Prelabrication Building MetLodologies lor Low Cost Housing

SLri P K AdlakLa, Ic//cu

SLri H C Puri, /cnbcr
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btgb/tgbttng tbc dt//crcnt prc/abrtcattcn tccbntqucs, and tbc cccncntca/ advantagcs acbtcvcd by tts adcpttcn.
KeyuorJs: Prelabrication, Precast RCC 'kular`, Precast joist
ITBCDLCTIC
In a building tLe loundation, walls, doors and windows, lloor
and rool are tLe most important components. JLese
components can be analysed individually based on tLe needs.
JLis will improve tLe speed ol construction and reduce tLe
construction cost.
Ioundations
Various type ol loundations normally adopted are:
(i) Cpen loundations.
(ii) Rib loundations.
(iii) Columns and lootings.
(iv) RCC ralt loundation.
Conventional metLods using in-situ tecLniques are lound to
be economical and more practical lor low cost Lousing ol
slums wLicL generally consists ol low rise structures. In
seismic regions, special attention is required to make tLe
loundations continuous using Lorizontal reinlorcement.
Prelabrication is not recommended lor loundations in normal
situations.
Walls
In tLe construction ol walls, rammed eartL, normal bricks,
soil cement blocks, Lollow clay blocks, dense concrete blocks,
small, medium and room size panels etc ol dillerent sizes are
used. However, bricks continue to be tLe backbone ol tLe
building industry. In actual construction, tLe number ol tLe
bricks or blocks tLat are broken into dillerent sizes to lit into
position at site is very large. As a result ol tLis, tLere is wastage
ol material and tLe quality ol construction also sullers.
Increasing tLe size ol wall blocks will prove economical due
to greater speed and less mortar consumption, wLicL can be
acLieved by producing low density bigger size wall blocks and
advantages ol industrial wastes like blast lurnace slag and lly
asL can be made.
Several prelabrication tecLniques Lave been developed and
executed lor walls but tLese medium and large panel
tecLniques Lave not proved economical lor low rise buildings
as compared to traditional brick work.
Iloor and Boof
Structural lloors/rools account lor substantial cost ol a building
in normal situation. JLerelore, any savings acLieved in lloor/
rool considerably reduce tLe cost ol buildings. Jraditional
cast-in-situ concrete rool involve tLe use ol temporary
sLuttering wLicL adds to tLe cost ol construction and time.
Lse ol standardised and optimised rooling components wLere
sLuttering is avoided prove to be economical, last and better
in quality.
Some ol tLe prelabricated rooling/llooring components
lound suitable in many low-cost Lousing projects are:
(i) Precast RC planks.
(ii) Precast Lollow concrete panels.
(iii) Precast RB panels.
(iv) Precast RB curved panels.
(v) Precast concrete/lerrocement panels.
(vi) Precast RC cLannel units.
PBEIABBICATIC AS APPLIED TC LCW CCST
HCLSIG
In India, adoption ol prelabrication building tecLniques Lave
many merits in tLe context ol availability ol materials, labour
and tecLnical skills. Advantages ol prelabrication are:
(1) In prelabricated construction, as tLe components are
readymade, sell supporting, sLuttering and scallol-
ding is eliminated witL a saving in sLuttering cost.
(2) In traditional construction, tLe repetitive use ol
sLuttering is limited, as it gets damaged due to
lrequent cutting, nailing etc. Cn tLe otLer Land, tLe
mould lor tLe precast components can be used lor
large number ol repetitions tLereby reducing, tLe cost
ol tLe mould per unit.
(3) In prelabricated Lousing system, tLere is saving ol
time as tLe elements can be casted belore Land during
tLe course ol loundations being laid and even alter
+ IE (If }curna/-AF
Shri P K Adlakha is with Adlakha and Associates, 35 Bani jhansi Boad,
ew Delhi 110 055 and Shri H C Puri is with DSIDC, Government of
Delhi Lndertaking.
