PRESENTATION

ON
PRE-FABRICATION
SUBMITTED TO: SUBMITTED BY:
AR. SULOCHANA DHIMAN ABHISHEK VERMA

AR. MANDEEP KAUR DARISHTI RAI

HAIZAL NAGPAL
HARSIMRAN KAUR
JYOTI GOYAL
PREFABRICATION P
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• Prefabrication is the practice of assembling components of a structure in a factory or other
manufacturing site, and transporting complete assemblies or sub-assemblies to the construction site E
where the structure is to be located. F
• Prefabricated building is the completely assembled and erected building, of which the structural parts
consist of prefabricated individual units or assemblies using ordinary or controlled materials.
A
• Prefabricated construction is a new technique and is desirable for large scale housing programmes.
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PRINCIPLES: (AIMS) P
1) To effect economy in cost. R
2) To improve in quality as the components can be manufactured under controlled conditions.
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3) To speed up construction since no curing is necessary.
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4) To use locally available materials with required characteristics.
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5) To use the materials which possess their innate characteristics like light weight, easy workability,
thermal insulation and combustibility etc. B
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NEED FOR PREFABRICATION: I
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o Prefabricated structures are used for sites which are not suitable for normal construction method such as
A
hilly region and also when normal construction materials are not easily available.
o PFS facilities can also be created at near a site as is done to make concrete blocks used in plane of
T
conventional knick. I
o Structures which are used repeatedly and can be standardized such as mass housing storage sheds, O
godowns, shelter, bus stand security cabins, site officers, fool over bridges, road bridges. Tubular
structures, concrete building blocks etc., are prefabricated structures. N
PROCESS OF PREFABRICATION P
• An example from house building illustrates the process of prefabrication. The conventional method of R
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 and to construct the house on site from these materials. E
• In prefabricated construction only the F
foundations are constructed in this way. A
While sections of walls floors and roof are
prefabricated structures with windows and B
door frame included and transported to the R
site lifted in to place by a crane and boiled
together. I
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USES OF PREFABRICATION: P
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 The most widely used form of prefabrication building and civil engineering is the use of prefabrication
concrete & prefabricated steel section in structures where a particular part or form is repeated many
E
times. F
 Pouring concrete section in a factory brings the advantages of being able to re-use moulds and the A
concrete can be mixed on the spot without having to be transported to and pumped wet on a congested
construction site. B
 Prefabricating steel sections reduces on-site cutting and welding costs as well as the associated hazards. R
 Prefabrication techniques are used in the construction of apartment blocks and housing developments I
with repeated housing units.
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 The technique is also used in office blocks, warehouses and factory buildings.
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 Prefabricated steel and glass section are widely used for the exterior of large buildings.
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 Prefabricated bridge elements and systems offer bridge designers & contractors significant advantages in
terms of construction time safety environmental impact constructability and cost. I
 Prefabrication can also help minimize the impact on transfer from bridge building. O
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ADVANTAGES OF PREFABRICATION: P
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 Self supporting readymade components are used so the need for formwork shuttering and scaffolding is
greatly reduced. E
 Construction time is reduced and buildings are completed sooner allowing on earlier return of the capital F
invested. A
 On-site construction and congestion is minimized.
B
 Prefabrication can be located where skilled labour, power materials space and overheads are lower.
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 Time spent in bad weather or hazardous environments at the construction site is minimized.
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 Materials for scaffolding is stored partly or in full and used.
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 Availability of precise structure and expect workmanship.
 Work time is reduced.
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 Fewer expansion joints are required.
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 Interruptions in connecting can be omitted.
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 Work is done with a better technology. O
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 DISADVANTAGES OF PREFABRICATION: P
 Careful handling of prefabricated components such as concrete panels or steel and glass panels is required. R
 Attention has to be paid to the strength and corrosion-resistance of the joining of prefabricated sections to E
avoid failure of the joint. F
 Similarly leaks can form at joints in prefabricated components.
A
 Transportation costs may be higher for voluminous prefabricated sections than for the materials of which
they are made which can often be packed more efficiently.
