PREFABRICATON

KUSH AGARWAL
Definition :
y Prefabrication is the ppractice of assemblingg components
p of a structure
in a factory or other manufacturing site, and transporting complete
assemblies or sub-assemblies to the construction site where the
structure is to be located.
located
Meaning :
y The assembly of buildings or their components at a location other
than the building site.
y The method controls construction costs by economizing on time,
wages, andd materials.
il
y Prefabricated units may include doors, stairs, window, walls, wall
panels, floor panels, roof trusses, room
room-sized
sized components, and
even entire buildings.
y The term is used to distinguish this process from the more
conventionall construction practice off transporting the h basic
b
material to the construction site where all assembly is carried out.
PREFABRICATION

Prefabricated building is the completely assembled and

erected building,
building of which is the structural parts consist of
prefabricated individual units or assemblies using ordinary
or controlled materials.
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 country.
country
AIMS OF PREFABRICATION
CONSTRUCTION
‰Prefabrication is used to effect economy in
cost.
cost
‰Components manufactured under controlled
conditions.
‰The speed of construction is increased since
no curing period is necessary.
‰Prefabrication helps in the use of locally
available materials with required
characteristics
h i i like
lik lilight-weight;
h i h easy
workability, thermal insulation, non-
combustibility etc.
combustibility, etc
ADVANTAGES OF PREFABRICATION

• High quality product
• L b
Labor related savings
l t d i
• Savings in time
• Overall efficiency is greatly increased
Overall efficiency is greatly increased
• Mass production is easier and quick
• Protected and controlled production environment
Protected and controlled production environment
• Potential for lower production costs and other cost 
savings
• Independence of climatic conditions
• The disruption of traffic is avoided
• E
Ensures high degree of Safety
hi h d fS f
CHARACTERISTICS ARE TO BE
CONSIDERED
y Easy availability;
y Light
Li h weight
i h for
f easy handling
h dli and d transport,
and to economies on sections and sizes of
foundations;
y Thermal insulation property;
y Easy
E workability;
k bilit
y Durability in all weather conditions;
y Non-combustibility;
N b ibili
y Economy in cost, and
y Sound insulation.
 Disadvantages :
y Careful handling of prefabricated components such as concrete panels or
steel and glass panels is required.
y Attention has to be paid to the strength and corrosion-resistance of the
joining of prefabricated sections to avoid failure of the joint.
y Similarly, leaks can form at joints in prefabricated components.
y Transportation costs may be higher for voluminous prefabricated
sections than for the materials of which they are made, which can often
be packed more compactly.
compactly
y Large prefabricated sections require heavy-duty cranes and precision
measurement and handlingg to pplace in pposition.
MATERIALS TO BE USED IN
PREFABRICATION SYSTEM
y Concrete,
y Steel,
y Treated wood,
y Aluminum,
y Cellular concrete,
y Light weight concrete elements,
y Ceramic pproducts, etc
COMPONENTS OF PREFAB
CONSTRUCTION
y Flooring and Roofing Scheme
y Beams
y Columns
y Walls
y Staircase
y Lintels
y Sunshade/Chajja
jj Projections
j
PREFABRICATION SYSTEMS
y The system of prefabricated construction depends on the extent of the
use of prefab components, their materials sizes and the technique adopted
f their
for h i manufacture
f andd use in
i building.
b ildi
VARIOUS PREFABRICATION SYSTEMS
¾ OPEN PREFAB SYSTEM
y This system
y is based on the use of the basic structural elements to form
whole or part of a building. The standard prefab concrete components
which can be used are:-
9Reinforced concrete channel units,
9Hollow core slabs,
9Hollow blocks and battens,
9Precast planks and battens,
9Precast joists and tiles,
tiles
9Cellular concrete slabs,
9Prestressed/reinforced concrete slabs,
9Reinforced/prestressed concrete beams,
9 Reinforced/prestressed concrete columns,
9Precast lintels and chajjas,
9Reinforced concrete waffle slabs/shells,
Room size reinforced/prestressed concrete panels,
9Room
9Reinforced/prestressed concrete walling elements, and
9Reinforced/prestressed concrete trusses
CATEGORIES OF OPEN PREFAB
SYSTEMS
y There are two categories of open prefab systems
d
depending
di on theh extent off prefabrication
f b i i used d in
i the
h
construction as given below:
9 Partial prefab open system
9 Full prefab open system
PARTIAL PREFAB OPEN
SYSTEM
y This system basically emphasizes the use of precast roofing
and flooring components and other minor elements like
lintels, chajjas, kitchen sills in conventional building
construction. The structural system could be in the form of
in-situ framework
f k or lload
d bearing
b walls.
ll
FULL PREFAB OPEN SYSTEM
y In this system almost all the structural components are
P f bi
Prefabricated.
d The
Th filler
fill walls
ll may bbe off bbricks
i k or any other
h
local material.
¾ LARGE PANEL PREFAB SYSTEM

9This system is based on the use of large prefab components.

