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BARC ARCH. BILDING CONSTRUCTION AND MATERIAL

ARCHITECTURE BUILDING
CONSTRUCTION.6 BARC

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PREFABRICATED STRUCTURE
Prefabrication is the Practice of assembling components of a structure in a factory or other
Manufacturing site and transporting complete assemblies to the construction site where the
structure is to / be located.

PROCESS OF PREFABRICATION:

 An example from house building illustrates the process of prefabrication.

 The Conventional method of building a house is to transport bricks timber, cement,
sand, Steel and construction aggregate etc., to the site, and to construct the house
on site from these materials.
 In prefabricated Construction. Only the foundations are constructed in this way
while
 sections of (walls, floors, roof are Prefabricated with window & door frames
included). transported to the site lifted into place by a crane and bolted together.
USES OF PREFABRICATION:

 The most widely used from of prefabrication in building and civil engineering is
the use of Prefabricated Concrete & prefabricated steel sections in structures where
a particulars part on form is repeated many line.
 Pouring Concrete section in a factory brings the advantages of being able to re -use
moulds and the concrete cab be mixed on the spot without having to be transported
to and pumped wet on a congested construction site.
 Prefabricating Steel sections reduces on site cutting and welding costs as well as
the associated hazard's.
 Prefabrication techniques are wood in the construction of apartment slacks and
housing developments with repeated housing units.
 The technique is also used in office blocks, warehouses and factory buildings.
 Prefabricated Steel and glass sections are widely used for the exterior of large
buildings.
 Prefabricated bridge elements and systems offer bridge designers & Contractors
significant advantages in terms of construction time, safety environmental impact
construct liability and cost.
 Prefabrication can also help minimize the impact from bridge building.

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 Radio bowers for mobile phone and other service often consist of multiple
prefabricated sections.
 Prefabricated has become widely used in the assembly of aircraft and space craft
with component such as wings and fuselage sections after being manufactured in
different countries or states from the final assembly site.
PRECAST CONCRETE

 Precast Concrete is a style of concrete, which is very helpful for speedy

construction as the concrete is casted in some other place instead of directly being
used on the site.
 Concrete is heavy—typically about 150 pounds per cubic foot—so concrete
elements don't have to be very big before moving them becomes unrealistic.
 Other times, it's just simpler to cast the concrete in place as the precast advantages
are outweighed by convenience, such as with concrete slabs and floors.

Figure 1: Basic Components of Precast Concrete

FLOORING /ROOFING SYSTEM

 The Guardian Floor and Roof System produced by Concrete Building Concepts has
proven itself to be a cost-effective solution that is stronger, more durable and faster to
install than traditional floor systems.

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 The Guardian Floor and Roof System can be easily installed on steel, precast concrete
and site-built concrete structures. Designed to provide precise adjustments and fine
tuning, Guardian Floor and Roof System panels can form the roof of a single-story
building.
 For multi-story structures, the panels form the elevated slab of an upper level and
simultaneously provide the ceiling attachment points for the level below. The
embedded steel bar joists incorporated in the Guardian Floor and Roof System provide
ample space for the easy installation of ventilation ducts, electrical lines and plumbing
lines. A variety of joist depths can be selected to facilitate the placement of trade
requirements and ceiling attachments such as step-downs and coffers. Openings in any
slab can be precast at the production facility.
 The Guardian Floor System is fabricated in widths of up to 8 feet and lengths of up to
40 feet.
 It is typically composed of two 8"-22" deep steel bar joists 48 apart which are embedded
in 3 thick reinforced concrete.
 The open web bar joist has a bottom chord constructed with double structural angles
that acts as an axially loaded tension member with smooth round bars used for diagonal
web members. The diagonal web members acting in tension and compression are
welded at the top with a longitudinal member embedded 1 1/2 deep into a top chord
comprising of a 3 concrete slab poured with 3000 psi concrete and reinforced with 6x6
welded wire mesh.
 The slabs are cast in continuously cambered steel forms to allow deflection control and
result in a fine steel-float finish superior to poured-in-place concrete.
 The panels are transported to the building site and placed on top of precast concrete
panels, tilt-up panels or beams of the structure, precisely levelled and welded together
at the joist seat and parallel slab joints.
 The slab joints are then grouted. All materials meet and exceed standards and
specifications for local and national codes.

