A presentation on

PREFABRICATION…
INTRODUCTION

The concept of precast structures also known as prefabricated/ modular

structures. The structural components are standardized and produced in plants in
a location away from the building site. Then transported to the site for assembly.
The components are manufactured by industrial methods based on mass
production in order to build a large number of buildings in a short time at low
cost. This work is carried out in two stages, manufacturing of components in a
place other than final location and their erection in position.
 PREPARATION

This requires certain stages of preparation. They are Casting, Curing, Transportation and erection.
Casting: – Precast components are casted with controlled cement concrete in moulds of required shape
and sizes. The vibrator is used to vibrate concrete and this removes any honeycombing inside the
components.
Curing: – After 24 hours of casting, the casted components are released from the mould and transported
to curing tanks. Certain special components like railway sleepers where high strength is required are
steam cured.
Transportation and erection: – After complete curing is done the components are transported to the site
with heavy trucks and erection will be done using cranes with skilled labour force.
PREFAB BUILDING COMPONENTS
COLUMNS: – A column is a vertical member carrying
the beam and floor loadings to the foundation. It is a
compression member and therefore the column
connection is required to be proper. The main principle
involved in making column connections is to ensure
continuity and this can be achieved by a variety of
methods.
BEAMS: – Beams can vary in their complexity of design
and reinforcement from the very simple beam formed
over an isolated opening to the more common
encountered in frames where the beams transfer their
loadings to the column. Methods of connecting beams
and columns are
A precasting concrete haunch is cast on to the column
with a locating dowel or stud bolt to fix the beam.
A projecting metal corbel is fixed to the column and
the beam is bolted to the corbel.
Column and beam reinforcement, generally in the form
of hooks, are left exposed. The two members are
hooked together and covered with insitu concrete to
complete the joint. This is as shown in the figure.
WAFFLE UNIT FOR FLOORING / ROOFING: – These are
suitable for roofs / floors spanning in two directions.
They are laid in a grid pattern. These units are cast in
moulds. The saving achieved is not much. Also
Shuttering are complicated and costly. Time
consumption for construction is less
 TYPES

• Site-cast (local precast):

no transportation - the size limitation is depending on the elevation capacity only - lower
quality because directly affected by weather - proper, large

• Free space required precast at a plant:

transportation and elevation capacity limits the size - higher, industrialized quality – less
affected by weather - no space requirement on the site for fabrication - „unlimited”
opportunities of architectural appearance - option of standardized components (precast
catalogue
 ADVANTAGES

PREFAB SLAB TO BEAM CONNECTION PREFAB COLUMN TO BEAM CONNECTION

• Saving in cost, material, time & manpower.

• Shuttering and scaffolding is not necessary.
• Installation of building services and finishes can be done immediately.
• Independent of weather condition.
• Components produced at close supervision .so quality is good
• Clean and dry work at site.
• Possibility of alterations and reuse
• Correct shape and dimensions and sharp edges are maintained.
• Very thin sections can be entirely precast with precision.
 DISADVANTAGES

• Handling and transportation may cause breakages of members during the transit and extra provision
is to be made.
• Difficulty in connecting precast units so as to produce same effect as monolithic. This leads to non-
monolithic construction.
• They are to be exactly placed in position, otherwise the loads coming on them are likely to get
changed and the member may be affected.
• Disadvantages:
• High transport cost
• Need of erection equipment
• Skilled labour and supervision is required.
 CONCLUSIONS

• The prefab components and prefab structures eliminate space and time over conventional
constructions. Although prefabrication is employed to a large extent in a wide variety of countries, in
India, construction industry, in spite of its expansion continues to adopt same conventional methods.
The root of the economic problem is the fact that the majority of the households do not have the
confidence needed to construct prefab houses. These structures are easy to erect as it is light
material. This type of prefab buildings were constructed in earthquake prone areas of Lature and
Gujarat.
A presentation on
PRESTRESSING……

Presented by
Ar. Abdur Raoof Khan
PRESTRESSED CONCRETE

“PRE-STRESSED CONCRETE IS A FORM OF REINFORCED CONCRETE THAT

BUILDS IN COMPRESSIVE STRESSES DURING CONSTRUCTION TO OPPOSE
THOSE FOUND WHEN IN USE.”

