Prefabrication, or prefab, is an innovative method of construction.
In this method, the components of a building or structure are first manufactured in a factory off site, and then transported to the actual site. After that, all the components are assembled as per the design, and the prefabricated building becomes ready to become operational.
The process of building a prefab structure deeply contrasts with traditional construction practices. There, all the components of the structure will be made from scratch on the site, one after the other.
When it comes to types, prefab has different types, such as modular buildings, panelized systems, and pre-engineered buildings (PEBs).
Prefab manufacturing has unmatchable benefits. For example, it can reduce the construction time significantly, save on maintenance costs, enhance quality control, and reduce the carbon footprint in the process.
All these features make it a popular alternative to the conventional mode of construction for all industrial projects.
What are the present challenges with India’s existing industrial infrastructure?
India’s industrial infrastructure, much of which dates back several decades, faces numerous challenges. Key issues include:
- Ageing Structures: Presently, many industrial buildings have become old to the point that their maintenance has became a hassle. Due to this, the structure has gone week, there are safety hazards, and there are inefficiencies in operations.
- Energy inefficiency: Older buildings often lack modern insulation and energy-efficient designs, resulting in higher energy consumption and increased operational costs.
- Environmental Concerns: Traditional industrial buildings are being made on old methods, which usually have a larger carbon footprint. From noise pollution to a lack of recyclability, old methods cannot cater to the modern need of sustainability.
- High Maintenance Costs: The amount spent on maintaining and upgrading an old building can break bank for small businesses. Besides, these structures need repeated repairs. This can lead to a loss of productivity and an increased downtime as well. Prefabricated structures can help industries avoid many of these issues and significantly reduce maintenance costs.
What does the data say?
- According to the Ministry of Commerce and Industry, India’s manufacturing sector accounted for 16-17% of the GDP in recent years. However, this aging infrastructure is a barrier to growth.
- A report by the Confederation of Indian Industry (CII) indicates that energy costs constitute a significant portion of operational expenses in older industrial facilities, sometimes as high as 30-40%.
Prefabricated industrial structures, due to their better insulation properties, can reduce these energy costs significantly. Moreover, given that these structures can be developed at a fraction of the time of conventional construction, business can quickly set up and scale up their operations.
Comparison: Old Industrial Structures vs. Prefabricated Buildings
| Old Industrial Structure | Prefabricated Structures |
| Automobile Manufacturing | |
| Large, open spaces with steel and concrete construction | Insulated panel systems provide superior thermal performance |
| Poor insulation leads to high energy costs | Quick assembly reduces downtime |
| Frequent maintenance issues with roofing and structural integrity | Enhanced structural integrity with less maintenance required |
| Textile Industry | |
| Multi-story buildings with traditional brick and mortar | Single-story, wide-span structures optimise workflow |
| Inefficient layout leads to reduced operational efficiency | Improved water management systems |
| High water usage for processes and cooling | Energy-efficient designs reduce operational costs |
| Pharmaceutical Manufacturing | |
| Strict regulatory requirements necessitate constant upgrades | Cleanroom-compatible modular construction |
| High contamination risk due to outdated building materials | Use of non-porous, easy-to-clean materials reduces contamination risk |
| Complex HVAC systems leading to increased energy consumption | Integrated HVAC systems designed for energy efficiency |
Prefabricated Buildings is the latest innovation in manufacturing and construction technology, offering far more advantages than its traditional counterparts. For any business, it is going to bring better efficiency, ease of scaling, all while being a sustainable solution that has a smaller carbon footprint.
Conclusion
Prefabrication offers a compelling solution to modernise India’s ageing industrial spaces.
The benefits are clear: faster construction times, reduced costs, better energy efficiency, and enhanced flexibility.
Prefab structures are not just replacements but significant upgrades that address the core issues faced by traditional industrial buildings.
About EPACK Prefab
EPACK Prefab is at the forefront of the prefabrication revolution in India.
We’ve been providing turnkey solutions for over 24 years to different industries in every corner of the country. Due to our constant focus on quality, innovation and sustainability, we have become one of the top prefabricated industrial structure manufacturers.
With state of the art manufacturing facilities in numerous parts of the country, we have built a team of excellent designers who can conceptualise an ideal industrial facility for your business. To find out multiple use cases of prefabricated buildings, check out our projects and connect with an expert at enquiry@epack.in to make your first prefab project dream come true.
In conclusion, the transition from ageing industrial structures to modern prefab solutions is not just a necessity but a strategic move towards a more sustainable and efficient industrial future for India.
EPACK Prefab is leading this transformation, offering expertise and innovative solutions that cater to the evolving needs of the industrial sector.
