Prefabrication

1. 1. PREFABRICATONPREFABRICATONPREFABRICATONPREFABRICATON KUSH
AGARWAL
2. 2. Definition :Definition : Prefabrication is the practice of assembling components of a structurep
g p in a factory or other manufacturing site, and transporting complete assemblies or sub-
assemblies to the construction site where the structure is to be locatedstructure is to be located.
Meaning :Meaning : The assembly of buildings or their components at a location otherThe
assembly of buildings or their components at a location other than the building site. The method
controls construction costs by economizing on time, d i lwages, and materials. Prefabricated
units may include doors, stairs, window, walls, wall panels, floor panels, roof trusses, room-sized
components, andpanels, floor panels, roof trusses, room sized components, and even entire
buildings. The term is used to distinguish this process from the more l f h bconventional
construction practice of transporting the basic material to the construction site where all
assembly is carried out.
3. 3. PREFABRICATIONPREFABRICATION Prefabricated building is the completely assembled
and erected building of which is the structural parts consist oferected building, of which is the
structural parts consist of prefabricated individual units or assemblies using ordinary or controlled
materials.
4. 4. PREFABRICATION Prefabricated construction is a new technique and is desirable for large
scale housing programmes, yet this has to take a firm hold in the countrythe country.
5. 5. AIMS OF PREFABRICATION CONSTRUCTION Prefabrication is used to effect economy in
costcost. Components manufactured under controlled conditions.conditions. The speed of
construction is increased since no curing period is necessary. Prefabrication helps in the use of
locally available materials with required h i i lik li h i hcharacteristics like light-weight; easy
workability, thermal insulation, non- combustibility etccombustibility, etc.
6. 6. ADVANTAGES OF PREFABRICATIONADVANTAGES OF PREFABRICATION •
High quality product L b l t d i• Labor related savings • Savings in time • Overall efficiency is
greatly increased• Overall efficiency is greatly increased • Mass production is easier and quick •
Protected and controlled production
environmentProtected and controlled production environment •
Potential for lower production costs and other cost savings •
Independence of climatic conditions • The disruption of traffic is avoided E hi h d f S f•
Ensures high degree of Safety
7. 7. CHARACTERISTICS ARETO BECHARACTERISTICS ARETO BE
CONSIDEREDCONSIDEREDCONSIDEREDCONSIDERED Easy availability; Li h i h f h dli
dLight weight for easy handling and transport, and to economies on sections and sizes of
foundations;foundations; Thermal insulation property; E k bilitEasy workability; Durability in all
weather conditions; N b ibiliNon-combustibility; Economy in cost, and Sound insulation.
8. 8. Disadvantages :Disadvantages : Careful handling of prefabricated components such as
concrete panels or steel and glass panels is required. Attention has to be paid to the strength
and corrosion-resistance of theAttention has to be paid to the strength and corrosion-resistance
of the joining of prefabricated sections to avoid failure of the joint. Similarly, leaks can form at
joints in prefabricated components. Transportation costs may be higher for voluminous
prefabricated sections than for the materials of which they are made, which can often be packed
more compactlybe packed more compactly. Large prefabricated sections require heavy-duty
cranes and precision measurement and handling to place in position.g p p
9. 9. MATERIALSTO BE USED INMATERIALSTO BE USED IN PREFABRICATION
SYSTEMPREFABRICATION SYSTEMPREFABRICATION SYSTEMPREFABRICATION
SYSTEM Concrete, Steel, Treated wood, Aluminum, Cellular concrete, Light weight concrete
elements, Ceramic products, etcp
10. 10. COMPONENTS OF PREFABCOMPONENTS OF PREFAB
CONSTRUCTIONCONSTRUCTIONCONSTRUCTIONCONSTRUCTION Flooring and Roofing
Scheme Beams Columns Walls Staircase Lintels Sunshade/Chajja Projectionsjj j
11. 11. PREFABRICATION SYSTEMSPREFABRICATION SYSTEMS The system of prefabricated
construction depends on the extent of the use of prefab components, their materials sizes and
the technique adopted f h i f d i b ildifor their manufacture and use in building.