B
 Large prefabricated structures require heavy duty cranes & precision measurement and handling to place R
in position. I
 Large groups of buildings from the same type of prefabricated elements tend to look drab and
monotonous.
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 Local Jobs are lost.
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CHARACTERISTICS TO BE CONSIDERED: P
 Easy availability.
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 Light weight for easy handling and transport, and to economies on sections and sizes of foundations.
 Thermal insulation property
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 Easy workability
F
 Durability in all weather conditions
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 Non-combustibility B
 Economy in cost R
 Sound insulation. I
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MATERIALS TO BE USED IN PREFABRICATION P
SYSTEM: R
o Concrete E
o Steel F
o Treated Wood A
o Aluminium B
o Cellular Concrete R
o Light weight concrete elements
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o Ceramic products etc.
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PREFABRICATION SYSTEM: P
• The system of prefabricated construction depends on the extent of the use of prefab components, their
materials sizes and the technique adopted for their manufacture and use in building. R
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VARIOUS PREFABRICATION SYSTEM: P
 OPEN PREFAB SYSTEM
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• This system is based on the use of the basic structural elements to form whole of part of a building.
The standard prefab concrete components which can be used are: E
o Reinforced concrete channel units, F
o Hollow core slabs, A
o Hollow blocks and battens,
B
o Precast planks and battens,
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o Precast joists and tiles,
o Cellular concrete slabs,
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o Prestressed/Reinforced concrete slabs, C
o Reinforced/Prestressed concrete beams, A
o Reinforced/Prestressed concrete columns, T
o Precast lintels and chajjas, I
o Reinforced concrete waffle slabs/shells,
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o Room size reinforced/Prestressed concrete panels.
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CATEGORIES OF OPEN PREFAB SYSTEM: P
• There are two categories of open prefab systems depending on the extent of prefabrication used in the
construction as given below:
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 Partial prefab open system E
 Full prefab open system F
o PARTIAL PREFAB OPEN SYSTEM
A
This system basically emphasizes the use of precast roofing and
B
flooring components and other minor elements like lintels, chajjas, R
kitchen sills in conventional building construction. The structural
system could be in the form of in-situ framework or load bearing walls. I
o FULL PREFAB OPEN SYSTEM C
In this system almost all the structural components are prefabricated.
The filler walls may be of bricks or any other local material.
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LARGE PANEL PREFAB SYSTEM: P
• This system is based on the use of large prefab components. The 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
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off the site. E
• These panels form a box like structure. Both vertical and horizontal panels resist gravity load. Wall panels are F
usually one storey high. Horizontal floor and roof panels span either as one-way or two-way slab.
A
WALL SYSTEMS B
• Structural scheme with precast large panel wall can be classified as:
o Cross wall system R
o Longitudinal wall system
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Cross wall system C
o In this scheme the cross wall are load
bearing walls where as the façade wall are
A
non-loading bearing this system is suitable T
for high rise building.
Longitudinal wall system I
o In this case cross walls are non-load O
bearing whereas longitudinal walls are load
bearing walls. N
PRECAST FLOORS
o Precast flooring units could be homogeneous or non homogeneous. P
Homogeneous floors:
o Could be solid slabs, cored slabs, ribbed or waffle slabs.
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Non-Homogeneous floors: E
o Could be multi-layered ones with combinations of light weight concrete or
reinforced/prestressed concrete, with filler blocks.
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STAIRCASE SYSTEM I
o 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 landing O
slabs or load bearing walls. N
BOX-TYPE CONSTRUCTION
o In this system, room size units are prefabricated and erected at site. Toilets and kitchen P
blocks also be similarly prefabricated and erected at site.
o This system derives its stability and stiffness from the box unit which are formed by the four R
adjacent walls. Walls are jointed to make rigid connections among themselves. The box unit E
rests on the plinth foundation which may be of conventional rests on the plinth foundation
which may be of conventional type or precast type. F
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JOINTS: P
The joints should be provided in the light of their R
assessment with respect to the following considerations:
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• Feasibility -The feasibility of joint shall be
determined by its loads carrying capacity in the F
particular situation in which the joints is to function. A
• Practicability -Practicability of joint shall be
determined by the amount and type of Material,
B
fabrication and erection and the time for fabrication R
and erection.
