Viability of prefabricated prefinished volumetric construction technology in India

Viability of prefabricated prefinished volumetric construction technology in India.

Piyush Tiwari Department of Architecture and Planning, Amity University, Sector-125, Noida (UP)

Abstract- Prefabricated prefinished volumetric construction, known as PPVC is a new innovative approach that can change the construction industry in different sectors of the world. It could improve the workflow, increase efficiencies, worker’s safety, resources management, minimize construction wastage, and reduce working laborer and construction durations. While PPVC has wide range of benefits, the viability of using PPVC in India remains unexplored. Therefore, the aim of this study is to understand the viability for adoption of PPVC. Keywords- Prefabrication, Prefabricated prefinished volumetric construction, Construction technology, Modular construction

I. INTRODUCTION

Prefabrication construction innovation targets making a technique for development in which a structure can be built in various parts that are pre-assembled off site with great assembling offices in a controlled environment. The pre-assembled units, then, at that point, moved from the industrial facility region to the building site and afterward introduced as conclusive structure parts. The construction remembers finish of different parts for design, projecting and restoring of various units, transportation of these units on location and establishment of different units. (Building and Construction Authority (BCA), 2019) PPVC, A sort secluded development in which building parts and modules are produced and collected at off-site manufacturing plants and afterward moved to the building site for the establishment. This strategy is creative just as cleaner way of getting sorted out the creation in development industry. Unlike in traditionally construction method, PPVC can be a faster way for implementation of any kind of project. Also increase the productivity rates. (Bon-Gang Hwang, 2019) With increasing population in our country, the housing problem today has assumed the gigantic proportions. The conventional strategies for development can't convey the required sum, until an upheaval in the development field. This should be possible in the event that we embrace pre-assembled framework. It can empower to determine these issues by accomplishing fast in development and efficient utilization of building materials while building a structure. It will lessen the waste produced during development. The success of prefab system will require high level government involvement in construction and housing sectors. It can achieve by creating building factories located at different parts of the country. There should be government policies for housing which will strongly affect the construction industry. The different user needs to be educated by ways of promotion, advertisements, workshops etc.

II. PPVC TECHNOLOGY

In PPVC 3d modules are designed and prefabricated at a separate prefabrication facility, which improves workmanship and safety because the modules were made in a dedicated factory area, with controlled environment that can ensure better quality and quantity control over the process. Finishing of piping, tiling, window frames and a waterproofing system, etc can also be done off site. (Institute of Engineers ,Singapore, 2020)

Kinds Of PPVC development modules There are two kinds of PPVC development modules - built up cement and steel. The decision of material is significant in light of the fact that it will conclude the sizes and number of modules required for an undertaking. This will influence the complete weight, which is significant for arranging since these modules should be shipped at the building site..

1.

2.

Reinforced cement PPVC modules-Reinforced cement PPVC modules have substantial dividers and floors. They are by and large heavier and more modest, consequently requiring more modules.

Steel PPVC module - Steel PPVC modules are upheld by steel outlines with lightweight dividers and have either concrete or lightweight ground surface. These are lighter and bigger, generally requiring less. (Prof. Chiew Sing Ping, 2019)

Figure 1-Types of PPVC modules. (Prof. Chiew Sing Ping, 2019)

Adoption for PPVC in different counties Pre-assembled Prefinished Volumetric Construction (PPVC) was presented by the Building and Construction Authority (BCA) in Singapore. A comparative development approach was additionally presented in Malaysia which is known as the Modular Construction System (MCS) and Modular Integrated Construction (MIC) in central area China. These advancements were generally embraced by Singapore and China, India is behind the latest thing of development innovation. The fundamental explanation is the absence of comprehension of this innovation. (Zhao Xu, 2019) Preferred Building Typology Pre-assembled Prefinished Volumetric Construction (PPVC) has been extraordinary handiness in private and commercial structures, hostel building and healthcare building to help the usefulness and nature of development. It will diminish the dependence on unfamiliar labor force. Likewise offers top caliber and effectiveness as the majority of the completions, mechanical administrations, electrical administrations, and so on are introduced along with the modules in manufacturing plant, prior to sending them for on