JLis paper was received on ovember 20, 2002. Written discussion on tLe
paper will be entertained till ]une 30, 2003.
laying slab, tLe linisLes and services can be done
below tLe slab immediately. WLile in tLe
conventional in-situ RCC slabs, due to props and
sLuttering, tLe work cannot be done, till tLey are
removed. Saving ol time means saving ol money.
(+) In prelabricated construction, tLere is better quality
control, sLape and size ol precast elements.
JLerelore, in structural design, lull advantage ol
properties ol cement and steel can be exploited. JLere
is disciplined use ol scarce materials like cement, steel
and timber.
(5) In precast construction, similar type ol components
are produced repeatedly, resulting in increased
productivity and economy in cost too.
(6) In precast construction, tLe construction is not
allected due to weatLer, rain, wind etc.
(/) In prelabricated construction, tLe work at site is
reduced to minimum and tLerelore, work is
qualitatively better, more reliable and clean.
(8) Because ol laster completion and reduction in time
period ol construction tLe Louses can be occupied
earlier, wLicL means early return ol tLe investment.
LIMITATICS CI PBEIABBICATICS
(1) As tLe precast elements Lave to beLave monolitLic on
erections, extra reinlorcement may be necessary in
some cases.
(2) Lxtra reinlorcement is required to take care ol
Landling and erection stresses.
(3) Jemporary props may be required in some cases,
belore tLe in-situ concrete joints acLieve strengtL.
(+) JLe cracks may develop at tLe joints between tLe
precast and in-situ concrete due to sLrinkage and
temperature stresses. Jo overcome tLem, extra steel is
required across tLe joint.
(5) As tLere are cLances ol leakage/seepage tLrougL tLe
joints between tLe precast components, extra care is
required to make tLem leak prool.
CBITEBIA ICB SELECTIC CI PBEIAB I IDIA
In India, tLe tecLnology adopted lor Lousing components
sLould be ol tLe order tLat, tLe production and erection
tecLnology be adjusted to suit tLe level ol skills and Landling
lacilities available under metropolitan, urban and rural
conditions. In otLer words, tLe structural systems and
components selected sLould ensure minimum material
utilization witL maximum structural advantage. However,
tLe component and systems so designed are to be
manulactured and erected by manual means in villages, semi-
mecLanical tecLniques in towns and more or less lully
mecLanical operations in tLe metropolitan cities.
In urban areas, tLe concentration ol construction activity does
not justily prelabrication. JLe answer is Lybrid construction
combining standardised mass-manulactured rooling and otLer
components (at site) witL in-situ brick walls or otLer
masonary structures. A wide variety ol rooling metLods to
suit tLese requirements Lave been developed and used on mass
scale in many Lousing projects sucL as lunicular sLell, cored
slabs, RCC cLannel units, precast cellular units, precast RC
planks and joists, prelab brick panels and joists, RCC joists
and Lollow concrete blocks, precast RCC 'Kular` slab.
TECHIQLES
Precast BC Plank Boofing System
JLis system consist ol precast RC planks supported over
partially precast joist. JLe completely linisLed slab can be
used as intermediate lloor lor living also. JLe total tLickness
ol slab is 6 cm. JLe scLeme is ideally suited lor spans upto +.2 m,
but can be used lor large spans, by providing secondary
beams. RC planks are made witL tLickness partly varying
between 3 cm and 6 cm. JLere are LauncLes in tLe plank
wLicL are tapered. WLen tLe plank is put in between tLe
joists, tLe space above 3 cm tLickness is lilled witL in-situ
concrete to get tee-beam ellect ol tLe joists. A 3 cm wide
tapered concrete lilling is also provided lor strengtLening tLe
LauncL portion during Landling and erection. JLe planks
Lave 3 numbers 6 mm dia MS main reinlorcement and 6 mm
dia _ 20 cm centre to centre cross bars. Concrete used is ol
grade M-15. JLe planks are made in module widtL ol 30 cm
witL maximum lengtL ol 150 cm and tLe maximum weigLt ol
tLe dry panel is 50 kg (Iigure 1).
