Building Construction VII

PREFABRICATION

SUBMITTED BY:
SAPARYA ANEJA B.ARCH 4-C
 PREFABRICATION

A prefabricated structure or building is a structure that has several factory-built components that are
assembled on a site. These pre-made components can consist of panels, modules or transportable
sections. In precast also known as prefabricated construction, the majority of structural components
are standardized and manufactured in dedicated facilities by industrial methods based on mass
production. These are then transported to the site and by suitable handling and erection schemes
they are assembled like building blocks.

HISTORY OF PREFABRICATION BUILDINGS

Buildings have been built in one place and reassembled in another throughout history. Possibly the
first advertised prefab house was the Manning Portable Cottage. A London carpenter, Henry
Manning, constructed a house that was built in components, then shipped and assembled by British
emigrants.

This was published at the time (advertisement, South Australian Record, 1837) and a few still stand in
Australia. One such is the “Friends Meeting House, Adelaide”. The peak year for the importation of
portable buildings to Australia was 1853, when several hundred arrived. These have been identified as
coming from Liverpool, Boston and Singapore (with Chinese instructions for reassembly). In Barbados
the Chattel house was a form of prefabricated building which was developed by emancipated slaves
who had limited rights to build upon land they did not own. As the buildings were moveable they
were legally regarded as chattels.

TYPES OF PREFABRICATION SYSTEM

 MATERIALS USED:

Prefabricated building materials are used for buildings that are manufactured off site and shipped
later to assemble at the final location some of the commonly used prefabricated building. The
materials used in the prefabricated components are many. The modern trend is to use concrete steel,
treated wood, aluminium cellular concrete, light weight concrete, ceramic products etc. While
choosing the materials for prefabrication the special characteristics are to be considered.

• Light weight for easy handling and transport and to economic an sections and sizes of
foundations,
• Thermal insulation property
• Easy workability
• Durability in all weather conditions
• Non combustibility
• Economy in cost
• Sound insulation

PRODUCTION OF PREFABRICATED STRUCTURES

The location of precasting yards consist of storage facilities suitable for transporting and erection
equipments and availability of raw materials are the critical factors which should be carefully planned
and provided for effective and economic use of pre-cast concrete components in construction.

The manufacture of the components can be done in a centrally located factor of in a site where
precasting yards set-up at or near the site of work.

FACTORY PREFABRICATION;

• Factory prefabrication is restored in a centrally located plant for manufacture of standardized

components on a long form basis.
• It is a capital-intensive production where work is done throughout the year preferably under
a covered shed to avoid the effects of seasonal variations high level of mechanization can
always be introduced in this system where the work can be organized in a factory like manner
with the help of constant team of workmen.
• The basic disadvantage in factory prefabricated, is the extra cost in occurred in transportation
of elements from plant to site of work sometimes the shape and size of prefabricable are to
be limited due to lack of suitable transportation equipment roads controls etc.

SITE PREFABRICATION

• In this scheme, the components are manufactured at site near the site of work as possible.
• This system is normally adopted for a specific job order for a short period.
• The work is normally carried out in open space with locally a valuable labour force. The
equipment machinery and moulds are of mobile nature.
 MANUFACTURE PROCESS OF PREFABRICATION STRUCTURE

The various processes involved in the manufacture of precast elements are classified as follows:

1) Main process 2) Secondary process 3) Subsidiary process

MAIN PROCESS:

It involves the following steps.

1) Providing and assembling the moulds, placing reinforcement cage in position for reinforced
concrete work
2) Fixing of inserts and tubes where necessary.
3) Depositing the concrete in to the moulds.
4) Vibrating the deposited concrete into the moulds.
5) Demoulding the forms.
6) Curing (steam curing if necessary)
7) Stacking the precast products.

SECONDARY PROCESS:

This process is necessary for the successful completion of the process covered by the main process.

1) Mixing or manufacture of fresh concrete (done in a mixing station or by a matching plant).

2) Prefabrication of reinforcement cage (done in a steel yard of workshop)
3) Manufacture of inserts and other finishing items to be incorporated in the main precast
products.
4) Finishing the precast products.
5) Testing the precast products

TRANSPORT OF PREFABRICATION STRUCTURES

Transport of prefabrication elements must be carried out and with extreme care

• Avoid any flock and distress in elements and handled as far as possible to be placed in final
portion
• Transport of prefab elements inside the factory depends on the method of production
selected for the manufacture.
• Transport of prefab elements from the factory to the site of action should be planned in
conformity with the trafficable rules and regulations as stipulated by the authority the size of
the elements is often restricted by the availability of suitable transport equipment, such as
tractor-am-tailor, to suits the load and dimension of the member in addition to the load
carrying capacity of the bridges on the way. While transporting the prefab elements in various
systems, such as wages, trucks, bullock cards etc. care should be taken to avoid excessive
cantilever actions
• Special care should be taken in negotiating sharp beds uneven of slushy roads to avoid
undesirable stresses in elements and in transport vehicles.
 • Care should be taken to ensure the base packing for supporting the elements are located at
specified portion

ERECTION

It is the process of assembling the Prefabrication element in the find portion as per the drawing. In
the erection of prefab elements, the following items of work are to be carried out.