12. 12. VARIOUS PREFABRICATION SYSTEMSVARIOUS PREFABRICATION SYSTEMS OPEN
PREFAB SYSTEM This system is based on the use of the basic structural elements to formy
whole or part of a building.The standard prefab concrete components which can be used are:-
Reinforced concrete channel units, Hollow core slabs, Hollow blocks and battens, Precast planks
and battens, Precast joists and tilesPrecast joists and tiles, Cellular concrete slabs,
Prestressed/reinforced concrete slabs, Reinforced/prestressed concrete beams,
Reinforced/prestressed concrete columns, Precast lintels and chajjas, Reinforced concrete
waffle slabs/shells, Room size reinforced/prestressed concrete panels,Room size
reinforced/prestressed concrete panels, Reinforced/prestressed concrete walling elements, and
Reinforced/prestressed concrete trusses
13. 13. CATEGORIES OF OPEN PREFABCATEGORIES OF OPEN PREFAB
SYSTEMSSYSTEMSSYSTEMSSYSTEMS There are two categories of open prefab systems d
di h f f b i i d i hdepending on the extent of prefabrication used in the construction as given
below: Partial prefab open systemPartial prefab open system Full prefab open system
14. 14. PARTIAL PREFAB OPENPARTIAL PREFAB OPEN SYSTEMSYSTEMSYSTEMSYSTEM
This system basically emphasizes the use of precast roofing and flooring components and other
minor elements likeand flooring components and other minor elements like lintels, chajjas,
kitchen sills in conventional building construction.The structural system could be in the form of f k
l d b llin-situ framework or load bearing walls.
15. 15. FULL PREFAB OPEN SYSTEMFULL PREFAB OPEN SYSTEMFULL PREFAB OPEN
SYSTEMFULL PREFAB OPEN SYSTEM In this system almost all the structural components are
P f b i d Th fill ll b f b i k hPrefabricated.The filler walls may be of bricks or any other local
material.
16. 16. LARGE PANEL PREFAB SYSTEM This system is based on the use of large prefab
components. The components such as Precast concrete large panels for wallsThe components
such as Precast concrete large panels for walls, floors, roofs, balconies, staircase, etc. The
casting of the components could be at the site or off the site.
17. 17. CLASSIFICATION OF STRUCTURALCLASSIFICATION OF STRUCTURAL SCHEMEWITH
PRECAST LARGE PANELSCHEMEWITH PRECAST LARGE PANELSCHEMEWITH PRECAST
LARGE PANELSCHEMEWITH PRECAST LARGE PANEL Wall Systems CrossWall System - In
this scheme, the cross wall are load bearing walls whereas the facadeWalls are non load bearing
this system is suitable for high risenon-load bearing this system is suitable for high rise buildings.
Longitudinal Wall System - In this scheme the cross walls are non-load bearing whereas
Longitudinal walls are load bearing walls.This system is suitable for low rise buildings.rise
buildings. A combination of the above system with all load bearing walls can also be adopted.
18. 18. PRECAST FLOORS precast flooring units could be homogeneous or non homogeneous.g
Homogeneous floors :- could be solid slabs, cored slabs, ribbed or waffle slabs. N h fl ld b l l d
hNon-homogeneous floors :- could be multi-layered ones with combinations of light weight
Concrete or reinforced/prestressed concrete, with filler blocks
19. 19. STAIRCASE SYSTEMS Staircase system could consist of single flights with in-built risers
and treads in the element only.The flights are normally unidirectional transferring the loads to
supporting landingg pp g g slabs or load bearing walls.
20. 20. BOXTYPE CONSTRUCTION In this system, room size units are prefabricated and erected
at site Toilets and kitchen blocks also be similarlyat site.Toilets and kitchen blocks also be
similarly prefabricated and erected at site. This system derives its stability and stiffness from the
box unit which are formed by the four adjacent walls.Walls are jointed to make rigid connections
among themselves.The box unit rests on the plinth foundation which may be of
conventionalrests on the plinth foundation which may be of conventional type or precast type.