location get together. To augment the efficiency of PPVC, normalization of configuration can be use and redundancy can be improved. (Zhao Xu, 2019) Involvement In DFMA PPVC is a critical lift to the development advances that help the Design for Manufacturing and Assembly (DfMA). Measured development is likewise related to it and depict the utilization of such innovation. Complete modules which made of various units are finished with interior completions, apparatuses, fittings are introduced in processing plants, and afterward moved to the site for establishment in a Lego-like way. PPVC likewise conveys critical benefits in on location security, quality control and manageability.

(Prof. Chiew Sing Ping, 2019) (Institute of Engineers ,Singapore, 2020) Comparison In a conventional labor serious industry, a large portion of the exchange works including primary, building, MEP and inside completing works are built and introduced nearby.

"Pre-assembled Prefinished Volumetric Construction (PPVC)" implies a development strategy by which unsupported volumetric modules (complete with wraps up for dividers, floor and roofs) are a. built and gathered; or b. made and gathered, in a licensed manufacture office, as per any authorize creation strategy, and afterward introduced in a structure under building works. (Prof. Chiew Sing Ping, 2019)

Figure 2- comparison of traditional vs PPVC technique. (Prof. Chiew Sing Ping, 2019)

III. BENEFITS OF USING PREFABRICATED PREFINISHED VOLUMETRIC CONSTRUCTION

Benefits of PPVC Economic benefits

PPVC is off-site construction technologies take most of the production away from the construction site, also, basically the lethargic inefficient site exercises are supplanted by more effective quicker plant processes. However, the infrastructure for factory production requires greater investment in fixed manufacturing facilities, and repeatability of output to achieve economy of scale in production.

Figure 3- Cost comparison of both construction technology. (Lawson, R.M., 2018)

• Save development time up to around 25% - half from regular development.

Modular construction allows for the building and the site work to be completed simultaneously. It can also reduce the need labor, finance and overall supervision costs. To save more time and money, all design and engineering areas are part of the manufacturing and installation process. In modular construction building floors, walls, ceilings, rafters, and roofs can be made simultaneously.

During ordinary development, walls can't be set until floors are in position, and roofs can't be added until walls are raised. Then again, with measured development, walls, floors, roofs are completely worked simultaneously, and afterward united in from a similar manufacturing plant to building site. This course of introducing particular unit development time to half contrasting and ordinary development. (Lawson, R.M., 2018) • It also save the manpower up to about 25% - 40% from conventional construction. All the fabrication and assembly process are completed at off-site factory, thus reduces labor intensive construction activities.

• Parallel on-site and off-site construction concurrently.

Assembly is independent of weather, which can increase work efficiency and avoids damaged building material. Reduction in floor construction time from 14 - 21 days of conventional construction to approx. 4 days only for PPVC on site installation. However longer preparation before construction.

• Higher consistency in quality and quality confirmation of building works in controlled industrial facility creation and get together climate. Joining conventional development strategies and quality assembling with outsider organizations who could offer assessments, testing, and affirmation for controlling the quality can be all in or all out. Additionally, business measured structures are worked with understanding to nearby, state, and public guidelines and codes. Because of transportation of the modules to the last site, every module ought to be worked to withstand travel distances. The last module-to-module gathering of autonomously solid parts can give an eventual outcome that is more sturdy than site-fabricated constructions. (Lawson, R.M., 2018) • Construction safety – Minimize labor intensive works at construction site. The indoor construction environment reduces the risks of accidents for workers.

• Environment –

Reduction in noise levels and residue contamination on location. The particular design is finished in an industrial facility controlled climate utilizing dry materials, the potential for significant degrees of dampness which can be caught inside new development could be disposed of for wood built structures.