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HOLLOW PRECAST REINFORCED CONCRETE FLOOR

 Hollow core Units derive their name from the circular voids or cores which run
throughout the slab. The units have a smooth finish and maximum capacity of 2.3
kn/sqm over a 16m span. They are available in standard 1200mm widths and in
depths of 150, 200, 250, 300 and 400 mm. They can be used effectively in all types
of building providing a fast and cost effective structure.
 For reinforced concrete floors, concrete of minimum grade M 30 shall be used. Pre -
stressed concrete floor units shall satisfy the strength requirements followed in
usual design practice, namely, a minimum of M 35 for post-tensioned and
pretension works. The thickness of the floor panel shall be such that the
serviceability requirements are satisfied. The minimum thickness of concrete layer
for cored slab is 50 mm. Panels shall be designed in accordance with the
recommendations given in IS 456:2000 governing reinforcement and detailing.

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TYPICAL APPLICATIONS INCLUDE:

 Flooring or roofing for single and multi-storey developments. The long spans of up
to 16.5m are ideal for most residential or commercial applications such as
apartments, offices, factories etc.
 Wall Panels – Hollow core can be installed either horizontally or vertically to
provide an effective wall cladding system, often used with steel structures.
 Benefits: Hollow core spans up to 16.5 m. which minimizes column requirements
Factory production decreases dependency on weather conditions and increases
programmer planning reliability.
 Eliminates the requirement for costly excavation for ground floors, removes the
need for provision/ compaction of infill material and provides an immediate d ry
working platform.

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PRECAST CONCRETE ELEMENTS:

 A precast building is assembled and connecting various prefabricated elements are

required in the building.
 The figure below shows the building structure with basic precast components.
 In Buildings the main components of precast concrete are:
1. Columns
2. Chajja
3. Beams
4. Slabs
5. Walls
6. Lintels
7. Sills
8. Steps and Staircases
PRECAST FOOTINGS:

Precast footings are foundations that are easy to install and use as soon as they arrive on site.
They are extremely strong and provide a stable and level base from which to build. The
installation of precast footings isn’t weather dependant and there is no mixing or other on-site
preparation required.

PRECAST BEAMS

 The cross-sections of a precast concrete beam will depend on its location within a
structure, its purpose and how it is connected to other members. The simplest will be
rectangular, probably with reinforcement links projecting out of the top around which
in situ concrete can be cast.

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 Precast concrete beams are an integral feature of many buildings today. They are
particularly suited to floor construction in houses, flats and commercial buildings
and provide a low-cost flooring solution.

PRECAST PRESTRESSED CONCRETE DOUBLE TEE BEAM

A Double-T beam is a load-bearing structure that resembles two T-beams connected to each
other side by side. The strong bond of the flange (horizontal section) and the two webs (vertical
members, also known as stems) creates a structure that is capable of withstanding high loads
while having a long span. The typical sizes of double tees are up to 15 feet (4.6 m) for flange
width, up to 5 feet (1.5 m) for web depth, and up to 80 feet (24 m) or more for span length.
Double tees are pre-manufactured from prestressed concrete which allows construction time to
be shortened.

PRECAST BEAM AND FILLER BLOCK

 Beam and block is also referred to in some countries as ‘rib and block’ or
‘lintel and block’. The technique is used to create in-situ, suspended concrete
floors (ground or upper) in concrete or masonry buildings and has become popular
in residential construction.
 Beam and block floors incorporate clay or concrete blocks, either solid or hollow
(sometimes referred to as ‘pots’), supported on a series of parallel, typically pre-
cast, pre-stressed concrete beams or ribs. Once the blocks are placed to infill between
the parallel concrete beams, a continuous working surface is created.

