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Tubular construction process: A game-changer for modern building techniques

Anubhav Gupta, chief strategy officer, APL Apollo, makes a point

The utilisation of tubular steel structures is a popular trend in the construction industry. They are durable, long-lasting, and, most importantly, customizable. Tubular construction is a structure-building technology in which parts are fabricated off-site and brought to the construction site for final assembly. Because of its significant benefits over traditional building processes, this technology has grown in favor in recent years.

Tubular construction is a building technology that uses steel tubes to produce a building’s super structure. These tubes are joined together using a nut and bolt system to make a solid and robust structure capable of supporting the weight of the building. It is an efficient method of constructing significant, long-lasting, and environmentally friendly structures.

The process of tubular construction
The tubular construction process begins with the design and engineering of the building. That includes creating detailed plans and specifications for each section of the building. These sections are then manufactured in a factory set-up, maintaining superior quality.

Once the sections are complete, they are transported to the construction site and assembled using cranes and other equipment. This process is much faster and more efficient than traditional construction methods, which require much on-site work and can be delayed by weather, labor shortages, and other factors.

Benefits of tubular construction:
*Quick speed: Tubular constructions are faster as tube fabrication can be done easily. The fabrication and welding processes are done at the fabrication workshop, which is later assembled at the construction site. This leads to saving a lot of time and engaging in multiple construction processes simultaneously. Compared to conventional construction techniques, which take approximately 24 days per slab, modern tubular construction takes eight days to complete. This process is the industry’s future, given the tight deadlines of projects these days.

*Cost-effectiveness: Another benefit of tubular construction is its cost-effectiveness. Considering tubular structures are lighter, and the total steel consumption per kg is 7-10% less than the conventional practices, the cost is reduced significantly. This helps in reducing the overall project cost and increasing the IRR. As part of the process, the structural tubes are supplied in cut-to-length sizes leading to faster fabrication at a lower cost. In addition, there is an extra carpet area with tubes as the principle material for construction as the column size in tubes is around 500×500 mm, compared with RCC and Built up sections where the column sizes are 800×800 mm and 650×650 mm, respectively. Using tubes, one can have an additional carpet area of 1-2% which could be converted into a usable area.

Conventionally in steel buildings, steel columns are covered in concrete boards involving more carpet area. In contrast, in the case of structure tubes, such encasing is not needed, leading to a smothering area around the column corners with a higher carpet area and reduced finishing cost.

*Environment friendly: Tubular construction is also more environmentally friendly. Because the modules are manufactured off-site, there is less disturbance and fewer emissions from on-site machinery. Also, tubular structures can be recycled and reused with maximum monetary returns (as per industry standards) even after years of use. There is 30% less Co2 emission as there is no on ground fabrication or welding. Also to add to that there is lesser ground water consumption compared to conventional processes.

*High tensile strength: Tubular structure has a high tensile strength and does not readily break. In other words, it can successfully withstand both external and internal stress. Uneven construction design, faulty alignment, an inadequate cover, or repeated temperature highs and lows might cause this stress.

Tubular structures are aesthetically more pleasant in appearance. It has a smoother surface, is easier to paint and needs no shuttering because of its perfect square shape.

How has tubular process revolutionized construction industry:
*Tubular construction is well-suited for all structures like PEB sheds, hospital buildings, schools, railway stations, data centers etc. Using prefabricated tubes makes the construction process faster and more efficient while ensuring the strength and stability of the structure.
*It can also be used in the construction of bridges and tunnels. Prefabricated tubes can be used to create the structural supports and foundations of these structures, making the construction process faster and more cost-effective.
*It can also be used to construct residential buildings like apartments and condominiums. Using prefabricated tubes allows for greater customization of building designs, making it possible to create unique and innovative structures.
*Steel tubular construction projects are completed faster. Tubular steel also makes structural manufacture and assembly easier. The high carpet area and lower steel consumption reduce project costs as well. Tubular building projects may provide a modern and visually appealing look while allowing for larger structures with clearer heights.
*The tubular structure is constructed with essential accessories and fasteners, allowing the construction industry to build any shape pipe connections while combining the structure with a standard profile building system.

Today, the construction industry is growing quickly and is expected to grow by 12% in 2023. The pace reflects the need for faster construction; lower project costs and faster & better IRR; better quality and aesthetically pleasing projects; and environment-friendly approach.

In conclusion, the tubular construction process is revolutionizing the construction industry by providing a faster, more efficient, and more sustainable method of building structures. As the demand for more innovative and eco-friendly construction methods continues to grow, tubular construction is likely to play a significant role in the future of construction. Structural steel tubes can be used in multiple & diverse project profiles like- housing, hospitals, railway stations, warehouses, data centers, and schools.

With its many benefits and increasing popularity, it is expected to become an essential part of the construction industry in the coming years.