1) Slinging of the prefab elements.

2) Tying up of erection slopes connecting to the erection hooks.
3) Cleaning the elements and the site of erection.
4) Adjustments to get the stipulated level line and plumb.
5) Changing of the erection tackles.
6) Putting up and removing the necessary scaffolding or supports.

ADVANTAGE OF PREFABRICA TION

• Self-supporting readymade components are used so the need for framework shuttering and
scaffolding is greatly reduced.
• Construction time is reduced and buildings are completed sooner allowing on earlier return of
the capital invested.
• On site construction and congestion minimised
• Quality control can be easier in a factory assembly line setting than a construction site setting.
• Prefabrication can be located where skilled labour; power materials space and overheads are
lower.
• Availability of precise structure and expert workmanship.
• Fewer expansion joints are required.

DISADVANTAGES

• Prefabricated houses are not necessarily 'better' for the environment than conventional
houses. In fact, both prefabricated houses and conventional houses are bad for the
environment. This is mostly because of the building materials and energy inputs they
demand.
• Most prefab and most conventional homes do not use renewable building materials, and
instead use materials that involve a great deal of energy to create. Brick, concrete, steel - all
of these are high-energy materials that typically must be shipped long distances.
 CASE STUDIES

ONE 9

Developed by the Moloney Group, is located at 19 Hall Street, just 7 km northwest of

Melbourne’s central business district in Moonee Ponds, a thriving hub of commercial, office, and
Retail activity, bordered by quality residential dwellings and excellent lifestyle amenities. Designed
By the Amnon Weber architecture firm and constructed by Vaughan Constructions using Hickory
Group’s prefabricated building systems, One9 comprises 34, one- and two-bedroom contemporary
Apartments over nine stories. The manufactured apartments were erected by Vaughan and Hickory
Using 36 unitized building modules in just five days; the daily schedule and progress are shown in
Figure 5. Vaughan subcontracted Hickory to deliver the 36 modules, complete with the facades and
Fully fitted with a combination of natural timber floors and high-grade carpets, built-in wardrobes,
And full-length balconies. The nature of tall buildings is such that the modules are clustered around
A precast concrete core or stabilizing system; the modules are generally designed to resist vertical
Loads and horizontal loads are transferred to the concrete core. The Hickory manufactured
Apartments offer light-filled and functional spaces for everyday living. Unique, modern design
Highlights the capability of the modular technology to adapt to complex architectural concepts, and
Features cantilevered terraces on all levels and clean framing on the front façade. One9 was
completed in November 2013.
 RESULTS ACHIEVED

Some astonishing results along with learning experiences achieved through this landmark project
noted as follows:

• Thermal Behaviour
• Acoustic Constraints
• Seismic Resistance
• Energy Consumption
• Life Cycle Analysis
• Future Pathways

CONCLUSION

Following learnings could be the key takeaways though this case study:

The building industry is refabricating architecture through prefabrication. Similar to the

Automobile, shipbuilding, and aerospace industries, the construction industry aims to deliver
An integrated prefab architecture that meets design requirements according to budget, quality
Specifications, as well as being on time. Using a case study-based methodology, this study was
Designed to review the classification and actual performance of assorted prefabricated architecture.
The earliest prefabricated buildings date back to the early seventeenth century, when houses were
Fabricated in England and shipped abroad. From literature, there are numerous benefits that can be
Realized by adopting prefabrication; notably, material and time efficiency, as well as reduced
impacts
Of construction on the environment. Some authors have described prefabricated architecture on the
Modular scale as a sustainable approach. Nonetheless, there are some hindrances to prefabrication;
Notably, transportation restrictions due to module size and weight, high level of project
coordination,
Negative market perception, and lack of general knowledge on prefab. Contrary to the general
Perception, designing with prefab components is not a barrier to creativity; rather, by standardizing
Typical prefab components and providing mass customization options, final costs are lowered
through
Economies of high-volume work. The building envelope of prefabricated architecture should be
tailored
To suit local climatic conditions and building codes to ensure a comfortable indoor environment. On
Average, greenhouse gas emissions from conventional construction were higher than for modular
Construction. Measuring seismic performance of a modular steel brace frame structure by energy
Dissipation characteristics showed that the structure was stable and behaved in a ductile manner up
To very high drift levels; there was no significant strength and stiffness degradation with cycling and
Showed superior energy dissipation per cycle in each of the load steps. For better implementation
Of prefabrication, early design stage should be considered and included in the construction
methods.
For the future, there is need to improve assurance of stakeholders by making known to the public
Performance data of existing prefabricated architecture; only then can prefabricated and
conventional
Architecture be juxtaposed and quantified. Further, reducing costs through mass customization,
Promotions, and policies will be an important factor to widen the commercialization of prefab.

Reference: https://iopscience.iop.org/article/10.1088/1742-6596/1780/1/012009/pdf