Founded in Greater Noida in 1999, EPACK Prefab, one of India’s leading pre-engineered building (PEB) companies, has constructed India’s fastest-built factory in a record time of just 150 hours. This factory will act as EPACK’s assembly unit and is located in Mambattu, Andhra Pradesh. It spans 151,000 sq ft and was built with a budget of Rs.19 million, with a total structure tonnage of 496 million tonne (mt).Rise of prefabricated buildingsPrefabricated buildings, commonly known as prefabs, are structures made up of components such as walls, roofs and floors that are produced in a factory. These components can be fully or partially assembled in the factory and then transported to the site for final assembly. According to Colliers, the Indian construction industry is expected to reach a $ 1.4 trillion market by 2025. Studies highlight the increasing momentum of offsite construction between 2020 and 2023. Bain & Company notes that modular construction can save as much as 20 per cent in labour and material costs, reduce the need for onsite labour by up to 30 per cent, and condense construction time by 20 per cent to 50 per cent.Breaking down the 150-hour timelineThe frame erection was completed within the first 20 hours, demonstrating the speed and precision of the modular frame assembly. By the 48th hour, the structural build was fully completed, providing a solid foundation for subsequent stages. The roof installation was finished by the 90th hour, ensuring the structure was weatherproof. By the 120th hour, cladding and final touches were completed, finalising the core structural elements. The project was fully completed by the 150th hour, with all safety and quality standards met after thorough checks.Sustainable building materialsHighlighting the choice of materials, Nikhel Bothra, Executive Director, EPACK Prefab, says, “The core material used was steel, chosen for its recyclability durability, and cost-effectiveness. Steel’s high scrap value and ability to withstand long-term use make it a sustainable option. This feature ensures the building’s stability even in high-temperature environments. Additionally, adequate insulation materials such as polyurethane foam or mineral wool were incorporated to minimise heat transfer through the building envelope. This helps regulate the internal temperature and reduces the impact of external environmental conditions on the building’s stability. As 90 per cent of the work was completed in the factory, including manufacturing and assembling with precision and safety assurance, the project significantly minimised material wastage, dust, and water usage during onsite construction.”Further, the designs were meticulously planned to incorporate local wind conditions, soil quality and temperature or climate factors. Advanced load measurements were conducted to ensure structural integrity under varying environmental conditions.Techniques and  technology usedThroughout the project, advanced construction techniques were employed to maintain both speed and quality. Pre-grouting was completed to ensure structural levelling and third-party inspectors verified the work. Alignment and levelling were continuously monitored to ensure the building’s structural accuracy. Brickwork and plastering were strategically planned, leaving space for precise adjustments, while material segregation and pre-planning ensured that all components were in place before assembly. The use of pre-assembled brace bay rafters and secondary members reduced lifting time, while constructing from both end walls allowed the roof sheeting platform to be mounted beforehand, increasing efficiency. Simultaneous cladding on all four sides further accelerated the construction timeline.Challenges in modular constructionIn India, the uptake of prefabrication technologies isslow, with prefabricated buildings comprising only 1 per cent of the country’s $ 100 billion real-estate market. Modular construction is not without its challenges. “Civil work execution and sequential planning are always complex in PEB construction, as it requires alignment between site work and pre-manufactured components,” shares Bothra. “The project also faced typical challenges related to material planning and resource deployment, ensuring that the right materials and manpower were available at the right time. Coordinating between paper plans, onsite implementation and tight construction timelines was also difficult.”EPACK Prefab currently targets industrial, infrastructure and institutional markets. The company has built manufacturing plants, warehouses, and educational facilities. The rise in e-commerce has contributed significantly to the increased demand for warehouses at state and district levels, particularly in areas near highways. The firm is optimistic that similar timelines can be achieved for larger-scale projects in the future.