NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A GOVERNMENT OF INDIA ENTERPRISE)

KUDANKULAM NUCLEAR POWER PROJECT

CIVIL DEPARTMENT

Project Report
Automation and Advanced Techniques in Construction
Submitted by

KARAN PANERI (19U1370)

VIRENDRA KUMAR MEENA (19U1356)

BHIM SINGH (19U1358)

ROHAN YADAV (19U1351)

RAHUL THAKUR (19U1369)

Under the guidance of

Shree K.T. Kakade (SO/E)

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 ACKNOWLEDGEMENT

It is our great pleasure to express sincere gratitude to our supervisor Shree K. T. Kakade (SO/E) and
Sh. K S Bandekar (ACE Civil HTS) and Sh. Shivalingaiah L (PE Civil HTS) for being helpful and
a great source of inspiration. We are highly obliged to him for his keen interest, advice, and
encouragement. Working under his leadership is a great privilege and an excellent learning opportunity
for us.

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 CANDIDATE’S DECLARATION
We hereby declare that the work carried out in this project report “Automation and Advanced Techniques
in Construction’’ by Karan Paneri, Virendra Kumar Meena, Bhim Singh, Rohan Yadav and Rahul
Thakur is an authentic record of our own work carried out during the period from Apr 2023 to July 2023
under the supervision of Sh. K.T. Kakade (SO/E) .

I have not submitted the matter in this report elsewhere for any kind of award.

Date: July, 2023 Place: KKNPP

Karan Paneri Virendra Kumar Meena Bhim Singh Rohan Yadav Rahul Thakur

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 CERTIFICATE

This is to certify that the above declaration made by the candidate is correct to the best of my knowledge.

……………………………..Sh. K.T. Kakade (SO/E)

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 ABSTRACT
Nuclear power plants have become a vital part of India's energy strategy, and their construction has
witnessed significant progress in recent years. India's nuclear power program aims to meet the growing
energy demands of its rapidly expanding economy while reducing reliance on fossil fuels. The
construction of nuclear power plants in the country involves a multi-faceted approach that includes site
selection, design, regulatory compliance, and safety considerations.

Advanced techniques, such as modular construction, 3D printing, and sustainable building practices,
have revolutionized traditional construction methods. Modular construction allows for the
prefabrication of building components off-site, reducing project timelines and minimizing waste. 3D
printing enables the creation of complex structures with precision, offering time and resource savings.
Sustainable building practices promote environmentally friendly materials and energy-efficient designs,
fostering eco-conscious construction.

Automation plays a pivotal role in enhancing construction processes. Robotic systems, AI, and IoT
technology have automated tasks traditionally performed by human workers. Robots can undertake
bricklaying, concrete pouring, and site monitoring, improving productivity and safety. AI algorithms
analyze data to optimize project schedules and resource allocation, while IoT devices enable real-time
equipment tracking, reducing downtime.

The combination of advanced techniques and automation holds immense potential to reshape the
construction industry. This study provides an overview of the advancements and sets the stage for
further exploration of their impact on project outcomes, cost efficiency, and the evolving role of the
workforce. The following sections delve deeper into the specific advancements and shed light on the
exciting developments in advanced techniques and automation in construction.

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CONTENTS
ACKNOWLEDGEMENT ....................................................................................................................... 2

CANDIDATE’S DECLARATION.......................................................................................................... 3

CERTIFICATE......................................................................................................................................... 4

ABSTRACT............................................................................................................................................... 5

List of Figures ........................................................................................................................................... 9

Chapter-1 ................................................................................................................................................. 11
INTRODUCTION .................................................................................................................................................11
1.1 Why go for Automation .............................................................................................................................12
Regulatory and permitting processes: ........................................................................................................12
Skills shortage and labor challenges: .........................................................................................................12
Fragmented nature of the industry: ............................................................................................................12
Resistance to change and technology adoption: .........................................................................................12
1.2 Key reasons why opting for automation ....................................................................................................12
Enhanced productivity and efficiency:.......................................................................................................12
Improved safety: ........................................................................................................................................13
Consistency and quality control: ................................................................................................................13
Cost savings and profitability: ...................................................................................................................13
Scalability and flexibility: ..........................................................................................................................13
Resource optimization:...............................................................................................................................13
Technological advancements and competitive advantage: ........................................................................13

Chapter - 2 ............................................................................................................................................... 14
ADVANCE CONSTRUCTION EQUIPMENTS ..................................................................................................14
Vacuum Excavator: ....................................................................................................................................14
Advance Excavator Bucket: .......................................................................................................................15
Self-Erecting Tower Crane: .......................................................................................................................15
Cutter Suction Dredging Machine: ............................................................................................................16
Robotic Machine for Tying Rebar: ............................................................................................................17
Robotic Machine for Rebar Placement IRON-Bot: ...................................................................................18
Drones for Painting: ...................................................................................................................................18
Concrete boom placer: ...............................................................................................................................19
Laser distance sensors: ...............................................................................................................................20
Cover Blocks Making Machine: ............................................................................................................21
Floating Crane: .......................................................................................................................................22
Harbour Crane: .......................................................................................................................................22
Truck Mounted Crane: ...........................................................................................................................23
Level Luffing Cranes: ............................................................................................................................24

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 LA-5P G self-leveling, 5-Point/Dot GREENBEAM Laser: ..................................................................24

Chapter - 3 ............................................................................................................................................... 27
ADVANCE CONSTRUCTION MATERIALS.....................................................................................................27
Self-Healing Concrete: ...............................................................................................................................27
Flexible or Bendable Concrete: ..................................................................................................................28
Light-generating cement or light-emitting cement: ...................................................................................29
Basalt Rebar: ..............................................................................................................................................30
Fe 600 GRADE: .........................................................................................................................................31
CFRP Rebar: ..............................................................................................................................................32
GFRP:.........................................................................................................................................................32
Epoxy Coated Rebar: .................................................................................................................................33

Chapter 4 ................................................................................................................................................. 34
INNOVATIVE TECHNIQUES IN CONSTRUCTION ........................................................................................34
Nanotechnology in Waterproofing:............................................................................................................34
Concrete canvas: ........................................................................................................................................34
Nanomaterials used in construction: ..........................................................................................................35
Plastic Formwork: ......................................................................................................................................36
Aerogel: .....................................................................................................................................................37
Plastic Cube Mould: ...................................................................................................................................38
VWT Mixer: ...............................................................................................................................................38
Vacuum Concrete:......................................................................................................................................39
Eurotec Chilled Water Plant: .....................................................................................................................42
E SHIELD: .............................................................................................................................................44
AC Helmets: ...........................................................................................................................................45
Tesla Bot: ...............................................................................................................................................47
AI-Powered Design: ...............................................................................................................................47
Bionic Exoskeletons: ..............................................................................................................................48
Smart Wearable: .....................................................................................................................................48
3D Printing: ............................................................................................................................................48
Modular Construction: ...........................................................................................................................50
a) Modular Design Methodology: ..............................................................................................................52
b) Balance of Plant/ Secondary Systems Modules Analysis ......................................................................52
c) Advantages of Modular Construction ....................................................................................................53
d) Challenges of Modular Construction .....................................................................................................54
e) Modular construction of Tunnels ...........................................................................................................55

Chapter 5 ................................................................................................................................................. 57
DIGITALISATION ...............................................................................................................................................57
Digital Documentation: ..............................................................................................................................57
Virtual Reality Technology: .......................................................................................................................58

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 AR (Augmented Reality) Technology: ......................................................................................................60
4D Construction Simulation:......................................................................................................................61
The Internet of Things (IoT): .....................................................................................................................63

Chapter – 6 .............................................................................................................................................. 65
Construction Industry vs Manufacturing Industry .................................................................................................65

Chapter – 7 .............................................................................................................................................. 67
CONCLUSION ......................................................................................................................................................67
1.1 What is Technology Adoption? .......................................................................................................................67
1.2 Can the Construction Industry Catch Up? .......................................................................................................67
1.3 Cost-Benefit Analysis: .....................................................................................................................................68

References ................................................................................................................................................ 70

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 List of Figures

Figure 1: TRUVAC APXX Vacuum Excavator 14

Figure 2: LDR Excavator Bucket 15
Figure 3: Self Erecting Tower Crane 16
Figure 4: Cutter Suction Dredger-CSD500 17
Figure 5: T-iROBO Automatic Rebar Tying Machine 17
Figure 6: IRON-Bot Robotic Rebar Placing Machine 18
Figure 7: Painting using Drones 19
Figure 8: Concrete boom placer 19
Figure 9: Laser Distance Sensors 20
Figure 10: Cover Blocks Making Machine 21
Figure 11: Floating Crane 22
Figure 12: Harbour Crane 23
Figure 13: Truck Mounted Crane 23
Figure 14: Level Luffing Cranes 24
: Figure 15 Self leveling STABILA laser 25
Figure 16: Self-Healing Concrete 27
Figure 17: Chemical Process of working of Self-Healing Concrete 28
Figure 18: Flexible or Bendable Concrete 29
Figure 19: Light Emitting Concrete 29
Figure 20: Basalt Rebar 30
Figure 21: GFRP bar 32
Figure 22: Epoxy Coated Rebar 33
Figure 23: Nanotechnology Process 34
Figure 24: Concrete Canvas 35
Figure 25: Plastic Formwork 36
Figure 26: Aerogel 37
Figure 27: Thermal conductivity and solar transmission through aerosol 38
Figure 28: Plastic cube mould 38
Figure 29: VWT MIXER 39
Figure 30: Steps to make Vaccum concrete 40
Figure 31: Suction mat 40
Figure 32: Strength comparison between ordinary and vaccum concrete 42
Figure 33: Chilled water plant 43
Figure 34: AC Helmet 46
Figure 35: Comparison between normal and AC Helmet 46
Figure 36: Tesla Bot 47
Figure 37: Bionic skeleton 48
Figure 38: 3D Printing Technology 49

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Figure 39: HPC NPP England, prefabricated IC liner 51
Figure 40: Small Modular construction of RB 52
Figure 41: Partitioned nuclear steam supply system, integrated modules and combined integrated module
52
Figure 42: Precast Tunnels 56
Figure 43: Flow chart of digital documentation 58
Figure 44: Demonstration of VR technology 59
Figure 45: Demonstration of AR technology 61
Figure 46: 4D Construction Simulation 61
Figure 47: Comparison between different industries 65

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 Chapter-1
INTRODUCTION
The construction industry has experienced remarkable advancements in recent years, driven by the
integration of advanced techniques and automation. These innovations have revolutionized traditional
construction practices, offering increased efficiency, enhanced safety measures, and improved project
outcomes. From cutting-edge building materials to state-of-the-art machinery and digital tools, the
construction sector is embracing technology to streamline processes and optimize productivity.