• Sustainability – Reusable steel material. Secluded development lessens in general wastage contrasted with on location development. The controlled climate of the industrial facility takes into account more precise development. This additionally permit the additional materials to be reused and get used.

FlexibilityMore modules can be added to a measured structure according to require. This can make high story building. On the off chance that the necessities change, particular structures can be dismantle and these modules can be moved and revamped according to the client prerequisite for next use. This will diminish the interest for building materials and limit the expense to make a structure. So, the whole structure can be reused if oversee appropriately.

Elimination of Weather Delays: 60 - 90% of the development is finished inside processing plant controlled climate, which take out the danger of climate delays.

Structures are finished sooner, making a quick profit from speculation. (constructionplusasia, 2020)

IV. POTENTIAL CHALLENGES

Confined choices – The assortment of configuration relies upon the modeler and firm to assemble the pre-assembled structure with at least one choices. This additionally make restricted measure of material choices and conceivable outcomes of the format which infers that there are chances the construction may not be adaptability in the plan than accepted.

Diminished worth during exchange - People can't do changes in the construction according to their need subsequent to purchasing.

Beginning speculation – Adoption of construction innovation has a high sum needed as introductory venture.

Not valuable for foundation – The construction innovation can't be utilized for making establishments or some other sub-structure.

The development for establishment just as for the plinth is finished by the traditional technique on location and afterward the development of superstructure should be possible by utilizing construction innovation.

Transportation of units - Transportation can be excessively costly for development of pre-assembled structures. The genuine transportation cost can influence by various factors, for example, transport distance, grant cost, and trailers length, street width, tallness leeway. Producer send pre-assembled parts utilizing truck with trailers to the building site. As indicated by the pre-assembled framework embraced just as area of site, complexities can emerge during moving of precast components.

Different dangers – Several sudden dangers are likewise connected with construction innovation if examination with conventional development strategy. This is because of most of the enormous structure components are developed off-site and afterward moved to on location a tremendous measure of hazard and obligation is implied from the producer to create precise unit according to indicated necessity with the goal that blunders and disparities can be stayed away from. If not done as expected outcomes in disappointment of design. (Ibrahim Yahaya Wuni, 2020)

V. CASE STUDY OF CLEMENT CANOPY

The Clement Canopy has floors from levels 2 to 40 were built using PPVC that were planned as six-sided substantial modules, weighing between 26 to 31 tons. It took 1,866 modules to develop the two buildings of Clement Canopy, which makes it the current world's tallest PPVC building made -up of concrete.

According to Building Construction Authority (BCA), the PPVC used at the Clement Canopy achieved many learning focuses in planning, production and site works. At the plan stage, early affirmation of drawings and materials became one of the significant obstacles towards guaranteeing a smooth production cycle. The utilization of a large crane implies that the crane's base and its tie-back to the main tower. Modules must be reinforced to cater for extra stacking also. Furthermore, severe site control and discipline must be kept up with to limit harms to the completions and guarantee the nature of the workmanship.

Saving manpower Another venture called, Anchor-vale Cove is a private undertaking containing 10 blocks and 16-story high. Situated in the Sengkang neighborhood region, it was created by the Housing Development Board (HDB), Singapore. Like the Clement Canopy, regular castin-situ development was embraced at level one. The floors from level two upwards were built with these modules.

Success Factor of PPVC technology As detailed by analysts at the Hong Kong Polytechnic University, the top success factors for the management of the beginning phases of the PPVC project life cycle include: • • • • • •

planning details Precise drawings and early plan freeze Great working coordinated effort, successful correspondence and data dividing between project members Viable partner onboard (stakeholder) Broad undertaking arranging and planning Early commitment of central participants

This has been affirmed by scientists at the Central South University and the National University of Singapore, featuring the significance of correspondence and cooperation among project partners. To limit requirements that might delay the cycles, they proposed the accompanying: • • • • •

Apply BIM to advance coordination and increment correspondence Use Information Technologies (e.g., electronic document) to defeat the extra interest of preparation, co-ordination and correspondence Furnish project groups and laborers with instructional courses Apply the Just-in-Time conveyance inventory network model Create and collect the module parts as close as conceivable to the building site to diminish transportation responsibility.

