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The role of prefabrication in architecture has Prefabrication in India began with the
been lauded for its potential to increase emergence of the Hindustan Housing Factory.
productivity and efficiency while not sacrificing The company was developed by the first Prime
quality. The values of better, faster and Minister of India, Pandit Jawaharlal Nehru, as a
cheaper are applicable to developed countries solution to the housing crisis that resulted from
such as the U.S., Japan, and Europe, whose the influx of refugees from West Pakistan in
middle class continues to demand this equation the 1950s. The Hindustan Housing Factory
in buildings that range from the remarkable to pioneered the production of pre-stressed
the prosaic. Developing countries, including concrete railway sleepers to replace dilapidated
China, India, Africa and many parts of South wooden sleepers on Indian Railways. The
America, that are beginning to rely on company changed its name shortly thereafter
prefabrication have the potential advantages of to reflect the diversity of its operations. It is
realizing housing quickly and affordably; now known as the Hindustan Prefab Limited or
however, greater reliance on manufactured HPL. Located in Delhi, today the government-
production has possibly more disadvantages run company prefabricates primarily precast
than advantages for these cultures. concrete for architectural and civil projects
throughout greater India.
With prefabrication, improved working
conditions would seem to be agreeable to When HPL began it was intended to produce
everyone: instead of building in the weather, low-income housing solutions for the deficit in
international fabricators supply controlled India. Precast wall panels and frame members
environments with ergonomically considered such as beams and columns provided a much-
equipment – and yet in many fabrication needed set of tools to erect quick structures for
environments, reliance on minimal skills, and a mass housing. The most difficult technology
disconnect with the community in which transfer obstacle for the HPL has been the cost
workers live, leaves little room for continued of machinery and materials for production.
fostering of personal and collaborative skills, Since the government could not recoup the
culture, tradition and community building. The return on investment for the factory through
potential for prefabrication to be used to create housing production, prefabrication from HPL
PREFABRICATION IN DEVELOPING COUNTRIES 49
began to service other markets including therefore serves to build more seismically
higher dollar civil and larger public and hotel resistant structures.
buildings.
The government of India has a goal to make
The quality of construction is much higher housing available for all its citizens by 2010.
when components are manufactured in a Among the logistics of this effort is an
stable environment such as the factory. This is ambitious new construction initiative. India is
especially true in India where today, planning to accomplish this task through a
prefabrication has become synonymous with prefabrication surge in order to build 3-4 level
durable, modern, and western construction multi-family structures. Kirby Building Systems
methods. Materials are used more efficiently, India Ltd., an affiliate of Alghanim Industries, a
are safer from climatic damage, and can be company located in Kuwait, has a state-of-the-
reused in the material stream. Because of art manufacturing plant in Hyderabad with the
these benefits, a general consensus in India is capacity to produce 40,000 tons of precast
to move prefabricated building systems beyond product annually. In addition, Kirby India has
precast concrete for large-scale construction to recently launched what it calls a technology-
additional market sectors including a resurgent driven Pre-Engineered Steel Building Solutions
interest in applying prefabrication technology (PEB). In 2004, Kirby completed a 33-meter
to housing. high building for the Kolkata-based Garden
Reach Shipbuilders & Engineers and a 25
Traditional construction techniques involve the meter building for the North Eastern Council.
use of timber molds or shuttering for roof Likewise, Minaean Habitat India, a subsidiary
spans and other structural systems. These of Minaean Building Solutions, Canada, is
temporary timber structures have a short currently developing a prefabricated building
lifespan and due to the volume of construction framing system that utilizes load-bearing steel
in the peak seasons of spring and summer for panels. Minaean Habitat has also recently
larger well-funded projects are often launched a modular building division in which
unavailable. This hinders construction structures are designed, engineered and
schedules and does not allow projects to be prefabricated ready for use within four days of
completed before cooler or rainy seasons receipt at site. Minaean has deployed this
begin. However, construction does not stop in system in a two-level housing project on the
the summer despite the lack of proper outskirts of Solapur, Mahrashtra.
equipment and material. Instead, using
makeshift methods for construction on site The HPL and Kirby Building Systems are just
leads to inappropriate means and hence a sub- two examples of a myriad of prefabrication
standard quality of construction in finished companies that are emerging within and
buildings. The prefabricated alternative to roof without India in order to serve the housing
construction removes the issues of timber demand of one of the most dense, heavily
molds and shuttering. Prefabrication in Indian populated, and fastest growing population and
housing improves uniformity and brings economy in the world.
unskilled labor inside where work is
supervised, monitored and controlled. Ethical Dilemmas of Technology Transfer
Material advances in the prefabrication housing “Technology transfer can affect the
market have also helped to mitigate material government, economy, and culture of both the
failures. The use of fly ash in concrete transferring and the receiving nations. It opens
increases its workability and improves thermal too many ethical dilemmas.”