One significant area of progress is the adoption of advanced techniques in construction. These techniques
encompass a range of innovative approaches, including advanced equipments, materials and machineries
that can be used in various construction activities to improve the efficiency as well as safety. Advance
cranes, excavators, use of drones for various tasks, carbon fibre reinforcement, flexible concrete etc. are
some of the examples that can change the future of construction.

Another driving force behind the transformation of the construction industry is automation. Automation
entails the utilization of robotic systems, artificial intelligence (AI), and internet of things (IoT)
technology to perform tasks traditionally carried out by human workers. Use of virtual reality (VR) and
augmented reality (AR) in construction project can boost the speed of construction and eliminate human
errors.

The combination of advanced techniques and automation in construction is the key to achieve
exponential growth. By adopting modern techniques we can optimize the resources and achieve high
productivity. The adoption of automation in construction brings substantial benefits, including increased
productivity, improved safety, cost savings, scalability, and a competitive edge. By embracing
automation, construction companies can optimize their processes, deliver projects more efficiently, and
ensure higher quality outcomes, ultimately driving success in a rapidly evolving industry.

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1.1 Why go for Automation
The construction industry has faced several challenges that have impacted its growth rate compared to
other industries. Some key factors contributing to the slower growth of the construction industry include:

Regulatory and permitting processes:

Construction projects often face complex regulatory requirements and lengthy permitting processes.
Obtaining necessary permits and approvals can be time-consuming and bureaucratic, causing delays in
project initiation and completion. These delays hinder the industry's growth potential and affect project
timelines and costs.

Skills shortage and labor challenges:

The construction industry has been grappling with a shortage of skilled labor. This shortage is due to
factors such as an aging workforce, limited training and apprenticeship programs, and the perception of
construction as a less desirable career option. The lack of skilled workers can lead to project delays and
hinder the industry's ability to meet demand and drive growth.

Fragmented nature of the industry:

The construction industry comprises various stakeholders, including contractors, subcontractors,
suppliers, and consultants. This fragmentation can lead to coordination challenges, communication gaps,
and difficulties in implementing standardized practices and technologies across the industry. The lack
of collaboration and standardization can impede efficiency and hinder overall growth.

Resistance to change and technology adoption:

The construction industry has traditionally been slow in adopting new technologies and innovative
practices. Resistance to change, lack of awareness, and risk aversion have prevented widespread
implementation of advanced techniques and automation. This slower adoption limits the industry's
ability to improve productivity, efficiency, and competitiveness.

1.2 Key reasons why opting for automation

Enhanced productivity and efficiency:

Automation streamlines construction processes, allowing tasks to be performed faster and with greater
precision. Robots and advanced machinery can complete repetitive tasks more quickly than human
workers, leading to increased productivity and improved overall project efficiency.

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 Improved safety:
Construction sites are inherently hazardous environments. By employing automation, particularly for
high-risk activities, the risk of accidents and injuries can be significantly reduced. Robots can handle
dangerous tasks such as heavy lifting, working at heights, and hazardous material handling, ensuring the
safety of workers.

Consistency and quality control:

Automation ensures consistent performance and adherence to predetermined standards. Machines and
robotic systems operate with precision, minimizing errors and inconsistencies that may arise from
human involvement. This leads to improved quality control and more reliable construction outcomes.

Cost savings and profitability:

While the initial investment in automation may require financial resources, the long-term benefits can
result in significant cost savings. Automation reduces labor costs by minimizing the need for extensive
manual work and mitigating errors that lead to rework. Additionally, increased productivity and
efficiency translate into shorter project timelines, reducing overhead costs and boosting profitability.

Scalability and flexibility:

Automation provides scalability and flexibility in construction projects. Modular construction, for
instance, allows for the assembly of pre-fabricated components, enabling faster construction and easier
scalability. Advanced technologies like 3D printing offer the ability to create complex structures with
ease, providing flexibility in design and customization.

Resource optimization:
Automation enables better resource management. Real-time tracking and monitoring of equipment,
materials, and workforce productivity allow for more efficient allocation and utilization of resources.
This reduces waste, prevents overstocking, and ensures optimal resource utilization throughout the
project lifecycle.

Technological advancements and competitive advantage:

Embracing automation positions construction companies at the forefront of technological advancements.
Keeping up with industry trends and leveraging advanced techniques not only enhances competitiveness
but also attracts clients who prioritize efficiency, safety, and quality in construction projects.

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 Chapter - 2

ADVANCE CONSTRUCTION EQUIPMENTS

Vacuum Excavator:
A suction excavator or vacuum excavator is a construction vehicle that removes heavy debris or other
materials from a hole on land. Suction excavation utilises high-powered fans to safely excavate up to
141 feet (43 meters) of depth depending on the configuration. First, a small surface area hole of about
10 inches (250 mm) is created. Then, the suction excavator hose removes materials below the
surface. Compressed air is used to fracture the ground for the suction excavator to remove the material
safely. No manual hand tooling is used in the process. Suction excavators eliminate the need for costly
and time-consuming manual labour. Buried pipe systems do not suffer damage. The output is up to
sixteen times that achieved by conventional excavation.

Figure 1: TRUVAC APXX Vacuum Excavator

CAPABILITIES
• Hydro Excavation
• Air Excavation
• Potholing/Daylighting to locate underground utilities
• Slot Trenching

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 • Cleanup of flood water, drilling spoils, catch basins, construction sites
• Valve box repairs
• Removal of non-hazardous liquids

Advance Excavator Bucket:

It is a bucket provided with sensor detecting real time underground utilities during earthwork. It has
ground penetrating radar (GPR) integrated into the excavator’s digging bucket, detecting underground
utilities in real-time and alerting the operator during excavation. This breakthrough solution enhances
the safety and efficacy of digging, construction, and earthworks operations, reducing the enormous costs
and environmental impact associated with everyday accidental damage. It provides the operator with
automatic and accurate alerts regarding buried utilities encountered during digging operations, in real
time, before the utility is hit. This bucket can easily be installed on any excavator, current or new, using
industry standard interfaces and attachment systems. It can detect all types of pipes and utilities,
including gas, power, communications, fiber-optics, water, sewage, oil and chemicals - in different soils
and types of substrates.

Figure 2: LDR Excavator Bucket

Self-Erecting Tower Crane:

A self-erecting tower crane, also known as a self-erecting crane or self-assembling crane, is a
specialized type of crane that is designed to be easily transported, erected, and dismantled without the
need for additional equipment or manual labor. It offers convenience, efficiency, and flexibility in
construction and other lifting applications.

 Max capacity - 6 t
 Max radius - 48 m
 Max tip capacity - 1.2 t
 Hook height per base - 38.5 m

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 Figure 3: Self Erecting Tower Crane

Cutter Suction Dredging Machine:

Cutter suction dredger is a kind of ship that is widely used in beach dredging projects. It uses the front
end of the suction pipe. The cutter suction pipe is equipped with a rotating cutter device to cut and agitate
the river bottom sediment, and then through the suction pipe, the Mud, mud transport, mud unloading
and other work processes can be completed continuously at one time. It is a high-efficiency, low-cost
dredger and a good underwater excavating machine. The split structure makes the installation and
transportation of the cutter suction boat simpler and more flexible, can be easily transported to any
location. With its robust design, it is the preferred choice in its class due to low maintenance, excellent
fuel consumption and high productivity levels.

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 Figure 4: Cutter Suction Dredger-CSD500

Model：RLCSD-500
Dredging Capacity：3500 m3/hr
Dredging Depth：1.5-15 m
Suction/Discharge Pipe Dia.：600/500 mm
Engine(s) Power：1100-1600 kw

Robotic Machine for Tying Rebar:

T-IROBO Rebar automatically ties the crossing reinforcing bars with wire and then moves to the next
intersection to repeat the procedure. T-iROBO Rebar (i) enables repetition of rebar binding operation
accurately, (ii) allows for increased productivity by saving labor costs and improving efficiency, (iii)
eases the physical burden of skilled construction workers and (iv) reduces the risk of delay in a project
due to the lack of workforce.