(Building and Construction Authority (BCA), 2019)

VI. CONSTRAINTS

The expanded hardships and the expenses of shipping of the entire units, are the fundamental points against carrying out of PPVC. Additionally, advancements spin around the look and feel might be very comparative. It is expected that assuming designers utilize this strategy, all independence, uniqueness and character will vanish from new project.

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Diminished adaptability for configuration changes later

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Unsupportive choice made by designers

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Impediments to configuration because of transportation limitations (for example modules' size)

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Confined site format (for example absence of extra room for PPVC modules/absence of room to dump and move the modules)

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Absence of PPVC encounters in term of plan

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Absence of PPVC encounters in term of establishment or installation

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Need for extra assurance materials for PPVC modules

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Expanded transportation and coordination contemplations

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Transportation limitations because of rules and guidelines

10. Absence of consciousness of PPVC's advantages among proprietors/designers 11. Expanded hierarchical necessities (for example changing jobs of venture members/expanded intricacy of obtainment and contracting issues) 12. Prerequisite for early responsibility 13. The requirement for extra venture arranging and plan endeavors Development Industry 14. Broad coordination needed before and during development 15. Higher starting expense for regular development strategy 16. Higher development expenses for the traditional development strategy 17. Require more correspondence among all partners 18. Complex code consistence and assessment process (Bon-Gang Hwang, 2019)

VII. MITIGATION

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Empowering close coordinated efforts between project partners during beginning stage of venture (1, 2, and 3)

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Apply Transitory Occupation Permit (TOL) to set up brief worksite nearby the building site to beat the limited site design issue (4)

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Utilization of Without a moment to spare conveyance (4)

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Offering instructional classes for project group and laborers to upgrade their insight and abilities (5, 6, and 7)

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Manufacture and collect the module parts as close as conceivable to the building site to decrease transportation exertion (8 and 9)

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Utilization of Data Advancements (for example electronic record move) to beat the additional prerequisite of preparation, coordination and correspondence (10 and 11)

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Lead practicality reads for PPVC strategy (12, 13, 14, 15, 16, 17, and 18)

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Foster frameworks/PC projects to perform itemized monetary examinations for both PPVC and customary development techniques (12, 13, 14, 15, 16, 17, and 18)

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Utilization of BIM to further develop coordination and work with correspondence among project partners . (Bon-Gang Hwang, 2019)

VIII. DISCUSSION OF MITIGATION

Transportation Planning • Requires a transportation intend to investigate and relieve issues achieved during conveyances. To keep away from likely harm to the module in significant distance travel.

• The Transportation Plan will agree with traffic administrative prerequisites and street width transforming radii ought to be appropriately thought about.

• On time conveyance idea will be adopted with the transportation issues to guarantee the followings: 1.

The ideal opportunity of conveyance

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Oversee site stockpiling

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Upgrade crane use

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Limit the lift and treatment of PPVC (Ibrahim Yahaya Wuni, 2020)

Government strategy It is noticed that no arrangement limits the volumetric measured development is delivered in India. The accomplishment of prefab framework would require the public authority inclusion. This should be possible by setting up building manufacturing plants situated in different parts of the entire country. There ought to be an administration strategy of prefab which would emphatically influence the structure business. The client should be instructed too by methods of ads, studios and so forth.

The public authority should approach in setting up building manufacturing plants and they ought to be situated in different spots in the entire country. For nonstop progression of creating a steady market should be made and govt. should fix the yearly standard for the development of pre-assembled houses for mass housing development. Since the govt strategy influences the structure history as it gives a huge scope market both positive and appealing. One more variable to remember is there should be a legitimate comprehension among makers, draftsmen, architect and manufacturers. The engineer and designers ought to go for normalization in arranging and plan. Additionally, manufacturers should be cognizant with regards to quality, strength and economy of pre-assembled parts. they should be taught by classes, workshops, exhibition of pre-assembled framework and so on.Precast PPVC Construction Situation in India. (Zhao Xu, 2019)

Precast PPVC innovation is generally utilized in developed nations, the utilization of this innovation in India in quiet less. Presently it is utilized in business towers and scarcely any administration private buildings.

