The document summarizes a case study of the Instacon Tower constructed in Mohali, India in 2012. The prefabricated steel structure was constructed in 48 hours using modular steel components fabricated off-site. Around 80-90% of the construction was completed in a controlled factory environment before components were transported and assembled on site. The modular construction approach using prefabricated steel components resulted in faster construction at lower cost compared to traditional methods.

1. AR- 602
BUILDING, CONSTRUCTION AND MATERIAL
SUBMITTED BY:
BARN1AR15034
BARN1AR15036
PREFABRICATED CONSTRUCTION

2. LITERATURE CASE STUDY:
INSTACON TOWER, MOHALI

3. INTRODUCTION
• LOCATION: Mohali, Punjab, India.
• COMPLETED ON: December 1, 2012.
• DEVELOPER: Synergy Thrislington, a Mohali-based
infrastructure company.
• SIZE OF THE PROJECT: 2,553.60 sq m
• The first building of its kind in India, the structure
was built with the assistance of three cranes and
more than 200 highly skilled technicians and workers.
• A dead load of 1,200-1,500 kg sq m along with a live
350 kg sq m, the 48-hour masterwork stands tall in
this vibrant city.
• COSTS: 8-9 Crore.
• It required 40-60 days for Instacon's units to be
manufactured in the factory.
DURING CONSTRUCTION

4. CONCEPT
Structural Design
Process
Structural stability
validation
Factory Fabrication of
steel Modular
Components & EPS
Panels
Provisioning of
Utilities in between
Modular Frames
Transportation to
Site
On Site Erection of
steel Structure &
EPS
Panels
In Situ Concreting
by
Shotcrete pumps
Finishing and fixtures
fitting
Shotcrete pumps

5. BUILDING MATERIALS:
• The external structure of the building comprises double-
skinned PUF panel (PVDF galvalume coated sheet) that
ensures thermal insulation.
• The core material used is mild steel, which is lightweight,
strong, flexible and environment-friendly.
• The steel is also coated with rust retardants and anti-
corrosive paints to avoid rusting.
• Brick, sand or gravel is not utilised in the constructing
process; however, concrete is used only in the
foundation and in a three-inch deck flooring.
• Internal wall and false ceiling: LAGYP™ gypsum boards.
CONSTRUCTION:
• Around 80-90 per cent of the work was completed in
the factory under a controlled environment.
• In this system, different units of the building such as wall
panels, columns, etc, were produced within the factory
and then transported them to the actual site where 10-
20 per cent of the work was carried out by simply
installing them.
• Also, utility arrangements such as HVAC, plumbing,
electrical, fire-fighting, etc, were fitted in the floor
frames of steel.
Deck sheet for flooring
Concrete
EPS Concrete
wall for internal
and external
partition
Cast in-situ
foundation

6. EPS Concrete Wall -130 mm thick
Slab and Column Detail
Slab to Column Joint
• A lightweight structure with a unique
bracing system.
• Sustainable, non-toxic and recyclable.
• Reduced the amount of waste, carbon
footprint and the impact on green spaces
at the actual site.
• The structure is also energy-efficient as it
provides floor insulation using the HVAC
technique, the energy recovery
ventilator (ERV) system and electrostatic
precipitator system for fresh air circulation,
lux-controlled curtains for temperature
maintenance, occupancy sensor,
temperature sensor, remote control
switches and LEDs.

7. PROBLEMS FACED IN
CONVENTIONAL CONSTRUCTION
• Time Consuming
• Cost Escalations/variations
• Poor Quality Construction
• Shortage of Skilled
Manpower
• Time over runs
• Unsafe Buildings
ADVANTAGES:
• Energy efficient houses
• Safety at Construction
• Earth Quake resistance
• Faster construction mode saves time.
• No Cost escalations
• Less Electricity Consumption
• Early return on Investment.
• Quicker income from rental.
• Minimal material wastage and increased
asset value.
• Economy of scale in manufacturing
• Salvage Value after lifetime
• Availability of more carpet area
Partition