Figure 5: T-iROBO Automatic Rebar Tying Machine

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Specifications:
External Dimensions - Length 640 mm, Width 568 mm, Height 315 mm
Weight – 20 kg
Drive System - Four-wheel drive + Parallel-Link mechanism
Speed - Longitudinal mobility 160 mm/s, Lateral mobility 35 mm/s
Power Source – 174 Wh Lithium-ion Batteries
Battery Backup – 5 hours

Robotic Machine for Rebar Placement IRON-Bot:

IronBot is an advanced robotic system that has also been utilized for rebar placement in construction
projects. With its computer vision capabilities and precision control, IronBot streamlines the process of
positioning and placing reinforcing steel bars (rebar) accurately and efficiently. Using IronBot for rebar
placement offers several advantages. It reduces the reliance on manual labor, increasing productivity
and reducing labor costs. The precision and accuracy of IronBot result in improved structural integrity
and construction quality. Additionally, IronBot's ability to handle repetitive tasks eliminates the risk of
human error and fatigue, ensuring consistent and reliable rebar placement. Overall, IronBot's application
in rebar placement brings automation, efficiency, and accuracy to the construction process, contributing
to streamlined operations, cost savings, and high-quality construction outcomes.

Figure 6: IRON-Bot Robotic Rebar Placing Machine

Drones for Painting:

Drones have found applications in various industries, and one emerging area is their use for painting
tasks. Drones equipped with painting systems offer several advantages for painting applications,
especially in large-scale projects or hard-to-reach areas. Here are some key points about drones for
painting:

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 1. Accessibility and reach
2. Efficiency and speed
3. Precision and consistency
4. Safety and reduced human exposure
5. Cost-effectiveness
6. Flexibility and adaptability

Figure 7: Painting using Drones

Concrete boom placer:

While people faced the issue of transporting concrete to a higher level in large quantity, the concrete
boom placer came in the picture.
A concrete pump is a machine used for transferring liquid concrete and pumping it to a higher level.
The use of boomer allows you to speed up the concreting process by saving the time of transporting the
mixture.
The pump offers a 360-degree rotation and helps displace the concrete all around the construction site.

Figure 8: Concrete boom placer

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The specifications of the models of Schwing stetter are:

The Launch of BSS 46 in India by Putzmeister is in line with its philosophy of opening new segments
& making the latest technology available to the Indian customers. The Boom Pump is mounted on a
trailer. With trailer configuration, it has opened the era of higher reach Boom Pumps in India which till
now were restricted because of non-availability of bigger Truck chassis. The pump is equipped with 5
arms for better reach and maneuverability. It has a maximum vertical reach of 45.1m (148ft) and
horizontal reach of 41.1m (134ft). It is also equipped with a 140 cum/hr core pump and is mounted
on a homologated trailer which is allowed to run on Indian roads.

Laser distance sensors:

Laser distance sensors are designed for non-contact distance measurements: laser gauges for measuring
ranges up to 10m, laser distance sensors for up to 270m. These sensors are used for positioning and type
classification in machine building and handling equipment.

Figure 9: Laser Distance Sensors

 Precise measurement of displacement, distance & position on different surfaces

 Large measuring range for both indoor and outdoor use
 High repeatability

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  High accuracy and signal stability
 Fast response time
 Extremely compact design without external controller

Cover Blocks Making Machine:

This machine offered by us are widely used in the construction industry to making high-quality Cover
Block Making Machine. In this process highly flowing pigments with concrete is poured into the rubber
molds and compacted in Vibro forming vibrating tables. The various customized size & thickness with
design add attractively.

Figure 10: Cover Blocks Making Machine

Material Mild Steel

Size 10X3

Model Name/Number KOVAI TABLE

Warranty 1 Year

Brand KOVAI

Capacity 5000 Blocks/Per Day

Usage/Application Industrial

Motor Power Up to 3 HP

Table - Specifications of Cover Blocks Making Machine

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 Floating Crane:
It is also called crane ship, crane vessel or floating crane. It is mostly used in offshore construction and
they are specialized in the lifting of heavy loads. They can also be used to load or unload ships or lift
sunken ships from the water. They are fixed and therefore cannot be rotated. They have a large capacity
of about 9000 tons.

Figure 11: Floating Crane

Harbour Crane:
It is also called mobile harbour or port harbor crane. It is mostly used in sea ports to unload or load the
ships. The flexibility of the machine makes it easy to use it at any place. Its main advantage is, that it is
among the powerful material handling cranes. Which means that materials will be transported from one
place to another safely and with ease.

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 Figure 12: Harbour Crane

Truck Mounted Crane:

It is in that types of cranes which have one engine. It means that same engine is used for undercarriage
and as well as for crane. They are mounted on a rubber tires truck, which provides great mobility.
Outriggers are used to stabilize the truck by extending it horizontally or vertically.
Its main advantage is that it can travel on highways itself, which makes it easy and less expensive. It
does not need any other vehicles to transport it. They can be rotated up to 180 degrees. But some of
them rotate up to 360 degrees but these are more expensive.

Figure 13: Truck Mounted Crane

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 Level Luffing Cranes:
They contain a hinged jib. In level luffing crane, the hook remains at the same level. While they move
the jib up and down. It is usually used for unloading and loading the ships with containers.
Careful movements are required while moving the jibs near the ground level.

Figure 14: Level Luffing Cranes

LA-5P G self-leveling, 5-Point/Dot GREENBEAM Laser:

The STABILA LA-5P G GREENBEAM Laser provides you the fastest, most reliable way to plumb and
square greater than 12 ft. up to to 60’.
The self-leveling, STABILA LA-5P G, projects 5-bright GREENBEAM laser dots, visible up to 60 ft.
Layout points can be transferred and right angles can be set in an instant. It features a mechanical on/off
switch and pendulum lock. This durable and compact, pouch laser is excellent for framing walls, interior
and exterior. Builders will appreciate the ability to work directly against wood plates and metal track, in
all conditions, even in brightly lit spaces. The highly efficient LA-5P G laser is powered by 3-AA
batteries, providing you up to 15 hours of constant run time.

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 : Figure 15 Self leveling STABILA laser

Features
 The self-leveling STABILA LA-5P G Set features 5-bright GREENBEAM laser, pouch, removable
framing base, target plate, metal wall mount plate and batteries.
 Quickly transfer layout points and set right angles, even in brightly lit conditions.
 The LA-5P G comes with a v-groove rare earth magnet built into the housing for secure attachment to
metal.
 5 green bright and tight dots are visible up to 60ft.
 Up dot accuracy tolerance: Will not exceed 3/16 in @ 50ft.
 Down dot accuracy tolerance: Will not exceed 1/4 @ 50ft.
 Level dot accuracy tolerance: Will not exceed 3/16in @ 50ft.
 Square dot accuracy tolerance: Will not exceed 1/8in @ 50ft.
 Warranty: Up to 2 years from the date of purchase.
 Mechanical off/on switch with pendulum lock.
 Self-leveling range: 4.5 degrees.
 Up to 15 hours of constant run time on 3-AA batteries.

Applications
 Positioning/setting interior and exterior walls.
 Transferring layout points from floor to ceiling.
 Laying out square within 60 ft.

25
Table – Technical specification stabila laser

26
 Chapter - 3

ADVANCE CONSTRUCTION MATERIALS

Self-Healing Concrete:
Self-healing concrete is a new type of concrete. It imitates the automatic healing of body wounds by the
secretion of some kind of material. To create self-healing concrete, some special materials (such as fibers
or capsules), which contain some adhesive liquids, are dispensed into the concrete mix. When cracks
happen, the fibers or capsules will break and the liquid contained in them will then heal the crack at once
using a bacteria called bacillus megaterium. The bacteria grow and spread when cracks appear, acting
as a natural filler and preventing cracks.

Figure 16: Self-Healing Concrete

27
Standard tests were conducted on normal concrete and self-healing concrete or bacterial concrete.
Tests conduct were compressive and flexural strength tests on a concrete cube for 7 and 28 days.
Compressive strength (N/mm2):

Self-Healing Concrete Normal Concrete

Compressive Strength, N/mm2 Compressive Strength, N/mm2

7 days 28 days 7 days 28 days

26.79 37.82 20.10 28.56

Table- Comparison of Compressive Strength

Figure 17: Chemical Process of working of Self-Healing Concrete

Flexible or Bendable Concrete:

A flexible or bendable concrete is an engineered cementitious composite (ECC) that exhibits the
property of ductile material unlike the brittle nature of conventional concrete. The material composition
of conventional concrete is altered in order to impart flexible nature in concrete. Flexible concrete is
composed of Cement, Fibers, Sand, Water and Super plasticizer. The tensile strength of flexible concrete
ranges from 10 to 15 MPa. The compressive strength of flexible concrete can be achieved up to 70MPa.
The initial cost of flexible concrete construction is high. The availability of special materials for flexible
concrete is difficult to obtain. The compressive strength of flexible concrete is less compared to
conventional concrete.

28
 Figure 18: Flexible or Bendable Concrete

Light-generating cement or light-emitting cement:

It is green cement that lights up without electricity. It works well by absorbing solar energy during the
day and then emitting it at night. Light-generating concrete was created by mixing fluorescent pigments
into a concrete mixture. The primary application of this material is for roads. This innovative concrete
can significantly reduce the amount of energy needed to light up roads as it works entirely using solar
energy.