Following are the reasons behind why precast development isn't famous in India: 1. Workers for hire's inclination for utilizing minimal expense work as against high capital venture.

2. For little development projects it isn't efficient on the grounds that precast innovation is helpful when there are reiterations of components.

3. Absence of appropriate transportation frameworks is significant impediment for precast innovation as enormous precast components are shipped from industrial facility to building site for erection.

4. Absence of stable interest for precast components.

5. Less degree of normalization of innovation 6. Absence of specialists in plan and assembling and absence of gifted works.

7. Negative insight about precast innovation as far as execution during outrageous climate conditions.

8. Absence of government upheld super undertakings.

9. Joints and association issues 10. Tax assessment issues.

Measures should be possible to give the development of Precast PPVC Innovation in India 1. Normalization of precast substantial components.

2. Interest in Exploration and Improvement.

3. Expanding number of qualified industry people.

4. Motivating forces for transformation of precast innovation.

5. Improvement of transportations frameworks 6. Government support.

7. Interest in precast innovation area. (constructionplusasia, 2020) (Bon-Gang Hwang, 2019) Construction innovation is known to have the accompanying impediments. Confined choices in Plan – The accessibility of assortment in the plan relies upon the firm or association picked to assemble the pre-assembled structure with – one might be left with a restricted measure of material choices and conceivable outcomes of the design. This suggests that there are chances the construction might have less adaptability in the plan than accepted or anticipated. Diminished exchange esteem - Greater part of individuals think they are of low quality and low strength, which makes them incredibly hard to exchange. High beginning speculation – The reception of construction innovation requests a high measure of starting venture. Non-appropriateness for base – The construction innovation can't be utilized in the development of foundation. (Bon-Gang Hwang, 2019) The development of establishment and plinth is finished by the traditional technique and afterward the development of superstructure is finished by utilizing construction innovation. Transportation of precast units - Transportation can end up being costly for development of pre-assembled structures. The real transportation cost taught depends on various principal factors, for example, transport distance, grant cost, and trailers assumptions. Producers of pre-assembled parts normally favor transport their components by truck and trailer to the building site. As per the idea of the pre-assembled framework embraced and area of the site, certain inconveniences can emerge during shipping the precast components. Expansions in random dangers – A few unexpected dangers are related with construction strategy in contrast with the conventional development technique. This is because of the explanation that most of the huge structure components are developed off-site; an immense measure of trust and obligation is put on the maker to deliver precisely what are according to determined necessities so even minor blunders and disparities might place the whole construction at serious risk. (Bon-Gang Hwang, 2019) The joints to be given between the center construction and the parts ought to be sufficiently able to move a wide range of stresses. The strength and heftiness of the whole design relies absolutely upon the strength of the joint. In this way, it is important to have thorough investigations on complete framework rather than part based review. Necessity of gifted work at site and absence of on location computerization is perhaps the greatest issue in reception of construction advances in development which requires exactness and accuracy. In this way, ability improvement and local computerization is needed for establishment of the pre-assembled frameworks.

The pre-assembled units are probably going to get harmed during erection or transportation as substantial apparatuses are needed for

erection and the game plan of the units must be done precisely and the cycle becomes ungainly in a blocked region. Work maintenance is one more issue as gifted work is needed in the pre-assembled development since it is unique in relation to in-situ development, which requests machine situated abilities both on location and in the assembling system. 9. Supportability Parts of Construction Manageability manages the course of use of current assets in a manner to keep away from the exhaustion and keep up with the environmental equilibrium. The possibility of supportability in the development business alludes to the decrease of effect on the climate and advancing the idea of green structures as development exercises request critical material stream, appeal of energy and certain unavoidable just as irreversible effects. Construction innovation has been distinguished as one of the choices having the capacity to assume a fundamental part in making development exercises more economical. The manageability parts of construction can be bifurcated into three sorts viz. social, financial and natural and is tended to by the abbreviation "SEE" perspectives. Social Perspectives - The acknowledgment of construction innovation in the development area is an incitement wherein different sorts of areas are related with bad quality lodging and surprisingly friendly avoidance.