Precast joist is rectangular in sLape, 15 cm wide and tLe
precast portion is 15 cm deep (Iigure 2). JLe above portion is
casted wLile laying in-situ concrete over planks. JLe stirrups
remain projected out ol tLe precast joist. JLus, tLe total deptL
ol tLe joist becomes 21 cm. JLe joist is designed as composite
Jee-beam witL 6 cm tLick llange comprising ol 3 cm
precast and 3 cm in-situ concrete (Iigure 3). JLis section ol tLe
joist can be adopted upto a span ol +00 cm. Ior longer spans,
tLe deptL ol tLe joist sLould be more and lilting would require
simple cLain pully block.
1c/ 84, Aprt/ 2003 5
Iigure 1 Precast BC plank
In residential buildings, balcony projections can be provided
along tLe partially precast joists, designed witL an overLang
carrying super imposed loads lor balcony as specilied in
IS : 8/5-196+, in addition to tLe sell load and tLe load due to
balcony railings. JLe main reinlorcement ol tLe overLang
provided at tLe top in tLe in-situ concrete attains sullicient
strengtL. JLe savings acLieved in practical implementations
compared witL conventional RCC slab is about 25%.
Prefabricated Brick Panel Boofing System
JLe prelabricated brick panel rooling system consists ol:
(af Prc/ab Brtck Panc/
Brick panel is made ol lirst class bricks reinlorced witL two
MS bars ol 6 mm dia and joints lilled witL eitLer 1:3 cement
sand mortar or M-15 concrete. Panels can be made in any size
but generally widtL is 53 cm and tLe lengtL between 90 cm to
120 cm, depending upon tLe requirement. JLe gap between
tLe two panels is about 2 cms and can be increased to 5 cms
depending upon tLe need. A panel ol 90 cm lengtL requires
16 bricks and a panel ol 120 cm require 19 bricks (Iigure +).
(bf Partta//y Prccast }ctst
It is a rectangular sLaped joist 13 cm wide and 10 cm to 12.5 cm
deep witL stirrups projecting out so tLat tLe overall deptL ol
joist witL in-situ concrete becomes 21 cm to 23.5 cm, it is
designed as composite Jee-beam witL 3.5 cm tLick llange.
SJRLCJLRAL DLSIC
JLe prelab brick panel lor rool as well as lor lloor ol residential
buildings Las two numbers 6 mm dia MS bars as
reinlorcement upto a span ol 120 cms.
JLe partially precast RC joist, is designed as simply supported
Jee-beam witL 3.5 cm tLick llange. JLe reinlorcement in joist
is provided as per design requirements depending upon tLe
spacing and span ol tLe joist.
An overall economy ol 25% Las been acLieved in actual
practice compared to cast-in-situ RCC slab.
Precast Curved Brick Arch Panel Boofing
JLis rooling is same as RB panel rooling except tLat tLe panels
do not Lave any reinlorcement. A panel wLile casting is given
a rise in tLe centre and tLus an arcLing action is created.
An overall economy ol 30% Las been acLieved in single
storeyed building and 20% in two or tLree storeyed buildings
(Iigures 5 and 6).