Figure 19: Light Emitting Concrete

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 Basalt Rebar:
Basalt rebar reinforcement is an alternative to steel and fiberglass for reinforcing concrete. Made from
volcanic rock, basalt rebar is tougher and stronger than steel with a higher tensile strength. Basalt rebar
is much lighter than steel rebar making it easier to work with and so much cheaper to ship. Basalt rebar
is naturally resistant to alkali, rust and acids. Moisture penetration from concrete does not spall. Needs
no special coating like fiberglass rods. Basalt rebar has the same thermal coefficient expansion as
concrete.

Figure 20: Basalt Rebar

Table- Comparison of Steel and Basalt Rebar

30
 Fe 600 GRADE:
FE 600 grade TMT steel bars have the highest Tensile to yield strength, ductility and elongation
compared to all other grades of TMT steel bars. This grade of TMT steel bars comes into use for heavy
constructions that require maximum strength and durability that lasts for a lifetime and withstand harsh
weather conditions and earthquakes.

Table - Comparison of Chemical Properties of TMT Bars

Table - Comparison of Mechanical Properties of TMT Bar

31
 CFRP Rebar:
Carbon Fiber Reinforced Polymer Rebar is an extremely strong and light fiber-reinforced polymer which
contains carbon fiber. It is used primarily as an alternative to steel reinforcement in concrete structures
such as parking structures, bridge decks, highways under extreme environments, and structures highly
susceptible to corrosion and magnetic fields. As a result of its excellent properties.

Table - Properties of Carbon Fiber Reinforcement Polymer Bar

GFRP:
Glass Fiber Reinforced Polymer rebar, commonly referred to as Fiberglass reinforcement, is a high
tensile strength alternative to steel reinforcement. Fiberglass reinforcing is highly resistant to corrosion
and can extend the lifespan of concrete structures enormously. The steel is used in constructions like
buildings, tunnels, waterside concrete, etc, Due to climate and exposure to chlorides causes major
corrosion issues.

Figure 21: GFRP bar

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 Epoxy Coated Rebar:
Also referred to as green rebar, is used in concrete subjected to corrosive conditions. These may include
exposure to deicing salts or marine environments. Epoxy coated rebar or corrosion resistant rebar is used
instead of conventional reinforcing bars to strengthen the concrete and protect against corrosion. The
epoxy coating is applied in a factory to the steel prior to shipping.

Figure 22: Epoxy Coated Rebar

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 Chapter 4

INNOVATIVE TECHNIQUES IN CONSTRUCTION

Nanotechnology in Waterproofing:
One of the most well-known applications of nanotechnology in modern life is the use of ceramic coating
for waterproofing. Water, oil, dirt, and other dry particles are repelled by nanocoating, which are surface
layers that are hydrophobic (water repellent) and oleophobic (oil repellent). Dry surface applications
make use of superhydrophobic coatings. Objects can be coated with a high hydrophobicity eco-friendly
nano coating to make them permanently watertight. The item resists oxidation, corrosion, ice, UV rays,
high temperatures, and chemical substances. It also has UV resistance. It can be applied to a variety of
surfaces and self-cleans when it rains. The color of the surface are applied to remains unchanged when
nano coatings are used.

Figure 23: Nanotechnology Process

Concrete canvas:
Take a layer of “concrete cloth,” then add water and allow to set. This innovation typically is used for
drains, channels, and passages, and it is now available commercially.

What is a concrete canvas?

Concrete canvas (CC), is a flexible, concrete impregnated fabric that hardens when hydrated to form a
thin, durable, water proof and fire resistant concrete layer. Concrete canvas concrete does not require
plant or mixing equipment as it is positioned on surface and added with water.

34
 Figure 24: Concrete Canvas

Nanomaterials used in construction:

Carbon nanotubes – Expected benefits are mechanical durability and crack prevention (in cement);
enhanced mechanical and thermal properties (in ceramics); real-time structural health monitoring
(NEMS/MEMS); and effective electron mediation (in solar cells).
Silicon dioxide nanoparticles - Expected benefits are reinforcement in mechanical strength (in
concrete); coolant, light transmission, and fire resistance (in ceramics); flame-proofing and anti-
reflection (in windows).
Titanium dioxide nanoparticles – Expected benefits are rapid hydration, increased degree of hydration,
and self-cleaning (in concrete); superhydrophilicity, anti-fogging, and fouling-resistance (in windows);
non-utility electricity generation (in solar cells).
Iron oxide nanoparticles – Expected benefits are increased compressive strength and abrasion-resistant
in concrete.
Copper nanoparticles – Expected benefits are weld ability, corrosion resistance, and formability in
steel.
Silver nanoparticles – Expected benefits are biocidal activity in coatings and paints.
Quantum dots – Expected benefits are effective electron mediation in solar cells.

Disadvantages:
 As nanoparticles are not cost-efficient, it limits their commercial applications
 Some nanomaterials may be hazardous due to the presence of very small particles

35
 Plastic Formwork:
Use of plastic formworks for concrete construction has many advantages such as durability, cost and
flexibility compared to other materials for concrete formworks.
There are different materials which may be used to manufacture formworks for example timber, steel,
and aluminium in addition to plastic that offer number of advantages compared to other materials for
example durability, cost effectiveness, and flexibility.
Construction of formworks takes time but also spent about 20 to 25% of the total cost of the structure.
It is one of the major factors that influence the success of construction of any structure in terms of safety,
cost, quality and speed.

Figure 25: Plastic Formwork

There are several advantages provided by plastic formworks in concrete construction: Cost effective,
Labour friendly, Eco friendly, Low maintenance, Versatile.

Plastic Traditional Steel

Items
formwork formwork formwork

Recycled 40% No 10%

Water resistant Yes No No

Deformation
No Yes Yes
condition

Stripping process Easy Moderate Difficult

36
 Any size can
Size Restricted Restricted
supply

Corrosion resistant Excellent Bad Bad

More than
Availability time 8 times 100 times
100 times

Table - Comparison of formworks

Aerogel:
Aerogels are synthetic low-density materials with unique physical properties. They are formed by
removing the liquid from a gel under special drying conditions, bypassing the shrinkage
and cracking experienced during ambient evaporation. This creates a solid three-
dimensional nanoporous structure containing 80-99% air.
Due to their high porosity, aerogels exhibit the lowest thermal conductivity of any solid, whilst
being transparent to light and solar radiation. Aerogels are often cited as a promising material for
translucent insulation applications. They can made from practically any material, although the
most common form is silica aerogel which can be produced as granules or in solid (monolithic) tiles.

Figure 26: Aerogel

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 Figure 27: Thermal conductivity and solar transmission through aerosol

Plastic Cube Mould:

Plastic cube mould (or Cube Mold) can be supplied in different models, each one with different
characteristics and weight. All the cube moulds have a reinforced band on the walls, and the inside
surfaces is very smoothed getting easier the specimen's ejection. It grant an additional resistance, and
foresee a "X" reinforced band on the base, improving the strength of the mould, and allowing the user
to give small blows with a rubber heated hammer by easing the specimen's ejection

Figure 28: Plastic cube mould

Manufactured from robust plastic are one piece and the specimens are ejected from the moulds by
compressed air. High quality plastic cube mould is manufactured from lightweight polyurethane
material and one piece. High quality plastic cube mould is manufactured in accordance with dimensions
and tolerances stated in the standards. The specimens are ejected from the moulds by compressed air.

VWT Mixer:
It is an Indian Invention protected under Indian Patent application no. 397/MUM/2015; that will
eventually replace transit mixers & eliminate central mix (RMC PLANTS)

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 Figure 29: VWT MIXER
The VWT Controlled Mobile concrete mixers are fully automatic truck-mounted mobile concrete mixers
which have the potential of replacing the present day combination of central ready-mix plant & transit
mixer trucks. The VWT mixers are provided with a fully automatic batching system which works on
weight, Volume & time thereby bringing huge consistency and reliability to the batching process without
using load-cells. These mixers are dust proof & can carry dry ingredients to the place of pour and supply
wet mixed concrete after reaching the site. They are designed to work on the truck engine itself. These
mobile mixers have many advantages over the presently available volumetric concrete mixers & these
mixers save huge amount of diesel fuel as they do not require a separate batch-mix plant and they do
not require any power during transit
The volumetric mixer varies in capacity size up to 12 m3 and has a production rate around 60m3 an hour
depending on the mix design.

Vacuum Concrete:
Also known as vacuum-assisted concrete or VAC, is a specialized type of concrete that incorporates a
vacuum process during its production. This process helps to remove excess air and water from the
concrete mixture, resulting in a denser and stronger final product.

39
Figure 30: Steps to make Vaccum concrete

Figure 31: Suction mat

40
 Steps for Laying Vacuum Concrete

1. A concrete mix of sufficient workability is prepared and laid in the formwork.

2. The surface of the laid concrete is compacted by a needle vibrator. Then, further compaction is done
with the help of a double beam screed vibrator. Here, a smooth surface is obtained.
3. The vacuum dewatering is started immediately after compaction using vacuum equipment which
includes
4. Suction mat
5. Filter pads
6. Vacuum pump
7. Filter pads are rested upon the fresh concrete leaving 4” (inch) filter cover exposed on all sides.
8. The top cover is placed on the filter pads covering the exposed concrete surface left by filter pads. This
top cover is connected to a vacuum pump through the suction hose.
9. The vacuum pump is then started for about 15-25 min decided by the thickness of the concrete floor.
As the pump operates, a vacuum is immediately created within the boundary of the mat and top cover.
10. The time for pumping is usually taken 15-25 min from an economic point of view. Pumping beyond
30 min causes an insignificant reduction in water content, hence should be avoided.
11. The atmospheric pressure compresses the concrete and the surplus water is suctioned out from the
concrete through fine wire gauge/muslin cloth giving the following results:
12. Water content lowered by 15-25% of the original water
13. Concrete layer depth decreased by 3%
14. Dewatering takes 1.5-2 min/cm of floor thickness. This dewatered concrete is compacted & dried until
the concrete does not leave footprints if someone walks over it. This dried concrete implies that
15. Concrete is dewatered adequately
16. Concrete is ready for finishing
17. The concrete surface is hardened and smoothened with the help of a power trowel & power floater after
skim floating it. These re-vibrate and assists in removing the capillaries or channels formed during
suction of water.