21. 21. JOINTSJOINTSJOINTSJOINTS The joints should be provided in the light of their
assessment with respect to the following considerations: Feasibility -The feasibility of joint shall
be determined by its loads- carrying capacity in the particular situation in which the joints is to
function.function. Practicability -Practicability of joint shall be determined by the amount and type
of Material, fabrication and erection and the time for fabrication and erectionfabrication and
erection. Serviceability - Serviceability shall be determined by the joints/expected behavior to
Repeated or possible overloading and li i h i l di iexposure to climatic or chemical conditions.
Fire-Proofing - Appearance -Appearance
22. 22. JOINTTECHNIQUES/MATERIALS NORMALLYJOINTTECHNIQUES/MATERIALS
NORMALLY EMPLOYED ARE:EMPLOYED ARE: Welding if cleats or projecting steel.
Overlapping reinforcement loops and linking steelOverlapping reinforcement, loops and linking
steel grouted by concrete. Reinforced concrete ties all round a slabReinforced concrete ties all
round a slab. Prestressing. Epoxy groutingEpoxy grouting. Bolts and nuts connection, and A
combination of the aboveA combination of the above.
23. 23. Components Fixing and Jointing :Components Fixing and Jointing : A h b i b ilt ithA house
being built with prefabricated concrete panels The steel formwork for the core wall construction.
Prefabricated wall panels being installed in public housing
24. 24. Installing and fixing the precast facades into positioninto position
25. 25. PRECASTING METHODPRECASTING METHODPRECASTING METHODPRECASTING
METHOD INDIVIDUAL MOULD METHOD U i ld hi h b il bl d f b dUsing mould which may be
easily assembled out of bottom and sides, transportable , if necessary this may be either in
timber or in steel using needle or mould vibrations and capable of taking prestressing
forcesprestressing forces. Used in – Rib Slab, beams, Girders window panels, box type units
and special elements.
26. 26. BATTERY FORM METHODBATTERY FORM METHODBATTERY FORM
METHODBATTERY FORM METHOD BATTERY FORM METHOD B f h d h i l b dj d i hBattery
form method shuttering panels may be adjusted in the form of a battery at the required distances
equal to the thickness if the concrete members. U d i I W ll ( P l Sh ll l f dUsed in – InteriorWalls (
Panels, Shell elements, reinforced concrete, battens, rafters , purlines, roof and floor slabs.
27. 27. STACK METHODSTACK METHODSTACK METHODSTACK METHOD BATTERY FORM
METHOD U d i Fl d R f l b lUsed in – Floor and Roof slabs panels.
28. 28. TILTING METHODTILTING METHODTILTING METHODTILTING METHOD BATTERY
FORM METHOD U d i M ld i W llUsed in – Mould exteriorWalls.
29. 29. LONG LINE PRESTRESSING BEDLONG LINE PRESTRESSING BED METHODMETHOD
METHODMETHODMETHODMETHOD METHODMETHOD BATTERY FORM METHOD U d i D
bl ib l b li d bUsed in – Double tees, rib slabs, purlines and beams.
30. 30. EXTRUSION METHODEXTRUSION METHOD BATTERY FORM METHOD - Long concrete
mould with constant cross section and vibration will be done automatically justconstant cross
section and vibration will be done automatically just as in concrete roads. Used in – roof slabs,
concrete walls, panels and beams.
31. 31. LimitationsLimitations of Prefabricationof Prefabrication 1. Small number of units required
may prove to be uneconomical. 2. Special connections, such as special bearings to t it th ti l d h i
t l l d ddtransmit the vertical and horizontal loads, can add cost to the system. 3 Waterproofing at
joints3. Waterproofing at joints. 4. Transportation difficulties. 5. Need for cranes.5. Need for
cranes.