EPACK Prefab: Achieving Sustainability With Prefabricated Construction

The choice is pretty clear - prefabricated construction is paving the way for creating a more responsible, sustainable and efficient construction industry.

Nikhil Bothra - Director, EPACK PREFAB

In the face of escalating environmental challenges posed by conventional construction methods, exacerbated by factors such as the recent construction bans in some cities due to severe bad air quality concerns, the imperative for a sustainable shift in building practices becomes more evident than ever. The construction industry's significant energy consumption, substantial waste production, and contribution to CO2 emissions demand a re-evaluation of traditional approaches.

India, grappling with a staggering annual production of approximately 150 million tonnes of construction waste, shoulders a substantial burden, accounting for a substantial 35-40% of the global Construction and Demolition (C&D) waste each year. This challenge is bound to intensify further with a growing population and an ever-increasing demand for housing and infrastructure in the country.

Prefabricated construction, often referred to as Pre-Engineered Buildings (PEBs) is a transformative solution that not only addresses environmental concerns but also presents an efficient alternative amidst the challenges posed by construction bans to curb air pollution. The resultant delayed project timelines underscore the urgency for resilient, eco-conscious building practices like the PEBs that can turn the current environmental challenge into an opportunity for sustainable development.

Water conservation: Traditional construction practices have historically often come at an environmental cost. The methods consume vast amounts of water for mixing concrete, curing, and other essential processes. In contrast, prefabricated construction does not utilize water during construction. This is particularly significant in regions facing water scarcity and in remote hilly regions where every drop counts. By eliminating water-intensive practices, PEBs help preserve this precious resource and contribute to a sustainable future.

Lower carbon emissions: One of the most compelling reasons to embrace prefabricated engineered structures is their significantly lower carbon footprint. Traditional construction projects churn out massive waste, including surplus materials, excess packaging, and discarded debris. This waste not only strains landfills but also exacerbates environmental degradation. However, PEBs are environmentally friendly as they emit 60% less carbon pollution during construction compared to conventional construction. This substantial reduction in emissions is achieved by streamlining the manufacturing process in a controlled environment, reducing energy consumption, and minimising waste.

Shorter construction time: Time is money in the construction industry, and shorter construction periods are a win-win for both builders and the environment. Prefabricated solutions can reduce construction time by more than 50% compared to traditional construction methods. The efficiency of assembling building components in a factory setting and transporting them to the construction site accelerates project timelines. This not only reduces the disruption caused by lengthy construction activities but also curtails associated energy and resource use.

Energy efficiency: PEBs are designed with energy efficiency in mind. The materials used in prefab construction provide superior insulation and maintain a consistent interior temperature regardless of external weather conditions. Also, India's diverse climate can pose a significant challenge to the on-site construction process. Harsh weather conditions, including scorching heat, heavy rains, and extreme cold, can disrupt construction schedules, and expose a substantial energy drain by excessive heating or cooling. Prefabricated construction eliminates this issue by shifting most of the work to a controlled indoor environment. By offering enhanced insulation, PEBs contribute to significant energy savings and promote energy-efficient living by using renewable energy sources such as solar panels or wind turbines.

Reduced material waste: The controlled environment of a factory setting ensures that PEBs have fewer defects and require fewer repairs and replacements. In contrast, traditional construction often generates considerable material waste due to on-site errors and over-ordering. PEBs' streamlined manufacturing process significantly reduces material waste, making them a more sustainable choice. Moreover, traditional construction methods often require wood framing, which contributes to deforestation. Prefabricated construction uses alternative materials such as steel and concrete, reducing the demand for wood and helping address deforestation.

Recyclability: Sustainability goes beyond the construction phase and extends to the life cycle of a building. In India, out of 150 million tonnes of construction waste every year only a mere 1% of this colossal waste is recycled, as projected by the Centre for Science and Environment (CSE). Such practices undermine the collective efforts towards a greener future and leave a lasting mark on the planet. When a PEB reaches the end of its life, it can be dismantled, and the components repurposed or recycled as they are designed for disassembly and reuse. This cradle-to-cradle approach minimises a lot of waste and adds to the overall sustainability of PEBs.

Improved resource management: Prefabrication optimises resource allocation within the factory. Materials and resources are efficiently managed, reducing over-ordering and minimising resource wastage. This results in a more efficient use of resources, promoting sustainable practices and responsible resource management.