18. Surface hardeners can also be used as the dewatered surface provides ideal conditions to receive
powdered hardeners. This adds to the abrasion resistance of the concrete

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 Figure 32: Strength comparison between ordinary and vaccum concrete

Properties of Vacuum Concrete

 Increase in strength to about 25%
 Increase in density
 Decrease in permeability
 Increase in durability
 Increase in abrasion resistance
 Increase in impact resistance by 10%

Eurotec Chilled Water Plant:

Eurotec Chilled Water Plants offer concrete cooling designed for regions with tropical and hot climates.
They produce 1 °C and 5 °C chilled water temperature using an Evaporative Condenser and 3 to 4 stages
concrete cooling system to save energy. The plant can be operated continuously.

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 Figure 33: Chilled water plant

FEATURES
1. Containerized structures
2. Low shipping & transportation costs
3. Fast set-up and dismantling for relocation
4. Using 3 to 4 stages cooling and evaporative condenser
5. Ability to produce chilled water at 1 °C or 5 °C
6. Easy maintenance
7. Energy-efficient
8. Fully automatic

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 Table - Specification of chilled water plant

E SHIELD:
‘Shield’ is a significant digital safety solution that captures EHS data, compares it with baseline data
and assigns Key Performance Indicator (KPI) scores to analyze EHS performance of sites in real time.
A dashboard, accessible at various levels across the organization, displays EHS risks, quacarries numb
of activities out and closures, tracks EHS compliance by monitoring activities and sub-activities,
workmen deployed, current risk rating of the project, critical activities, major hazards and physical
progress that empowers the team to identify activities requiring greater attention to improve productivity
Integrated with thermal & optical video cameras, the LTTS i-BEMS Shield enables features such as
automated temperature detection, monitoring of building air quality, and smart maintenance of social
distancing norms.

I. Temperature detection
Unmanned dual sensors thermo graphics and day/night camera for detection of people with high body
temperature at all entry points
 Real time detection
 Monitoring of multiple people
 Unmanned operation
 High accuracy of 0.30 C

II. Face detection and tracking

Real time tracking of symptomatic individual across non overlapping cameras till they are isolated and
checked by the nearest available medical officers

44
  Real time detection
 Simultaneous tracking of up to 200 people
 Detection of people through their eyes
 Can recognize people even at rangers of 20-25 m
 Easy to integrate with existing CCTV infrastructure

III. Air quality management

Real time monitoring and reporting of particles such as CO2, PM2.5, PM10, TVOC for both indoor and
outdoor environment
 Real time analysis and benchmarking against recognized standards as LEED, BREEAM,
USFDA, FSSAI, FoSTaC
 Plug and play solution that can easily integrate with existing infrastructure

IV. Occupancy management

High accuracy, real time people counter solution to gain complete visibility into a zone historical and
real time occupancy levels
 High accuracy, typical upwards of 98%
 Consolidated, multi-location, real time tracking
 H.264 compression standards to reduce network load

AC Helmets:
 Prevents temperature rise and heat stress
 Reduces exhaustion and prevents headaches and fatigue
 Keeps users sweat-free and comfortable
 2-3 times more effective at cooling the head than the torso
 Maintains a comfortable head temperature for optimal performance

Regular Helmets:
The temperature of the head rises by 4°C

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 Figure 34: AC Helmet

Realising that most companies might not want to purchase helmets for all their workers upfront, they
launched their lease model. Under this, companies can lease Jarsh helmets for as low as Rs 15 per day
or 450 per month. "This scheme was launched so that it also serves as a trial for those companies who
are not ready to buy the helmets yet,” says the alumni of VNR Vignana Jyothi Institute of Engineering
and Technology who pursued his Bachelor's in Mechanical Engineering from there.
The approximate cost of the helmet is Rs 7,000.

Figure 35: Comparison between normal and AC Helmet

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 Tesla Bot:
Elon Musk’s recent announcement that Tesla is developing their first fully-automated humanoid could
result in significant disruption to the construction industry. The robot is designed to handle mundane,
repetitive, or dangerous tasks, typically undertaken by humans.

Figure 36: Tesla Bot

The robot will use the same cameras and sensor technology and the same cutting-edge artificial
intelligence developed for Tesla cars. If the Tesla bot is developed and released successfully as planned,
it could transform the way the construction industry undertakes higher risk activities and result in
significant cost savings and less risk to workers.

AI-Powered Design:
The tunneling industry benefits from an abundance of publicly available data on past tunneling projects,
which is the perfect space for artificial intelligence and big data to flourish. Tunnels.ai is a bold project,
driven by a community of civil engineers collating and organizing data.
Behind the scenes, artificial intelligence algorithms have then been developed to use this data to predict
key design and construction parameters for tunneling projects, including tunnel design parameters, TBM
specifications, cost predictions, carbon emission predictions, etc. Best of all, tunnels.ai is completely
free and all they ask for is that you voluntarily join the community and contribute data if you enjoy the
tools.

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 Bionic Exoskeletons:
Bionic skeletons were first developed by the US military, and tech companies recently started to develop
and release similar designs for the construction industry. Workers are often limited by national
regulations limiting the maximum weight they can safely carry, which is approximately 25kg.

Figure 37: Bionic skeleton

Bionic exoskeletons enable the workers to carry weights up to 90kg, with little effort needed by the
operator to handle this weight. These exoskeletons are available for purchase today, however, they do
not come cheap, with the average cost setting the buyer back upwards of $100,000. However, this is still
a new technology and it is believed to mature and be more affordable with time.

Smart Wearable:
Smart wearable are allowing construction contractors to monitor the status and whereabouts of workers
at any given time during their shift. This can allow for monitoring of worker productivity and safety
with the employer being immediately notified if the worker suffers from an injury or needs medical
assistance.

3D Printing:
3D printing (sometimes referred to as Additive Manufacturing (AM)) is the computer-controlled
sequential layering of materials to create three-dimensional shapes. It is particularly useful for
prototyping and for the manufacture of geometrically complex components.
A 3D digital model of the item is created, either by computer-aided design (CAD) or using a 3D scanner.
The printer then reads the design and lays down successive layers of printing medium (this can be a

48
liquid, powder, or sheet material) which are joined or fused to create the item. The process can be slow,
but it enables almost any shape to be created.
In the construction industry, 3D printing can be used to create construction components or to 'print'
entire buildings. Construction is well-suited to 3D printing as much of the information necessary to
create an item will exist as a result of the design process, and the industry is already experienced
in computer aided manufacturing. The recent emergence of building information modelling (BIM) in
particular may facilitate greater use of 3D printing.
Construction 3D printing may allow, faster and more accurate construction of complex or bespoke items
as well as lowering labour costs and producing less waste. It might also enable construction to be
undertaken in harsh or dangerous environments not suitable for a human workforce such as in space.

Figure 38: 3D Printing Technology

Advantages

I. Faster Speed of Construction

The biggest advantage of using a 3D printer in construction would be the speed with which the projects
could be completed. Not only does it take much lesser time to build the structures, but it can also work
24 by 7. In recent years, 3 D printing has been successful in building a home from scratch in a matter of
days. According to some reports, 3D printing could save about 60% of the time on jobsite.

II. Low waste construction

The construction industry is a major contributor to global waste production. But with 3D printing, this
waste generation could be lowered by considerable numbers. A 3D printer uses the resources with

49
precision, thus cutting down any wastage.

III. Reduced health and safety hazards

The construction industry is usually considered a risky business. Especially the concrete work can be
hazardous to health. Using a 3D printer for these jobs could minimize the risks of injuries and fatalities.
That’s one of the prime reasons to try this technology in the construction industry.

IV. Increased accuracy

With 3D printing, construction companies can achieve a high level of accuracy in building concrete
structures. In a 3D printing model, instead of pouring concrete into traditional molds, 3DCP (3D
concrete printing) pours materials in layers using a computerized process. This increases the quality and
precision of the structures.

V. High level of design freedom

3D printing allows architects and designers to build complex designs that are otherwise labor intensive
and expensive. With 3D concrete printing, one can easily achieve any shape with ease. This allows the
designers to be more creative in the construction space.

VI. Tailored Constructions

In traditional methods of construction that use mold and cutting, customization was a very time-
consuming and labor-intensive process. In addition to that, there was no guarantee of durability of such
constructions that are created on an experimental basis. But 3D printing ensures enhanced structural
integrity. It also allows the alteration of certain parts to fit certain requirements.

