muc/Mdc .100% equation (2) Where Wp and Wc denote the percentages of material wastage for

projects of prefabrication and projects of conventional cast-in-situ; MDp and MDc for material delivered on

site; and MUp and MUc for material used for builImprovts ire y dexy �Wquati Equation (3) W=Wc-
Wp/Wc .100% equation (3) Results:

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