Prefabricated House Manufacturing Process
The prefabricated house manufacturing process mainly includes five steps: modular production, foundation treatment, installation of foundation piles and splicing of crossbeams, on-site assembly, and post-processing.
Modular Production: This is the fundamental step in the manufacturing of prefabricated houses. The entire building is disassembled into individual modules, which are then manufactured in a factory. These modules cover structural parts such as ceilings, floors, and walls, with all water and electrical pipelines also prefabricated. For example, at the China Construction Hailong Intelligent Construction Industrial Park in Shenzhen, Guangdong, the ceilings, walls, and waterproof layers of bathrooms in houses are all manufactured in the factory. The factory adopts parallel operations and automated production lines, which can significantly shorten the construction period by more than 60% compared to traditional buildings, greatly improving production efficiency.
Foundation Treatment: Leveling the foundation and pouring a cushion layer are crucial steps to ensure that the excavation depth and ground height meet design requirements. Taking rural areas in South Korea as an example, excavators are first used to clear weeds and level the foundation. Surveyors continuously measure to ensure engineering accuracy. After excavating about 60 centimeters, a white plastic sheet is laid, and then a concrete pump truck is used to pour the foundation. No steel bars are used in the foundation, and the white plastic sheet prevents water loss and enhances the strength and durability of the concrete.
Installation of Foundation Piles and Splicing of Crossbeams: After the concrete solidifies, base plates are installed. A drill is used to create holes, which are then secured with expansion screws. The base plates fix the foundation piles to the cushion layer. The foundation piles are prefabricated in advance, weighing about 5 tons each, and are installed using a mobile crane. Each foundation pile has reserved holes at its four corners for easy lifting. After installing the crossbeams, horizontal measurements are taken and adjustments are made, and they are secured with nuts. Foam sealant is used to fill gaps, and the areas where nuts are fixed are sealed with cement.
On-site Assembly: The prefabricated modules are transported to the construction site and assembled like building blocks. For example, at a construction site of a real estate project in Shanghai, tower cranes transport the prefabricated 'building blocks' and install them in the appropriate positions. Each 'building block' has a detailed 'ID card', including information such as the project name, product model, and production date, facilitating management and traceability.
Post-processing: Grouting is carried out on the gaps between components, and soil is backfilled to pour the foundation, completing the foundation frame structure. In some projects, most of the construction processes are completed in the factory, with on-site casting for connections. This approach reduces noise, dust, construction waste, and traffic congestion, which are nuisance factors for residents.
