Modern Methods of Construction (MMC) are innovative and efficient techniques and technologies in the construction industry that improve the speed, quality, and sustainability of a construction project. MMC includes new construction methods such as modularization, 3D printed construction, flat slab construction, prefabrication, and other advanced techniques. In contrast to traditional construction methods, buildings designed using MMC can be constructed faster, more cost-effectively, with less waste, and with greater customization.
Dodge Data and Analytics 2020 SmartMarket report shows that about 91% of the general contractors indicated a positive impact of modular construction on project cost, with 48% reporting a 10% or better reduction in cost.
In this blog, we will understand each of the modern methods of construction, their benefits, and their effective application in the building lifecycle.
The most applied 11 new construction methods are as follows:
The 3D volumetric construction involves off-site manufacturing of 3D units in a controlled factory environment before transporting and assembling them on-site. Large 3D structural units finished with services, fixtures, and fittings are stacked to erect buildings. Hence, this construction is called 3D volumetric construction or modular construction. Modular units might range from prefabricated steel structures to complete external and internal finishes with services installed.
Manufacturing prefabricated modules in a controlled environment with the same materials reduces construction time and money, as well as allows for consistency and quality control. This construction method can be excellent for consistency and rapid assembly for the development of modular homes, hotels, hospitals, educational facilities, and similar buildings.
Precast flat panel system is a type of modular construction where large, flat panels are created off-site and brought to the construction site for the building assembly. Typically made of concrete, steel, timber, or composite materials, these panels can be used for walls, roofs, and floor units. They are prefabricated with openings for windows, doors, and other fixtures.
Precast panels can provide cladding for building envelopes that are designed with insulation materials and can also be used as load-bearing elements. Staircases, elevator shafts, and foundation walls are also constructed using precast flat panel system. It’s a cost-effective and sustainable construction method that reduces waste, speeds up construction times, and offers design flexibility.
Flat slab construction is a reinforced concrete construction method that builds flat slabs of concrete, reinforced and supported by concrete columns or walls. This method of construction removes the need for beams, with the slab load placed on supporting columns and a square slab called a ‘drop panel’. Flat slab construction is ideal for spaces with irregular floor plans and varying column grids, as it creates more open, column-free spans.
With these flat panels, the column is strengthened against pressures caused by heavy use, thereby increasing both its load capacity and longevity. It helps to shorten the floor-to-floor height which can be beneficial to cut material costs and building weight. The absence of beams eliminates the risk of beam collapse during an earthquake and provides greater fire safety.
The Marina Bay Sands hotel and casino in Singapore is a notable example of flat slab construction.
Precast cladding panels are precast concrete or glass panels manufactured off-site to create the exterior facade of a building. Manufacturers design these cladding panels in various shapes, sizes, colors, and textures to meet the unique design requirements of a building.
For example, an exterior wall panel may be designed with insulation materials to improve the thermal performance and reduce energy costs of a building. For larger construction projects, contractors may also instruct manufacturers to add steel reinforcement cages within a panel to protect the concrete from splitting under pressure. The construction technique also allows architects and designers to use multicolored metal panels or glass panes for aesthetic purposes.
Precast cladding panels are durable, can withstand harsh weather, and require minimal maintenance. As they can be designed to reduce the energy consumption of a building, they increase the overall sustainability of the project.
The oldest and most widely used building material in the world, concrete, surprisingly is now one of the modern methods of construction. The material is popular for its strength, durability, fire resistance, and longevity, essential factors for making a solid structure.
Concrete or cement floors are flat slabs of concrete with two types: in situ concrete floors poured on-site and prefabricated concrete floors that are transported to the site. When mixed with rebar or reinforcement steel, concrete can withstand heavy loads, making it suitable for ground floors. Walls made of concrete are typically used as retaining walls, seat walls, interior wall finishes, and decorative walls on the exterior.
Compared to any other material, concrete or cement floors are versatile and can be treated with a variety of finishes. For example, acid-stained painted, epoxy flooring, polished concrete, and textured concrete for slip resistance. Concrete walls and floors provide sound insulation, are easy to clean, and can be recycled or reused. Self-healing concrete is modern alternative to traditional materials that automatically repairs any cracks or fissures, leveraging the bacteria in the concrete building itself.
Twin wall technology is a modern method of construction that applies a combination of precast concrete and in-situ concrete. Two parallel prefabricated concrete panels are sandwiched together using either steel lattice girders or fresh concrete to provide structural integrity. As manufacturers create these panels according to the specific dimensions given by contractors, they are quicker and less costly to install.
Not only does this building technique offer great structural integrity, but waterproofing for the structure as well. As these walls include two separate panels and a connecting space, they are also effective at resisting sound and fire. The technology is useful while constructing different types of buildings such as homes, offices, warehouses, schools, and many other types of buildings.