IN OTHER WORDS IT IS A COMBINATION OF STEEL AND CONCRETE THAT

TAKES ADVANTAGES OF THE STRENGTHS OF EACH MATERIAL.
 THREE MAIN TYPES OF INTERNAL
PRESTRESSED CONCRETE

• PRE-TENSION CONCRETE: PRE-STRESSING STEEL IS TENSION

STRESSED PRIOR TO THE PLACEMENT OF THE CONCRETE AND
UNLOADED AFTER CONCRETE HAS HARDEN TO REQUIRED
STRENGTH.
• BONDED POST-TENSIONED CONCRETE: UNSTRESSED PRE-
STRESSING STEEL IS PLACED WITH IN THE CONCRETE AND THEN
TENSION STRESSED AFTER CONCRETE HAS HARDEN TO REQUIRED
STRENGTH
• UN-BONDED POST-TENSIONED CONCRETE: DIFFERS FROM
BONDED POST-TENSIONING BY PROVIDING THE PRE-STRESSING
STEEL PERMANENT FREEDOM OF MOVEMENT RELATIVE TO THE
CONCRETE.
PRE-TENSIONED CONCRETE

PRE-TENSIONED CONCRETE IS WHEN THE STEEL REINFORCEMENT IS STRESSED

PRIOR TO CONCRETE BEING PLACED AROUND THE STEEL.
Advantages of Pretension
• Pretension is the easiest controlled of the bonded stressing's with the least
chance of error in the bonding process.
• Tension caused by the steel is spread throughout the length of the concrete
since it is bonded within the concrete along the length of the member.
PRE-TENSIONED CONCRETE

Concerns With Pre-tension

• Usually uses a mold which is able to resist the forces within the
tendons. Which are more expensive than regular molds.
• Exception comes when the sides of the mold our anchored
allowing mold to be created between the anchors without
supporting stress.
BONDED POST-TENSIONED CONCRETE

Process
• Concrete is casted around a curved duct (usually corrugated), to
allow room for the Tendon to be inserted.
• After the concrete has hardened the tendons are pulled in tension
and then wedged.
• The duct is then injected with grout
 BONDED POST-TENSIONED CONCRETE

Advantages
– Tendons are less likely to de-stress in accidents
– Tendons can be easily 'weaved' allowing more efficient designs
– Higher ultimate strength due to bond generated between the
strand and concrete
– No issues with maintaining the anchor
 UN-BONDED POST-TENSIONING

• In post-tensioning, the steel in the concrete is stretched after the curing

process.
• Unlike bonded, un-bonded provides tendons freedom of movement by
coating each tendon with grease and covering it with a plastic sheathing.
• Tension on the concrete is achieved by the cables acting against the steel
anchors that are buried in the perimeters of the concrete.
ADVANTAGES / APPLICATIONS
Bridge decks

This innovative form is result of

post tensioning.

• Post-tensioning allows longer clear spans, thinner slabs, fewer beams and more
slender, dramatic elements.
• Thinner slabs mean less concrete is required. It means a lower overall building
height for the same floor-to-floor height.
• Post-tensioning can thus allow a significant reduction in building weight versus
a conventional concrete building with the same number of floors reducing the
foundation load and can be a major advantage in seismic areas
 ADVANTAGES / APPLICATIONS
• A lower building height can also translate to considerable savings in mechanical systems and
façade costs.
• Another advantage of post-tensioning is that beams and slabs can be continuous, i.e. a single
beam can run continuously from one end of the building to the other.
• Reduces occurrence of cracks .
• Freezing & thawing durability is higher than non prestressed concrete.
• Post-tensioning is the system of choice for parking structures since it allows a high degree of
flexibility in the column layout, span lengths and ramp configurations.
• In areas where there are expansive clays or soils with low bearing capacity, post-tensioned
slabs-on-ground and mat foundations reduce problems with cracking and differential
settlement.
• Post-tensioning allows bridges to be built to very demanding geometry requirements,
including complex curves, and significant grade changes.
• Post-tensioning also allows extremely long span bridges to be constructed without the use of
temporary intermediate supports. This minimizes the impact on the environment
and avoids disruption to water or road traffic below.
• In stadiums, post-tensioning allows long clear spans and very creative architecture.
• Post-tensioning can also be used to produce virtually crack-free concrete for water-tanks.
• The high tensile strength & precision of placement gives maximum efficiency in size & weight
of structural members.
 LIMITATIONS OF PRESTRESSING

• The limitations of prestressed concrete are few and really depend only
upon the imagination of the designer and the terms of his brief. The only
real limitation where prestressing is a possible solution may be the cost
of providing moulds for runs of limited quantity of small numbers of non-
standard units.
MACHINERY
BEAM – COLUMN JOINT
Thank you…