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 There are several ways to achieve this. One involves inverted T-beams that incorporate
continuous ledges on their lower sections that give the blocks full support. Beams are
typically 130-250mm-deep and can be made to span up to 6m. The beam profile will
depend on the span, the shape of the block and the loading requirements.
 With the beams in place and supported at either end, laying the infill blocks is a quick
process: assuming the blocks are to hand, a worker can drop one into place every five
to ten seconds. A typical current block specification is to have dimensions of 440 x 215
x 100mm thickness, 3.5N/mm2 or 7N/mm2 minimum compressive strength, and able
to support a minimum transverse load of 3.5kN on a 420mm span.
 The advantage of beam and block is that no shuttering (support) is required on the
underside of the floor as the beams are supported at each end, either on
internal load bearing walls or on perimeter walls. Once the filler blocks are installed, a
continuous working surface is created upon which further work can take place safely.
Often, a sand and cement grout is brushed over the top surface to fill any gaps and
prevent insects and vermin from entering, as well as to assist with air tightness.

PRECAST COLUMNS

 Precast concrete columns may be single or double storey height. The method of
connection to the foundation and to the column above will vary with manufacturer.
Foundation connection may be via a base plate connected to the column or by

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reinforcing bars projecting from the end of the column passing into sleeves that are
subsequently filled with grout. Alternatively, a column may be set into a preformed
hole in a foundation block and grouted into position.

 Column-column connections may be by threaded rods joined with an appropriate

connector; with concrete subsequently cast round to the dimensions of the cross-section
of the column. Alternatively, bars in grouted sleeves, as described above, may be used.
This results in a thin stitch between columns while the previous approach requires a
deeper stitch. Connections may be located between floors, at a point of contra-flexure,
or at floor level.
 Columns are provided with necessary supports for the ends of the precast beams
(corbels or cast-in steel sections). There will also be some form of connection to provide
beam-column moment connection and continuity. For interior columns this may be by
holes through which reinforcing bars pass from one beam to another. For edge columns,
some form of bracket or socket is required.
 During erection columns must be braced until stability is achieved by making the
necessary connections to the beams and slabs.

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PRECAST WALL PANELS

FACTORY WALL PANELS is shaped and structured to make full use of its profile to provide
greater stability and to facilitate services and modifications like electrical, plumbing, etc.

Even after the panels are fixed, modification made can be repaired with cement-sand mortar.
These are easy to erect and shift machineries can be used along with local labor force. With
slight modifications, the panels can be used for permanent formwork for concreting.
Sustainable type of construction as volume of material consumed is minimal.

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 A precast wall is an ideal solution for providing stability to a frame structure that
can carry vertical loads. Most construction companies use precast walls with fl oor
slabs to form a complete structure. The precast walls are a suitable one for
enhancing the stability to a building thereby showing ways for ensuring optimal
results. Curtain walls, load-bearing wall units, shear walls, and form work for cast-
in-place concrete are the four types of precast walls are available for the buildings
allowing us to maintain a better environment.

PRECAST STAIRCASE:

The precast staircases give ways for eliminating the need for an expensive framework. Apart
from that, they are a suitable one for improving the look of a building with unique styles. It is
possible to install them in a building for saving more time.

PRECAST SLAB:

A precast slab is the most used component in several construction sites because it suits any
type of architecture which adopt to the requirements. Some of them include hollow core units,
double -tee units, solid core slabs and bi axial voided slabs which ultimately help to gain more
advantages. A hollow core slab provides maximum structural efficiency by reducing the dead
weight. Double-tee units are primarily designed for flooring purposes and lighter in weight. At
the same time, the depth of units may vary depending on the span.