Modular Construction:
Prefabrication and pre-assembly of modules are construction techniques used in many industries,
including nuclear power plants. A module is an assembly consisting of multiple components such as
structural elements, piping, valves, tubing, conduits, cable trays, reinforcing bar mats, instrument racks,
electrical panels, supports, ducting, access platforms, ladders and stairs. Modules may be fabricated at
a factory or at a workshop at the plant site, and multiple modules can be fabricated while the civil
engineering work is progressing at the site in preparation for receiving the modules. This reduces site
congestion, improves accessibility for personnel and materials, and can shorten the construction
schedule. It can also significantly reduce on-site workforce requirements. Modularization also facilitates
mass production of modules in the event that several reactors are being built at the same time. Mass
production reduces production times and labour requirements. Modularization makes it easier to assure
a controlled production environment, with associated improvements in quality and efficiency. It makes
it possible to manufacture modules before the site itself is available, and, in the case of concrete, it
facilitates the use of accelerated curing techniques. The decision to apply a modular approach should be
made in the conceptual design stage, and then it must be followed throughout the project, for detailed
50
design, engineering, procurement, fabrication, and installation, through to the completion of
commissioning. This allows equipment to be designed to conveniently fit into a module, and for modules
to be sized to match the capacity of VHL cranes and transport routes to the site. A site accessible by sea
can accept larger modules. For less accessible sites, sub-modules can be shipped to the site and then
assembled into larger modules before installation.

Figure 39: HPC NPP England, prefabricated IC liner

Prefabricated IC Liner lowered them on 96 hydraulic jacks to its position. Wall is made of 3 modules
and dome is made of single module.

Modularization also affects testing procedures as many components can be initially tested at the
fabrication facility to help eliminate potential faults before formal post-installation tests at the
construction site. Other impacts of modularization are: the need to complete the total plant design before
fabricating modules; the need for factories or workshops to fabricate modules; earlier expenditures on
engineering, materials and components for fabricating modules; the need for expensive heavy lift cranes;
and the costs of transporting modules. For example Argentina's CArem reactor is one of the small
modular construction.

51
 Figure 40: Small Modular construction of RB

a) Modular Design Methodology:

There are two methods to modularise the nuclear island and nuclear steam supply system.
 Breaking a large system down by partitioning
 Integrating the system into one module.
Integrated modules can be combined to form a larger plant. “Packaging of the Nuclear Steam Supply
System for shop fabrication” technologies were introduced (Technology Transfer Modularization Task
team. DOE, 1985), and onsite assembly using shipbuilding techniques was studied further (Lapp, 1989)
and implemented in the AP1000 (Sutharshan et al., 2011) shown in figure below.

Figure 41: Partitioned nuclear steam supply system, integrated modules and combined integrated module

b) Balance of Plant/ Secondary Systems Modules Analysis

With the nuclear island taking up 28% of the whole plant costs (World Nuclear Association, 2020),
modularising the rest of the plant may also provide significant benefits to associated costs in the

52
Conventional Island (15%), Balance of plant (18%) and site development and civil works (20%). A few
studies have considered the modular design and cost savings of the conventional island and balance of
plant. The Stone & Webster Engineering Corporation, (1977) modularisation report showed that civil
parts of the plant may be modularised, saving $1.5million+ (1977 USD) on Reinforcing and Structural
Steel and over $4million+ (1977 USD) on Precast Concrete. It also highlighted pipe racks could save
between $3-6million (1977 USD), along with savings in electrical and equipment.

c) Advantages of Modular Construction

1. Saves Time

An obvious one is that modular construction allows a chunk of the work to be made in a factory while
site work and foundations are simultaneously performed on the site. This time-saving benefit keeps the
project on schedule and speeds up construction time while still being efficient. There is potential to save
30 to 60 percent of overall schedule through a modular approach.

2. No Possibility of Weather Delay

Furthermore, by fabricating the modules inside a controlled environment, worries about weather
delaying construction of the modular units is virtually eliminated. It also provides workers safer and
more comfortable conditions to be more productive and produce a higher quality product. Also, the
modules arrive on-site usually outfitted with flooring, cabinets, counters, plumbing and electrical
fixtures, and appliances, thereby needing little effort and time to be ready for use.

3. No Need to Store Materials

Another advantage of modular construction involves storage of materials. When a site is tight on space,
for instance in a compact urban setting like Philadelphia, staging and moving materials around is
difficult. This causes clutter, slows down work and creates theft concerns. By building the modules in a
factory, construction sites can remain cleaner and safer, and provide more space to work and move
around freely.
4. Lower Labor Costs

An important and potentially controversial advantage involves economics of labor. Skilled labor is in
short supply for construction in most places and can be very expensive in cities for a variety of reasons.
Without getting into politics, this leads to real challenges when trying to get a building constructed for
a given budget and timeline. Modular allows those coveted skilled workers to remain in fixed locations
with controlled and safer conditions as mentioned. Modular plants can be located to attract those
competitive workers and take advantage of important access to raw materials and logistic connections,
like highways and rail lines, common in other industries, such as automotive and technology products.
Savings on labor can vary widely, but there is a potential for up to 25 percent on construction costs.
5. Lower Volume of Waste
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According to a recent UK study, up to a 90% reduction in materials can be achieved with modular
building. With the environment being a growing concern in the construction industry, modular strategies
are becoming more popular to limit the amount of waste on each project. There are even efforts to
maximize recycling within factories that put the building portions together.
6. Less harm to environment

Modular construction techniques generally have a smaller environmental footprint compared to

traditional construction methods

d) Challenges of Modular Construction

Modular construction sounds progressive and remarkably advantageous. Yet, as with other construction
methods, there are some real challenges that can affect success or failure of your modular project.
1. Mass Production / Limited Variety

First, a modular (think mass production) approach on scale is better the more uniform and repetitive the
spaces and products. So naturally, apartment buildings and hotels are likely candidates if each unit can
be standardized and stacked. At this stage of technology, trying to create distinct or non-repetitive
modules reduces, and potentially defeats, the time and cost advantages for both buyer and supplier
parties.
2. Higher Amount of Complex Decisions / Front Loaded Design

Second, modular demands that more decisions and greater design and engineering be completed up front
in the process. It requires architects, engineers and contractors to be familiar with the intricacies of the
modular fabrication and erection stages. For instance, the taller the building (higher modules stacked)
the more attention is needed to how they are connected together to be aligned and how both modules
and the exterior skin will allow for compression. (The weight of stacked modules can actually crush
wood below.) This front-loaded design process forces buyers and owners to make final selections on
things like finishes and appliances so they can be purchased well before the work even begins. Those of
you familiar with the construction business may see this as an advantage: You know that changes made
late in the process can be a headache.
3. Approval Process Can Be Complicated

Third, the approvals process can be complicated. No matter how they are constructed, all projects must
meet federal, state and local laws and codes. However, the codes that are applicable change based on
method. Some states and local jurisdictions are more favorable to modular production than others.
Ideally, the modules are made subject to state codes (such as Pennsylvania Industrialized Housing Act)
and can be inspected and completed at the factory with only connections and work performed on site
subject to local inspection. On the contrary, states like Maryland require local inspections of systems
preventing walls from being closed and finishes applied until on site. In places with strong union
influence, how contractors navigate trade relationships can further complicate both the approval and
execution phases.

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4. Risk is on Few Suppliers

Additionally, you’re concentrating execution risk for the project into one or a few suppliers. Modular
manufacturers have mostly focused on making single-family homes as their bread-and-butter products.
While the number of companies producing commercial and multi-family products is growing, it’s still
very limited in those that are interested, capable and have the financial capacity to deliver. Buyers,
whether they’re owners or general contractors, must perform full diligence on companies before entering
into an agreement that puts all their eggs in one basket. And, they must continue to be diligent following
up throughout their work. Even if bonded, it would have to be a huge disaster to switch to another
manufacturer in the middle of a project.
5. Transportation Costs & Risk

Then there’s the transportation risk. Since modules are prefabricated in a factory miles from the job site,
they need to be transported either directly to the job site or staged at a place nearby and then set in place.
The transporters and riggers must be extremely careful with each module as one mishap during
transportation and the entire module could need significant repairs or replacement. This could potentially
hold up an entire sequence of installation. On our Philadelphia project delivery, staging and set went
fairly smoothly with limited cracking of interior drywall due to lifting the modules into place. This
damage was easily repairable, so not much to worry about there.
It’s important for the transportation and rigging companies to spend serious effort in tracing down the
roads and plotting the logistics of moving the modules throughout their entire journey. They can’t get
hung up by bridges, tight turns, traffic problems, crane setup and temporary road closure permits.
Module sizes are usually limited first by allowable size on road (maybe 10 feet wide by 70 feet long)
and capacity of available crane (to lift as much as 25 tons) across the depth of a project site. Make sure
you also have your insurance advisor work with a broker and carrier familiar with the many related risks
to off-site construction.

6. Difficult Financing Process

Another challenge involves financing. Since modular construction requires purchasing and making
things on a faster timeline, the bills are usually much larger earlier in the construction period than
investors and lenders may be used to seeing and paying. Therefore, take time to work with the
manufacturer and contractor to understand the amounts and timing of anticipated funding (create a
projection by month) and update it as the project unfolds. This will help to make sure that adequate
monies are available to keep the job going and prevent mechanic’s liens. A related item is that someone
representing the contractor, owner and bank should plan to visit the factory at stages of production to
make sure that funds are being invested into your modules and not into somebody else’s

e) Modular construction of Tunnels

NPP has large network of tunnels. The utilization of precast tunnel culverts can be helpful in decreasing
the construction time of the structure and improve the accessibility to other buildings of the site during

55
construction. The in -situ construction of the site will only be restricted to foundation plain concrete
cement. it also ensures that the standardize construction of joins and quality in the dimensioning of
tunnel section can be maintained. Overall, modular construction offers numerous advantages in tunnel
projects, including speed, cost savings, improved quality control, enhanced safety, minimized
disruptions, design flexibility, and environmental benefits. These benefits make modular construction
an increasingly attractive option for tunnel construction around the world.