The components such as Precast concrete large panels for walls,
walls
floors, roofs, balconies, staircase, etc. The casting of the
components could be at the site or off the site.
CLASSIFICATION OF STRUCTURAL
SCHEME WITH PRECAST LARGE PANEL
y Wall Systems
¾ Cross Wall System - In this scheme, the cross wall
are load bearing walls whereas the facade Walls are
non load bearing this system is suitable for high rise
non-load
buildings.
¾ 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.
¾ A combination of the above system with all load bearing
walls can also be adopted.
y PRECAST FLOORS

¾ precast flooring units could be homogeneous or non

homogeneous.
g
9 Homogeneous floors :- could be solid slabs, cored slabs, ribbed
or waffle slabs.
9 N
Non-homogeneous
h floors
fl :- could
ld be
b multi-layered
l l d ones withh
combinations of light weight Concrete or reinforced/prestressed
concrete, with filler blocks
y STAIRCASE SYSTEMS
¾ Staircase system could consist of single flights with in-built
risers and treads in the element only. The flights are normally
unidirectional transferringg the loads to supporting
pp g landingg
slabs or load bearing walls.
y BOX TYPE CONSTRUCTION

y In this system, room size units are prefabricated and erected

at site.
site Toilets and kitchen blocks also be similarly
prefabricated and erected at site.
y 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 conventional
type or precast type.
 JOINTS
y The joints should be provided in the light of their assessment with respect
to the following considerations:
y Feasibility -The feasibility of joint shall be determined by its loads-
carrying capacity in the particular situation in which the joints is to
function.
y Practicability -Practicability of joint shall be determined by the
amount and type of Material, fabrication and erection and the time for
fabrication and erection.
erection
y Serviceability - Serviceability shall be determined by the
joints/expected behavior to Repeated or possible overloading and
exposure to climatic
li i or chemical
h i l conditions.
di i
y Fire-Proofing -
y Appearance -
JOINT TECHNIQUES/MATERIALS NORMALLY
EMPLOYED ARE:

y Welding if cleats or projecting steel.

y Overlapping reinforcement,
reinforcement loops and linking steel
grouted by concrete.
y Reinforced concrete ties all round a slab.
slab
y Prestressing.
y Epoxy grouting.
grouting
y Bolts and nuts connection, and
y A combination of the above.
above
Components Fixing and Jointing :

A hhouse bbeing
i built
b ilt with
ith
prefabricated concrete panels

Prefabricated wall panels being The steel formwork for the

installed in public housing core wall construction.
Installing and fixing the precast facades
into position
PRECASTING METHOD
y INDIVIDUAL MOULD METHOD
9 Using
U i mould ld which
hi h may bbe easily
il assembled
bl d out off bottom
b andd
sides, transportable , if necessary this may be either in timber or in
steel using needle or mould vibrations and capable of taking
prestressing forces.
forces
9 Used in – Rib Slab, beams, Girders window panels, box type
units and special elements.
BATTERY FORM METHOD
y BATTERY FORM METHOD
9 Battery form
B f method
h d shuttering
h i panelsl may be
b adjusted
dj d in
i the
h
form of a battery at the required distances equal to the thickness
if the concrete members.
9 Used
U d iin – Interior
I W
Walls
ll ( Panels,
P l Sh Shellll elements,
l reinforced
f d
concrete, battens, rafters , purlines, roof and floor slabs.
STACK METHOD
y BATTERY FORM METHOD
9 U d iin –
Used Fl
Floor and
dRRooff slabs
l b panels.
l
TILTING METHOD
y BATTERY FORM METHOD
9 U d iin –
Used M ld exterior
Mould i Walls.
W ll
LONG LINE PRESTRESSING BED
METHOD METHOD
y BATTERY FORM METHOD
9 U d iin –
Used D bl tees, rib
Double ib slabs,
l b purlines
li and
d bbeams.
EXTRUSION METHOD

y BATTERY FORM METHOD - Long concrete mould with

constant cross section and vibration will be done automatically just
as in concrete roads.
9 Used in – roof slabs, concrete walls, panels and beams.
Limitations of Prefabrication
1. Small number of units required may prove to be
uneconomical.
2. Special connections, such as special bearings to
t
transmit
it the
th vertical
ti l andd hhorizontal
i t l lloads,
d can add
dd
cost to the system.
3
3. Waterproofing at joints.
joints
4. Transportation difficulties.
5. Need for cranes.