This is the principle reason of the victory of the construction innovation and the two fashioners and producers need to acknowledge this reality. Throughout the process of everything working out, various foundation improvements have been obtained through construction innovation yet at the same time there are a few misinterpretations on the grounds that specific part of the populace actually believes that the structures developed utilizing construction innovation has inferior quality, low strength and so on Monetary Viewpoints - The pre-assembled structures endeavor to accomplish decrease of wastage of materials which in the long run prompts decrease in cost and season of development, minimization of season of development so that overwhelms are kept away from and decline in development abandons as each and all prefab units are checked prior to sending nearby. This multitude of variables demonstrate that construction innovation might be important for the financial parts of manageability. Natural Viewpoints - The ecological manageability parts of construction might be grouped into six sorts viz. water, encapsulated energy, species file per hectare, transport energy, functional energy use and waste which might be tended to by the abbreviation "WESTOW" perspectives. The expanding contamination is a central issue which is identified with the harm made by contamination due development exercises.

Prefab constructions ought to have more command over plant-based construction, which ought to decrease the danger of tainting of the climate. Transport might be an ecological exhibition factor, where construction might be more terrible than conventional structures. Makers of the pre-assembled parts ought to effectively think about all the natural effect of their items by growing better techniques for materials obtainment, reusing, contamination control and waste minimization norms. (Bon-Gang Hwang, 2019) IX. CONCLUSION Quick adoption and correct execution of PPVC will add critical additions in the development of construction business. Where good conditions win and conditions merit, the correct execution of PPVC further develops the project execution as far as time, cost, quality, security and supportability. Be that as it may, not all executed PPVC projects have accomplished the ideal degree of progress. As PPVC is acquiring critical consideration around the world, it is pivotal to set up an extensive structure for estimating the achievement of PPVC projects The housing issue today has accepted the massive extents. The conventional strategy for building development can't take care of complete advancement, until we acquire an unrest the development in the field. This should be possible by embracing pre-assembled framework. It ought to take care of these issues generally by accomplishing speed in development and financial utilization of building materials. This would likewise decrease the waste produced at the building site.

REFERENCES • •

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Bon-Gang Hwang. (2019). Prefabricated Prefinished Volumetric Construction: Key Constraints and Mitigation Strategies.

Building and Construction Authority (BCA). (2019, September 19). Prefabricated Prefinished Volumetric Construction (PPVC). Retrieved from Building and Construction Authority (BCA): https://www1.bca.gov.sg/buildsg/productivity/designfor-manufacturing-and-assembly-dfma/prefabricated-prefinished-volumetric-construction-ppvc/prefabricated-prefinishedvolumetric-construction-case-study-the-clement-canopy constructionplusasia. (2020). Building the future with prefabricated prefinished volumetric construction (PPVC). Retrieved from constructionplusasia: https://www.constructionplusasia.com/my/building-the-future-with-prefabricated-prefinishedvolumetric-construction-ppvc/ Ibrahim Yahaya Wuni. (2020). Risks of modular integrated construction: A review and future research directions.

Institute of Engineers ,Singapore. (2020). The Singapore Engineer. Retrieved from issue: https://issuu.com/desmond6/docs/tse_nov_20_web

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Lawson, R.M. (2018). Sustainability and Process Benefits of Modular.

Prof. Chiew Sing Ping. (2019). PPVC - A DfMA Game-Changing .

Zhao Xu. (2019). Comparative analysis of modular construction practices in mainland China, Hong Kong and Singapore.