Figure 42: Precast Tunnels

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 Chapter 5

DIGITALISATION
Digitalisation has become a popular concept around the world today due to its ability to create efficiency
in operations, effectiveness, and provide new opportunities. Industries such as banking, manufacturing,
and retailing have all come to understand the benefit of Digitalisation and have keyed into the future by
using it as a new approach for ensuring competitive gain and efficiency. While these other industries
have adopted the use of this obviously beneficial development, the construction industry is yet to fully
embrace it in the delivery of its services. This failure to harness the inherent benefit of digitalisation has
significantly affected the industry, especially in developing countries, as no major transformation is
evident within their construction sector. The case is no different with South Africa, as most construction
services are still being delivered using traditional delivery methods. This has adversely affected the
growth of the industry, the quality of services rendered, and the satisfaction thereof.
The major stages of construction where digitalisation is evident are the design phase, and the feasibility
phase. The major construction processes where digitalisation is mostly visible are, construction cost
control, cost planning, preliminary cost estimate and building system analysis. It is, however, less
evident in the maintenance schedule. In addition, the most significant benefits to be derived from the
digitalisation in the industry includes time-saving in construction projects delivery, increase
productivity, increase the speed of work, increase document quality, speeding up of response time, and
simpler working methods. The study, therefore, recommends the need for further adoption of digital
technology in other aspects of construction aside feasibility and designing. This will go a long way in
achieving the holistic benefits inherent in digitalisation. Also, more focus is needed in the digitalisation
of construction processes such as maintenance schedule.
The findings of this study will go a long way in assisting construction professionals and stakeholders in
understanding the inherent benefit in digitalisation. However, though result reveals that there is the
considerable use of digital technology in some aspect of the construction processes within the South
African construction industry, care must be taken in generalizing the result as it is based on the
perception of construction professionals. Herein lies the limitation of the study. Therefore, further study
is needed to effectively determine the practical adoption of digitalisation within the industry.

Digital Documentation:
In the age of digital transformation, businesses are looking to eliminate manual processes. For
construction firms, many still exist, including:
 Contractor/ subcontractor onboarding
 Permit to dig
 Health & safety reports
 Material requisition
 Risk assessments

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 Project approvals

Example- FlowForma’s construction software makes the move to digital documentation easy. The no
code platform digitizes construction workflows, forms, and document generation for businesses to get
up and running straight away. This helps construction firms avoid delays in construction projects.
Construction firms, such as FlowForma customer Sullivan Engineering, have saved over 700 hours per
year on repetitive tasks, using intelligent process and workflow automation. With FlowForma’s process
automation tool.

Figure 43: Flow chart of digital documentation

Virtual Reality Technology:

VR in construction has opened up many new possibilities. VR-based solutions can help architects,
engineers, and constructors visualize and plan projects with increased accuracy and efficiency. It can be
used for interactive 3D design reviews, providing builders with a better understanding of a project's
scope and potential problems before it even starts. Additionally, VR can be used to optimize on-site
inspections and ensure quality control during construction.

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 Figure 44: Demonstration of VR technology

Advantages
I. Reduce time spent on revisions- When a model is purposefully engineered for a VR experience,
bolstered by including interactive options, it offers far greater adaptability to designers and
modelers. This utilization of VR in construction enables them to swiftly evaluate alterations
without remaking significant parts of the model. Moreover, it diminishes their reliance on
frequent site visits or voluminous reference materials, thanks to the accurate simulation they can
employ instead.
II. Provide content reusability -Herein lies the potential for an innovative solution facilitated by
the application of virtual reality technology in construction. By leveraging VR in construction,
the transition from 3D design to the realities of on-site construction becomes markedly more
seamless. The virtual reality experience allows the project execution team to understand and
interact with the design in an immersive environment. It gives them a deeper understanding of
the project, reducing the likelihood of misinterpretations and errors.
III. Make training safer - At this juncture, the inclusion of VR in construction training emerges as
a transformative tool. By offering highly interactive, lifelike simulations that closely mimic
actual construction site conditions, virtual reality in construction presents a trailblazing solution
to this quandary. With VR, workers can gain hands-on experience in a controlled, risk-free
environment.
IV. Boost worker engagement- Using VR in construction presents innovative solutions in this
scenario. By offering immersive and interactive training sessions, virtual reality in construction
goes beyond skill enhancement, instilling in workers an understanding of their indispensable role
in successfully completing a project. This understanding can invigorate their sense of
responsibility, leading to augmented performance.
V. Improve team coordination- Harnessing the potential of VR in construction can play a

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 transformative role in addressing this issue. Virtual reality in construction allows for a more
detailed, comprehensive, and interactive presentation of reference materials. Through immersive
VR simulations, workers can better understand the structure they are working on, enhancing their
ability to perform their tasks accurately and efficiently.
VI. Save on costs and materials- The power of virtual reality in construction can be harnessed to
tackle these issues. We can ensure optimal use of materials and labor by enabling precise
planning and prediction through VR in construction. Not only can VR help visualize the result,
but it can also facilitate the step-by-step execution of the project, significantly minimizing
instances of material waste, optimizing the utilization of skilled labor, and in a broader
perspective, improving the overall efficiency of the construction industry.

AR (Augmented Reality) Technology:

AR provides the tools for construction companies to plan a project from start to finish, ensuring
accuracy, preventing rework and saving building costs. This overall precision and efficiency can afford
construction companies greater confidence in their projects, improving client relations and creating
long-term ROI.
As technology continues to evolve, a number of applications are beginning to harness the abilities of
AR. Apps like Smart Reality allow users to generate 3D models on any 2D plan, and Pair 3D allows
architects to drop furnishings into their designs to determine the building’s visual impaction. AR app
that allows users to estimate material costs on generated models and order directly on the app.
Although only large construction firms have fully scaled AR so far, it will become more accessible in
the coming years as the technology comes down in costs and 5G networks expand. Many companies are
offering the technology on a per-project basis and with free trials, allowing construction managers to
experiment with the new technology and apply it to their business.
From eliminating errors to offering insight, augmented reality in construction can effectively streamline
the entire project life cycle. Companies investing in this innovative technology are already enjoying the
benefits, and it is a cutting-edge trend that can no longer be ignored in the industry. In 2022, the
technology will continue to mature and become economically feasible, while seeing increased
investment and adoption. Like forklifts and power tools, we can expect this innovative technology to
become a common fixture on construction sites moving forward.
Augmented Reality in construction makes it possible to present the results even before the work is
complete. Misunderstandings can be identified more easily. Paper schedules and delays in
communication are also eliminated as AR Overlays help identify issues faster. This also makes it easier
to conduct inspections as they arise.

Advantages
 Increasing Accuracy and Pinpointing Details
 AR Granting Super-Human Powers to Your Construction Team:

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  No Need for Drawings or Tables:
 This will save both time and money, reducing costs while maximizing the workforce’s output

Figure 45: Demonstration of AR technology

4D Construction Simulation:

The 4D simulation is an effective tool for optimizing the construction process while providing a visual
overview for all project stakeholders. It gives everyone the same clear starting point to understand and
discuss the building process, security risks and optimization opportunities.
The 4D Simulation (3D + Time) is a method by which the 3D objects from the PDMS model are
combined with construction schedule-related activities. The technique can help us in visualizing the
scope, time frame, and location of these activities at the same time in a virtual environment. It eliminates
the need for using 2D drawings and other documents (like Gantt chart).

Figure 46: 4D Construction Simulation

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Advantages

I. Improved Construction Scheduling

4D building information modelling techniques help create information about the scheduling of building
products to design a visual step-by-step method. 4D scheduling models can help integrate the time-
related data like construction time, drying periods, etc., thus setting a realistic time frame for a
construction project.
Large-scope construction projects can demand complex scheduling of a large amount of materials,
systems, and people. Creating a 4D model helps monitor the construction project progress and plan
future steps. Such modeling can help project managers figure out when to book equipment, buy
materials, hire specialists, and much more.
However, small-scale construction projects can benefit from 4D construction planning as well. Having a
clear scheduling picture can help cut the cost and improve client satisfaction.

II. Better 4D Construction Visualization

4D Building Information Modelling can be very helpful when creating visuals for project planning. By
comparing a scheduled plan with the actual plan, managers can improve the timeline and ensure
consistency across all aspects of the upcoming construction phases.
This type of visualization is especially helpful when additional construction needs to be done on an
existing building. It can help coordinate the actions of the contractors and the rest of the team with the
work on the existing site. Seamless results of such complex projects heavily depending on proper
visualization, modeling, and smart planning offered by 4D BIM tools.

III. Optimized Material Use

The key to cutting the cost of any construction project is top-notch resource utilization. Contractors are
constantly searching for new ways to use the material in the most optimized manner possible.
Whether you are planning to build a series of complex buildings or work on a small-scale project,
material use is always on the agenda. By taking advantage of 4D BIM tools, you can save resources and
win extra funding for your project.
In addition to optimizing material use, 4D building information modeling along-side Revit
software allows you to optimize the workforce to cut the project cost.