Precast BC Channel Boofing
Precast cLannels are trougL sLaped witL tLe outer sides
corrugated and grooved at tLe ends to provide sLear key
action and to transler moments between adjacent units.
ominal widtL ol units are 300 mm or 600 mm witL overall
deptLs ol 130 mm to 200 mm (Iigure /). JLe lengtLs ol tLe
units are adjusted to suit tLe span. JLe llange tLickness is
6 IE (If }curna/-AF
Iigure 2 Partially precast |oists
Iigure 3 BC planks laid over partially precast |oists
Iigure 4 Brick panel being casted
JLe widtL ol a panel is 300 mm and deptL may vary lrom 100 mm
to 150 mm as per tLe span, tLe lengtL ol tLe panel being
adjusted to suit tLe span. JLe outer sides are corrugated to
provide transler ol sLear between adjacent units. JLe 'kulars`
are placed inverted so as to create a Lollow during precasting
(Iigure 8). Lxtra reinlorcement is provided at top also to take
care ol Landling stresses during lilting and placement. JLere is
saving ol about 30% in cost ol concrete and an overall saving
ol about 23%.
Precast Concrete Panels Boofing
JLe system comprise ol precast panels 600 mm 600 mm and
only 30 mm tLick (Iigure 9). JLe reinlorcement consists ol
2 mm dia MS wire or equivalent welded mesL. JLe panels are
1c/ 84, Aprt/ 2003 /
30 mm to 35 mm. WLere balcony is provided, tLe units are
projected out as cantilever by providing necessary reinlorce-
ment lor cantilever moment. A saving ol 1+% Las been
acLieved in actual implementation in various projects.
Precast Hollow Slabs Boofing
Precast Lollow slabs are panels in wLicL voids are created by
eartLen 'kulars` witLout decreasing tLe stillness or strengtL.
JLese Lollow slabs are ligLter tLan solid slabs and tLus save
tLe cost ol concrete, steel and tLe cost ol walling and
loundations too due to less weigLt.
Iigure 6 Brick arch panels laid
Iigure 7 Precast BC channels being laid
Iigure 9 Precast panel being casted
Iigure 8 Kullars being placed in precast BC panel
Iigure 5 Curved brick arch panels
placed over lully precast RCC beams ol /5 mm widtL and 125
mm to 150 mm deptL depending on tLe span. JLe ends ol
panels are tapered so as to lorm a V-groove wLen placed over
beams. JLis groove is lilled witL cement mortar. JLe beams
are designed as simple supported.
Alter placement ol panels and lilling ol tLe V-grooves a screeding
concrete 25 mm tLick witL cLicken mesL reinlorcement is
laid. JLis screeding concrete act as lloor linisL and as
eartLquake strengtLening measure. JLe panels can also be
casted in lerrocement by using cement mortar 1:2 and line
6 mm down grit and cLicken mesL reinlorcement in two
layers. A saving ol about 25% Las been acLieved in actual
practice over conventional system.
SEISMIC STBEGTHEIG ABBAGEMETS CI
PBECAST BCCIIG SYSTEMS
IS-+326, 1993 Las given recommendations regarding
strengtLening measures lor precast rooling tecLniques. JLe
code recommends tLat lor building category A, B and C based
on seismic co-ellicient, a tie beam is to be provided all round
tLe lloor or rool to bind togetLer all tLe precast components
to make it a diapLragm. JLe beams sLall be to tLe lull widtL ol
supporting wall less tLe bearing ol precast components. JLe
deptL ol tLe beam sLall be equal to tLe deptL ol tLe precast
components plus tLe tLickness ol structural deck concrete,
wLenever used over tLe components. Jie beams sLall be
provided on all longitudinal and cross walls.
In category D, structural deck concrete ol 35 mm tLickness
reinlorced witL 6 mm dia bars, 150 mm botL ways and
ancLored into tie beams sLall be provided. Ior economy, tLe
deck concrete itsell can serve as lloor linisL.
CTHEB LSES CI PBEIABBICATIC
JLe use ol prelabrication lor otLer materials can be made like
lintels, sun sLades, cupboard sLelves, kitcLen working slab
and sLelves, precast lerrocement tanks, precast staircase steps,
precast lerrocement drains (Iigures 10 and 11).
(a) Thin Precast BCC Lintel
ormally lintels are designed on tLe assumption tLat tLe load
lrom a triangular portion ol tLe masonary above, acts on tLe
lintel. Bending moment, will be WL/8 wLere W is tLe load on
tLe lintel and L is tLe span assumed lor tLe design purpose. By
tLis metLod, a tLickness ol 15 cm is required.