The precast foundation is a reinforced concrete component made up of a tied rebar beam cage incorporated within a semi-precast concrete element that acts as formwork. It is a modern method of construction where concrete foundation units are pre-engineered and manufactured off-site using reusable molds and then transported to the construction site for installation.
Precast concrete foundation is suitable for any elevated structure. It typically supports precast concrete walls, columns, and beams that are connected together to form a complete foundation system. Precast concrete foundation technique is economical, reduces on-site disruption, and takes a shorter construction period. When the construction is performed on highly contaminated ground, this technique is the best choice as it decreases soil excavation quantity.
Precast foundation units can be installed in both residential and light commercial foundation systems.
Insulated Concrete Formwork (ICF) is a modern method of construction employing twin walled panels that are either polystyrene panels or blocks. This technique involves dry stacking hollow foam blocks or panels, which are then filled with factory-made ready-mix concrete to form the walls and floors of a building.
Polystyrene blocks effectively provide high levels of thermal insulation, resulting in lower energy consumption and HVAC (heating, ventilation, air conditioning, and cooling) expenses. Apart from thermal insulation, ICF structures facilitate strong acoustic insulation and damage resistance.
Construction companies are preferring the ICF construction method for both high-performance commercial and residential buildings. This is due to the adoption of more stringent energy efficiency and natural disaster resistant building codes.
3D printing is a new construction method for manufacturing construction units or entire buildings using a computer-aided 3D printer. This 3D printer prints concrete, polymer, metal, or other materials, layer-by-layer. Also referred to as ‘additive construction’, the modern method of construction has three main types of 3D printing techniques:
The technologically advanced method includes both on-site and off-site fabrication of construction elements, using industrial robots, gantry systems, and tethered autonomous vehicles. The recent emergence of building information modeling (BIM) in particular may facilitate greater use of 3D printing.
Construction 3D printing allows for faster and more precise construction of complex or bespoke structures. It decreases labor costs, generates less waste, and leads to safer construction sites. Till date, numerous housing, construction components, bridges, and civil infrastructure have been successfully built with the help of 3D printing.
The 2,600-square-foot office headquarters of Dubai Future Foundation (DFF) is the world’s first 3D-printed office building.
In this process, tunnel formwork is brought to site in half units and in the form of an inverted “L” which are bolted together at the top to form each tunnel. The inbuilt wheels and jacks of the formwork help it to position itself in and out and adjust to the final height.
This modern technique is mostly used in constructing cellular structures with high repetition such as hotels, hostels, private housing, and commercial facilities.
Thin joint masonry, a relatively new construction technology, uses quick-set mortar adhesives that reach full bonding strength in a matter of hours. This technique uses a thinner depth of mortar (3mm or less compared to 10mm) which results in faster laying and increased productivity. The mortar bonds quickly, usually within two hours which enables more structures to be laid in a day.
This modern technique enables more accurate and consistent laying of masonry units, making the building stronger and more durable. It is most suited to low-rise buildings where the load-bearing capacity of the masonry units is not as critical as in high-rise buildings.
Challenge – The Hamilton Building is a 15-story commercial office building located in Minneapolis, USA. The construction site of the project was in proximity to residential properties and a university. Hence, the challenge was to execute the project with minimal disruption and waste generation. Also, building an innovative high-rise building also required contractors and architects to deliver architectural finesse.
Solution –
The office building was constructed using 3D volumetric modules, manufactured off-site in a controlled factory. Each module was pre-fitted with electrical, plumbing, and finishes, reducing on-site work and shortening the construction timeline. This minimized disruptions like noise and dust, crucial due to nearby residential areas and a university. The factory setting also reduced material waste. Once delivered, the modules were efficiently assembled into a 15-story structure, ensuring high-quality construction and allowing for complex architectural designs.
Outcome:
The Hamilton Building makes use of efficient, sustainable construction. Using 3D volumetric modules, it was completed quickly with minimal disruption, reduced waste, and high-quality results, showcasing the potential of off-site construction.
There is a broad range of modern methods of construction (MMC), serving as alternatives to traditional construction methods. Due to new advancements and increasing awareness of sustainability issues, modern methods of construction processes are becoming more popular. However, the majority of construction professionals are still apprehensive to adopt MMC for their project deliveries.
A holistic change of mindset within the industry that technology is a friend rather than an enemy is necessary to develop. Businesses that embrace positive changes and use them in their favor will have a significant competitive advantage over their peers. The question is – Are you ready to harness the opportunities of the Fourth Industrial Revolution for your company?
Contact our team at Constructive Solutions, Inc. to enquire about your project.
MMC is particularly suitable for projects that require a high degree of repeatability and standardization.
MMC needs specialized design and engineering expertise, high upfront costs, adequate transportation, and site access for off-site manufacturing.
Contrary to traditional construction mostly done on-site, MMC utilizes off-site manufacturing of building components
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This post was last modified on September 5, 2024 12:05 am
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