IV. Improved Project Coordination

With 4D BIM scheduling and visualization, managers have an easier time coordinating the team. It helps
build a strategy based on a high-quality model and lets each team member know how their actions fit
into the big picture.
By using construction sequencing, project engineers can have an easier time creating a plan for the
construction team, thus improving the overall design, eliminating conflicts, and streamlining contractor
services.
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By using the right tools like Revit software to create the 4D model, project engineers and contractors
can have an easier time distributing work, thus tweaking the project schedule and meeting deadlines on
and off site.

V. Enhanced Tracking Opportunities

When you need to track every activity on the building site, it’s easy to get overwhelmed, thus losing
time and making mistakes. It’s especially noticeable for large-scale projects like heavy industry projects.
By taking advantage of tracking software that integrates with 4D BIM construction models, it’s possible
to improve the process, thus cutting costs and saving time.

VI. Minimized Workflow Clashes

Construction sequencing simplifies scheduling and resource optimization, thus preventing workflow
clashes. With contractors, project engineers, and other team members being on the same page, it’s much
easier to keep disputes down and minimize unfortunate errors.
4D BIM construction tools help keep the entire team coordinate its actions. As a result, you can minimize
the number and duration of countless meetings that tend to accompany construction projects.
By using 4D construction opportunities, you can visualize the project’s progress and create a simulation,
thus helping each team member get on with their responsibilities and speed up the process. Additionally,
construction sequencing creates a strong contact between the site and the back office, helping engineers,
designers, and contractors exchange ideas and track progress.

VII. Better Project Safety

When it comes to personnel safety on and off the construction site, 4-dimension BIM models come in
handy as well. You can use construction animation sequencing to monitor the progress of the project
and boost overall safety across the job site.
With 4D building construction models, you have full visibility over the project and the team working
on it, thus increasing its safety for both the team and the client.

The Internet of Things (IoT):

IoT has the potential to revolutionize the construction industry by enabling enhanced connectivity,
automation, and data-driven decision-making. Here are some key applications and benefits of IoT in the
construction industry:

Advantages
I. Real-time monitoring and asset management: IoT sensors can be deployed on construction
equipment, tools, and materials to track their location, usage, and performance in real time. This
enables better asset management, reduces theft and loss, and improves equipment maintenance
scheduling.
II. Safety and worker monitoring: IoT devices can monitor the safety of construction sites and
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 workers. Wearable devices with built-in sensors can track vital signs, detect hazardous
conditions, and provide real-time alerts in case of emergencies or accidents. This enhances
worker safety and enables prompt response to potential risks.
III. Remote equipment management: IoT enables remote monitoring and control of construction
machinery and equipment. This allows for proactive maintenance, real-time diagnostics, and
remote troubleshooting, reducing downtime and improving overall efficiency.
IV. Energy management and sustainability: IoT can help optimize energy consumption in
construction sites by monitoring and controlling lighting, heating, ventilation, and air
conditioning (HVAC) systems based on real-time occupancy and environmental conditions. It
enables better energy efficiency and contributes to sustainability goals.
V. Supply chain and logistics optimization: IoT can streamline the supply chain and logistics
processes in construction by tracking and managing the movement of materials, equipment, and
personnel. Real-time data on inventory levels, delivery status, and location helps in efficient
scheduling, reducing delays, and optimizing resource allocation.
VI. Smart building and infrastructure: IoT technologies enable the integration of various systems
within a building or infrastructure project, such as lighting, security, HVAC, and occupancy
monitoring. This integration enhances energy efficiency, occupant comfort, and operational
efficiency.
VII. Data-driven decision-making: IoT generates a vast amount of data that can be analyzed to gain
valuable insights for construction projects. Data analytics and machine learning algorithms can
be used to implementation of IoT in the construction industry requires robust cyber security
measures to protect sensitive data and ensure the integrity of connected systems.
VIII. Overall, IoT has the potential to improve safety, efficiency, productivity, and sustainability in
the construction industry, leading to cost savings and better project outcomes.

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 Chapter – 6

Construction Industry vs Manufacturing Industry

Construction and Manufacturing industries, both requires skilled labor, resource management, and
adherence to safety standards, but there are also notable differences. Construction projects are typically
temporary and site-specific, requiring on-site coordination and management. In contrast, manufacturing
processes are often repetitive and standardized, taking place in dedicated facilities. Additionally, the
construction industry is heavily influenced by factors such as weather conditions, land availability, and
local regulations, while manufacturing is influenced by market demands, technological advancements,
and global competition.

Manufacturing industry Construction industry

Spend amount of revenue on 3.5 percentage 1 percentage

Innovation
Adopting new equipment/ Quickly adopt Believes in traditional method
technology
Complexity and Fragmentation Not so complex as product is Every product is unique
already designed on software’s
Regulatory and Safety Concerns Less concern More concern as most of the
fatality occurs in this sector
Cultural Resistance to Change Promote changes Changes occurs very slowly

Availability of Trained Use more of robots Skilled trained manpower is not

manpower easily available

Figure 47: Comparison between different industries

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Figure 47: Comparison between different industries

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 Chapter – 7
CONCLUSION
There can be little doubt, at the start of 2021, that in order for businesses and companies in the
construction industry to not only survive but thrive, they have to keep up to speed with the latest
technological developments and innovations. The term used for this process is called ‘technology
adoption’ and in this article, we will look at why the manufacturing industry is quite successful at
utilising this concept and what should construction companies learn from it.

1.1 What is Technology Adoption?

Technology adoption can best be described as the ability of an organization, a department or, simply, an
individual to successfully react to innovation and to utilize these changes in their everyday working
practices. These changes could include the introduction of new tools or machines, learning the latest
computer software, using innovative materials, streamlining communication, etc. However, there are
a few basic obstacles the construction industry is particularly susceptible to.
It is fairly well-known that the construction industry is traditionally conservative in outlook and thus,
has been using many of the same tried and tested workplace methods, materials, tools, and ways of
communicating that have been around for years. Of course, this is not to say that there have been no
welcome changes and developments in the industry but, compared to the manufacturing sector, it lags
far behind with a severe lack of progress in efficiency, productivity, and sustainability. While the
manufacturing industry has seen increases of almost 100% in these areas over the past few decades,
the construction industry has unfortunately remained relatively stagnant.

1.2 Can the Construction Industry Catch Up?

The question to be asked now is what can construction do to get better? How can it gain some semblance
of parity? The answer is plain and simple: it needs to take a leaf out of the manufacturing industry’s
book and consider such innovations as:

I. Modular and offsite construction

This would involve increased labour off-site in controlled factory environments, with possible
investment in new machine tools, training, and expanded floor or yard space for module sub-
assembly.

II. Developing new, multi-functional materials

An ongoing process that can combine structural integrity with other functions such as optical,
electrical, magnetic or thermal. This would benefit greatly from investment in research and
development!

III. BIM technology, virtual meetings, and walkthroughs

This technology is mostly up and running and in regular use and affords productive, real-time
collaboration between AEC professionals. This can be used as a good example of successful

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 technology adoption, with relatively minimal outlay on costs, it emphasises the major advantages
of close collaboration between disciplines.

IV. Digital communications

There are two aspects to this for construction, the data that is input during the design phase and
how this is then translated to be of use for the construction phase in the field. This could involve
the use of Reality Modelling, photogrammetry, and making use of Cloud services. The investment
would be needed for training, software and digital infrastructure.

V. Drone inspections
The relatively low costs of purchasing drones and hiring experienced operators (or training new
ones) should ensure that this technology is quickly adapted for construction. The rewards would be
in being able to have an overview of construction sites, pinpointing problem areas, determining the
overall structural integrity of the build, providing access to spaces that are difficult or impossible
to get to physically and many more.

This is just a shortlist of the possibilities that are available and ready to be used. All of these can benefit
from targeted investment, but this requires the will to do so on the part of those who hold the purse
strings.

1.3 Cost-Benefit Analysis:

The growth of construction industry is very limited comparison to other industries in past decades. But
India’s growing economy shows that a large part of it comes from construction industry and the
upcoming decade is going to be very important because a lot of projects are starting related to Nuclear
Power Plant as well as other sectors.
In NPCIL, many projects are delayed due to various reasons that eventually becomes loss of crores of
revenue per day. Adaptation of various advance technologies requires initial investments in terms of
machineries, skilled manpower, training etc. but the long term output is going to be profitable.

Figure 48 – Investment vs Revenue graph

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One unit of 1000 MW will generate approx Rs. 15.6 crores revenue per day which means if we can
reduce the construction time by one year, it will reflect as Rs. 5616 crores of revenue. So by investing
2% of project cost in automation and advance equipments, we will be financially profitable with timely
completion of the project.

Automation in the construction industry has proven to be a game-changer, offering numerous benefits
and opportunities for increased efficiency, productivity, and safety. By leveraging technologies such as
robotics, artificial intelligence, and advanced machinery, automation has the potential to streamline
construction processes, reduce costs, and accelerate project timelines. It enables repetitive and labor-
intensive tasks to be performed with greater precision and speed, freeing up human workers to focus on
more complex and creative aspects of construction. Additionally, automation can enhance safety by
minimizing worker exposure to hazardous conditions and improving overall site monitoring. While
challenges like initial investment costs and potential job displacement exist, the long-term advantages
of automation in the construction industry are substantial and hold the promise of a more advanced and
sustainable future for the sector.

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