JLin precast RCC lintels are designed taking into account tLe
composite action ol tLe lintel witL tLe brick work. Design
cLart prepared lor tLin precast RCC lintels in tLe brick walls
ol normal residential building is applicable only wLen tLe
load on tLe lintel is unilormly distributed. JLe brick work
over tLe lintel is done in a mortar not leaner tLan 1:6. JLe
tLickness ol tLe lintel is kept equal to tLe tLickness ol brick
itsell Laving a bearing ol 230 mm on eitLer supports.
Lse ol precast lintels speeds up tLe construction ol walls
besides eliminating sLuttering and centreing. Adoption ol
tLin lintels results in upto 50% saving in materials and overall
cost ol lintels.
(b) Doors and Windows
Innumerable types and sizes ol doors and windows used in
single and similar buildings. JLis involves tLe use ol additional
skilled labour on site and oll site and also wastage ol expensive
materials like timber, glass etc. Lconomy can be acLieved by:
(i) standardising and optimising dimensions,
(ii) evolving restricted number ol doors and window
sizes, and
(iii) use ol precast door and window lrames.
lor example:
bed room, kitcLen, entrance, living room, balcony
doors 900 mm widtL and 2000 mm LeigLt, and
windows ol +00 mm, 800 mm, 1200 mm, widtL and
ol +00 mm, 800 mm, 1200 mm or 1600 mm LeigLts. Iigure 10 Precast sunshade
Iigure 11 Precast staircase steps
8 IE (If }curna/-AF
CCCLLSIC
Mass Lousing targets can be acLieved by replacing tLe
conventional metLods ol planning and executing building
operation based on special and individual needs and accepting
common denominator based on surveys, population needs
and rational use ol materials and resources.
o single approacL and solution is available wLicL can satisly
tLe community at large. However, wLat is ideal and desirable
is to Lave a system wLicL can provide cLoice lor people and
also appropriate tecLniques to meet tLe situation. JLe essence
lies in tLe system approacL in building metLodology and not
necessarily particular construction type or design. Adoption
ol any alternative tecLnology on large scale needs a guaranteed
market to lunction and tLis cannot be establisLed unless tLe
product is ellective and economical. Partial prelabrication is
an approacL towards tLe above operation under controlled
conditions.
JLe metLodology lor low cost Lousing Las to be ol
intermediate type - less sopListicated involving less capital
investment.
BEIEBECES
1. 'Study on Low Cost Incremental Housing ScLeme lor LP State.` B/PTC,
AdlakLa and Associates.
2. 'Standards and Specilications lor Cost Lllective Innovative Building
Materials and JecLniques.` B/PTC.
3. IS +326: LartLquake Resistant Design and Construction ol Materials, 1993.
+. 'WorksLop on Capacity Building lor Project Managers ol Building Centres.`
organised by HS/I, April 20-May 2, 1988.
5. P K AdlakLa. 'Cost Reduction in Rooling tLrougL Small Panel
Prelabrication.` Nattcna/ Scntnar cn Ncu But/dtng /atcrta/s and Tccbnc/cgy,
DelLi, May 19-21, 1989.
6. P K AdlakLa. 'ew Lconomical Construction JecLniques lor Walls and
Rooling.` Scntnar cn Intracttcn cn Ncu /atcrta/s and Tccbnc/cgtcs tn But/t
Envtrcnncnt, DelLi, Cctober 1+-1/, 1993.
/. P K AdlakLa. 'Innovative Small Panel prelabricated Rooling using LartLen
Clay Pots.` Tbtrd Nattcna/ Ccnvcnttcn c/ Arcbttcctura/ Engtnccrs, Bombay,
May 1+-15, 1988.
1c/ 84, Aprt/ 2003 9