performance. In addition, fly ash concrete
block is beginning to replace traditional clay Prefabrication will continue to grow in India as
bricks because it does not contain expansive the demand for fast affordable housing
soils that cause walls and floors to crack with increases. However, technology transfer of
fluxes of temperature and humidity. Fly ash is prefabrication process, including materials and
captured from the coal burning process that digital tools, can affect the environment,
generate electricity and then reused to economy and culture of the receiving country
manufacture more durable and stable building negatively. There are risks associated with the
materials in a factory environment. The transfer of prefabrication technology. The host
material manufacturing is more predictable and country may not have the infrastructure, the
manufacturing and/or professional prowess to
50 WITHOUT A HITCH: NEW DIRECTIONS IN PREFABRICATED ARCHITECTURE
accept it. The negative affects can be social, majority of buildings are relatively simple and
environmental and/or economical. do not require the complexity of systems
coordination and parameters available in the
Transportation software. Professor Moirera suggests that
additional tools be developed for the South
The Auroville Earth Institute in 1999 built a American method of project delivery. This
prototype-prefabricated house in New Delhi would be a software system that allowed for
that showed advances in structural capacity more flexibility in the process for projects that
during earthquakes. Initially envisioned as a require more or less information. This is
disaster resistant and cost effective prototype, likewise an issue in other developing countries,
it was intended that the house would be especially India. With the increase of
precast anywhere and shipped by truck to a developing countries having digital products
disaster location. Precast in Auroville, and such as computers, the developed country
transported over 2,900 km to New Delhi in a providers must consider culture specific tools.
single lorry of 22.5 tons, the prototype was
assembled in 66 hours by an 18 man team. Human Rights
The transportation cost alone was equal to the
cost of manufacturing the prototype. The Human rights issues are also of concern with
model was economically unviable for India. The regard to prefabrication technology transfer.
solution to low cost prefabricated housing must As technology made way for mass production
overcome the obstacle of shipping costs. and assembly line manufacturing methods in
Prefabricating regionally might better serve the early part of the 20th century in the U.S.,
developing countries. (Fig. 1) developing countries are using the same
process to produce goods abroad today. Along
with industrial manufacturing and economic
benefits come labor challenges. Prefabrication
presents problems: trading traditional
handicraft construction jobs for automation.
The culture of local building tradition passed
through generations is abruptly discontinued.
(Fig. 2)
Schedule
Outdated Technology
Experience suggests that it is unlikely that the about modern culture than the technology
AEC industry will see the scale of funding itself. Technology in prefabrication is therefore
required to broadly transform its production capability, embodied knowledge in an artifact,
techniques. Therefore, just as with less method or process. Technology transfer refers
developed countries’ dependence on transfer to the exchange of capability from one party to
from developed countries, in large measure another to the mutual benefit of both. A
technological changes in the AEC industry rely massive technology transfer process has been
upon transfers from government research occurring during the later part of the 20th
funded industries such as aerospace and century in which developed countries are
automobile production. In short, not only is transferring technologies to less developed
building relatively not as technologically countries; many efforts have been
innovative as other industries, but in less unsuccessful. This is because many of the
developed countries this is exacerbated. India, technology transfer trials were imposed or
for example, is receiving transfers from the forced. In these situations, the technology
U.S. AEC industry, an industry already behind might take hold for a short while, but will die
in the latest technologies. This second order out in the end.
transfer means that the technologies are
always outdated. A more effective method of transfer is the
“pull” method. This method can be described
Climate and Vernacular as the receiving country “pulling” the
technology from the developed country
One of the most significant influences on because of need. In this condition, the less-
vernacular architecture is the macroclimate of developed country is doing all within its power
the area in which the building is constructed. to prepare for the technology. Therefore, the
Buildings invariably perform well when built technology is “just in time,” not present any
with regard to the local climate rather than a sooner or later than it needs to be. The pull
technological trend that may not be as method also has advantages with regard to
appropriate. The local environment and the social and environmental concerns. Instead of
construction materials that market can produce being forced to accept, the developing country
governs many aspects of prefab development. has prepared an adaptation plan for the
Vernacular, by definition, is sustainable, and conservation of the social, environmental and
will not exhaust local resources. For a country economic conditions of their country. Again, if
that has followed vernacular practices transfers are imposed, the technology will have
successfully for generations, like India, moving difficulty taking hold without a colossal effort
to a concept like prefab may not prove to be by the giving country, and in most cases will
climatically as suitable. require the provider to make decisions
regarding a culture with which they are
For example, in many hot regions of India, unfamiliar.
masonry walls that are heavy and dense
conduct heat slowly. This simple process, Allan Reddy relates 3 elements that are a
called thermal lag, reduces peak cooling loads requirement for transfer host countries in a
in summer and peak heating loads in winter. pull method: information about the method, an
The result is a more comfortable home all year understanding of it, and the means to carry it
long that produces significant savings in out. With regard to prefabrication in India it is
energy. However, in India there are 6 distinct the bringing together of these elements that
climate zones ranging from cold and dry to may prove the successful transfer of the
warm and wet. Therefore, India’s architecture technology. India must be versed in the
is varied in its use of materials, style of technology both in theory and practice and
construction and cultural difference that cannot have the ability to support the technology into
be generalized. Prefabrication in a technology the long term. It is with this knowledge and
transfer mode struggles take into consideration capacity that they will be able to make
these vernacular differences. decisions regarding the adoption to the benefit
of both economics and social/environmental
Proceed with Pulling ethics.
Technology is social, environmental and Relatively simple technologies that have been
economic before it is technical. The method of captured in a product such as a cell phone are
its development and use says much more simply distributed and used by the population
PREFABRICATION IN DEVELOPING COUNTRIES 53