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MANUFACTURING PROCESS OF PRECAST CONCRETE:

1. Precast concrete is poured into a wooden or steel mold with wire mesh or rebar.
This mold may also have prestressed cable, if needed.
2. It is cured in a controlled environment — usually at a plant.
3. Once finished, the precast concrete is transported to a construction site and put into
place.
 It’s important to note that not all precast concrete is prestressed with cable
reinforcement.
 The addition of this reinforcement is particularly useful in many structures and
buildings where maximizing the strength of the concrete is essential.
 The addition of the wire or rebar provides tension within the concrete, which is rele ased
once curing is complete.
 The release of the wire or rebar tension transfers strength to the concrete, creati ng an
even stronger material.

THE FOLLOWING FIGURES ILLUSTRATE THE PRECAST CONCRETE

PROCESS:

1. PRODUCTION OF REINFORCED CAGES AND MAIN CONNECTIONS:

The precast factory often has specialist workshops for the manufacture and
maintenance of moulds, and for the production of jig-built reinforcing cages and
connections.

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2. ASSEMBLY OF MOULDS:
The reinforced cage is positioned in the partly assembled mould, then the remaining
mould section is completed.
3. MIX BEING POURED:
Carefully specified concrete is placed into the mould. Many precast works now
employ computer controlled batching plants.
4. COMPACTION OF CONCRETE USING POKER VIBRATOR:
To ensure that optimum density is obtained and that specified strengths are
achieved, concrete is placed and compacted using high-frequency external
vibrators or pokers.
5. PRECAST CONCRETE BEING MOVED TO THE STORAGE AREA:
Once an appropriate strength has been reached, the precast units are moved to the
storage area. Units are usually handled within hours of casting as part of the rapid
production cycle. The product exhibits a high degree of dimensional accuracy and
quality of finish. Economies of production are achieved through the repetitive and
automated process.
6. STORAGE OF HIGH-QUALITY UNITS IN WORKS AREA:
The finished precast components are stacked on clean battens or plastic pads
positioned to suit the design of the component. Care is taken to keep the stacks
vertical and to ensure that battens are placed directly above one another within the
stack.
7. TRANSPORT TO SITE:
The components are delivered to site in a pre-determined sequence to ensure that
hardened concrete are ready for instant erection.
8. ERECTION AT SITE:
The components are erected straight from the lorry. This leads to faster erection
times with reduced on-site activity.

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ADVANTAGES OF PRECAST CONCRETE:

 Since precast is manufactured in a controlled casting environment it is easier to

control the mix, placement, and curing
 Quality can be controlled and monitored much more easily
 Since a precaster can buy materials for multiple projects, quantity discounts can
lower costs
 Weather is eliminated as a factor—you can cast in any weather and get the same
results, which allows you to perfect mixes and methods
 Less labor is required and that labor can be less skilled.
 Saves Construction Time: Precast Concrete construction saves time, the risk of
project delay is also less. The precast concrete casting can be carried on
simultaneously with other works on site such as earthwork, survey, etc. and thus
saves time.
 Cost-effective: The simplified construction process reduces the time, increases
the productivity, quality and safety and thus the cost is reduced.

DISADVANTAGES OF PRECAST CONCRETE

 High Initial Investment: For installing a Precast Concrete plant, heavy and
sophisticated machines are necessary which requires a high initial investment. A
large scale of precast construction projects must be available to ensure sufficient
profit.

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 Transportation Issue: The construction site can be at a distant location from the
Precast Concrete plant. In that case, the precast members must be carried to the site
using trailers.
 Handling Difficulties: Proper care and precaution have to be taken for handling
precast concrete. Usually, precast members are heavy and large which makes it
difficult to handle without damage.
 Modification: Limitation in case of precast structures, it is difficult to modify the
structure. For example, if a structural wall is to be dismantled for modification it
will impact the overall stability of the structure.
 Sensitive Connection Works: Assembling of the precast members is one of the key
points for ensuring strong structural behavior.

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