chapter 1. industrialization of
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INDUSTRIALIZATION OF
CONSTRUCTION WORKS
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The history of technology, in the field ofconstruction, represents man's efforts to controlhis material environment for his own benefit.Man has been able to do this using tools andapplying reason to the properties of matter andenergy. For many thousands of years, his
progress in technology was made by trial anderror, which made possible impressive results. Itwas only toward the end of the 18th century,once with the Industrial Revolution, thattechnology started to transform itself form craftskills. to applied science.
GENERAL CONSIDERATIONS
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CONSTRUCTION
INDUSTRIALIZATION
Definition of industrialization: The application of scientific principles to the optimalconversion of natural resources into structures, machines, products, systems, andprocesses (DEX 1998).
Industrialization is concerned with both on-site and off-site methods ofconstruction organized in a systematic way in such that erection can proceed as acontinuous operation. This is achieved by careful planning of activities carried out andby setting up a production line to provide an organized flow of components. Muchtraditional building procedure remains site-bound and labor-intensive. Tradition is stillused in the field of wet construction. However, by incorporating factory producedunits and components into traditional in situ concrete construction, and by employingmechanical plant and equipment, erection time has been shortened considerably,particularly on work of a repetitive nature. Sometimes the contractor uses part of thesite as a workshop or temporary factory for the production of woodwork or pre-castcomponents. Whether traditional or industrialized, on-site organization of materials,components, and labor is vital in construction procedure; pre-planning of each stage
is essential, and adequate time should be allowed for working out details beforeoperations can commence. Preplanning of activities should cover - site layout, worksequence, design, manufacture, and fixing of standardized components, mechanicalplant.
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1.3. BASIC PRINCIPLES OF INDUSTRIALIZATIONThe efficiency of industrialized production results from the careful, systematic application
of the ideas and concepts outlined above. The following summary lists the basic
principles of mass production:
- Prefabrication of building components. Many prefabrication technologies deliver abetter product because building is done in a quality controlled sheltered environment.
Just as importantly, prefabrication can dramatically improve productivity. The method
controls construction costs by economizing on time, labor, wages, and materials.
- Developing new construction methods like industrial type production to constantly
improve efficiency in the scope of improving labor productivity (minimizes the amount of
human effort required).
- Careful division of the production operations into specialized tasks comprising of
relative simple, highly repetitive human motion patterns and minimal handling or
positioning of the workpiece that can be easily learned and rapidly performed with a
minimum of unnecessary motion or mental readjustment.
-Developing new and improved construction materials in factory type prefabrication
up to the total elimination of the time consuming operations (reinforcement bending,
tying wires, welding etc.) within the construction site. These operations must improve
construction quality.
- Simplification and standardization of component parts through:
1. dimensional co-ordination agreement made between the manufacturers of
building units and the designers in order to simplify assembly by standardizing sizes;
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2. modular design a technique that uses a standard size module (1M = 100 mm) as
the fundamental unit for space planning. Larger spaces comprise multiple modules
(n x M), while smaller spaces sub modules (M/n). to allow large production runs of parts
that are without difficulty fitted to other parts without adjustment. The imposition of other
standards (e.g. dimensional tolerances, parts location, material types) on all parts of the
product further increases the economic benefit that can be achieved.
Carefully designed, construction engineering and management, projects are required to
achieve the maximum benefits that application of these principles can provide. Planning
begins with the original design of the product; raw materials and component parts shall
be adaptable to production and handling by mass techniques. The entire production
process is planned in detail, including the flows of materials and information throughout
the process. For the industrialization of construction to be efficient, the production flow ofcomponents/ materials shall be:
- Carefully estimated because the selection of techniques depends upon the volume to
be produced and anticipated short-term changes in demand.
- Large enough, first, to permit the task to be divided into sub-processes assigned to
different individuals; second, to justify the substantial capital investment often required
for specialized machines and processes; and third, to permit large production runs sothat human effort and capital are efficiently employed.
- Planed in detail because the large, continuous flow of product from the factory
requires distribution and marketing operations to bring the product to the client.
Advantages of industrialization in construction: In addition to lowering cost, the
application of the principles of industrialization has led to major improvements in
uniformity and quality. The large volume, standardized design, and standardized
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materials and processes facilitate statistical control and inspection techniques to monitor
production and control quality.
Limitations of industrialization in construction - the resulting system is inherently
inflexible, because maximum efficiency is desired; tools, machines, and work positions
are often quite precisely adapted to details of the parts produced but not necessarily to
the workers involved in the process. Changes in product design may converge toward
high costs. Usually, a production line is designed to operate most efficiently at a
specified rate. If the required production levels fall below that rate, operators and
machines are being inefficiently used; and if the rate goes too high, operators must work
overtime, machine maintenance cannot keep up, breakdowns occur, and the costs of
production rise. Proper planning can eliminate the problems encountered; flexibility to
accommodate changes economically must be planned into the system.