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• Serviceability - Serviceability shall be determined
by the joints/expected behaviour to Repeated or C
possible overloading and exposure to climatic or A
chemical conditions.
• Fire-Proofing
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• Appearance
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JOINTS: P
• JOINT TECHNIQUES/MATERIALS
NORMALLY EMPLOYED ARE:
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• Welding of cleats or projecting steel. E
• Overlapping reinforcement, loops and F
linking steel grouted by concrete. A
• Reinforced concrete ties all round a
slab.
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• Prestressing.
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• Epoxy grouting.(adhesive)
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• Bolts and nuts connection. C
• A combination of the above. A
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COMPONENTS FIXING AND JOINTING: P
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INSTALLATION AND FIXING THE PRECAST P
FACADES INTO POSITION: R
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PRECASTING METHODS: P
 INDIVIDUAL MOULD METHOD
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• Using mould which may be easily assembled
out of bottom and sides, transportable , if
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necessary this may be either in timber or in steel F
using needle or mould vibrations and capable of
taking pre stressing forces. A
• Used in – Rib Slab, beams, Girders window B
panels, box type units and special elements. R
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 BATTERY FORM METHOD C
• Battery form method shuttering panels may be A
adjusted in the form of a battery at the required
distances equal to the thickness of the concrete T
members. I
• Used in – Interior Walls ( Panels, Shell elements, O
reinforced concrete, battens, rafters , purlines,
roof and floor slabs. N
 STACK METHOD
P
• Used in – Floor and Roof slabs
panels. R
 TILTING METHOD E
• Used in – Mould exterior Walls. F
 LONG LINE PRESTRESSING BED A
METHOD
B
• Used in – Double tees, rib slabs,
purlins and beams. R
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 EXTRUSION METHOD C
• Long concrete mould with constant
cross section and vibration will be
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done automatically just as in T
concrete roads.
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• Used in – roof slabs, concrete walls,
panels and beams.
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ON-SITE PREFABRICATION: P
In this scheme, prefabricated components are produced at site or near the site of work as possible.
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This system is normally adopted for a specific job order for a limited period. Though there is definite
economy with respect to cost of transportation, this system suffers from basic drawback of its non- E
suitability to any high degree of mechanization and no elaborate arrangements for quality control. Normal
benefits of continuity of work is not available in this system of construction. Under this category there are
F
two types that is semi-mechanized and fully-mechanized. A
• Semi-mechanized B
The work is normally carried out in open space with locally available labour force. The equipment R
machinery used may be minor in nature and moulds are of mobile or stationary in nature.
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• Fully-mechanized
The work carried out under shed with skilled labour.The equipments used are similar to one of factory
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production. This type of precast yards will be set up for the production of precast components of high A
quality, high rate of production.
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OFF-SITE PREFABRICATION: P
FACTORY PREFABRICATION R
Factory prefabrication is resorted to in a factory for the commercial production for the
manufacture of standardized components on a long-term basis. It is a capital intensive production E
where work is done throughout the year preferably under a closed shed to avoid effects of
seasonal variations. High level of mechanization can always be introduced in this system where
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the work can be organized in a factory-like manner with the help of a constant team of workmen. A
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PREFAB BUILDING COMPONENTS: P
• Flooring R
• Roofing E
• Beams F
• Columns A
• Walls B
• Staircase R
• Lintels I
• Sunshade/Chajja
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projections
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COLUMNS: P
 A column is a vertical member carrying the beam and floor loadings to the foundation.
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 It is a compression member and therefore the column connection is required to be proper.
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 The main principle involved in making column connections is to ensure continuity and this can be
achieved by a variety of methods. F
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Column to Column Connection
 BEAMS: P
 Beams can vary in their complexity of design and reinforcement from the very simple beam formed over R
an isolated opening to the more common encountered in frames where the beams transfer their loadings
to the column.
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F
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 A
beam.
 A projecting metal corbel is fixed to the column and the beam is bolted to the corbel.
B
 Column and beam reinforcement, generally in the form of hooks, are left exposed. The two members R
are hooked together and covered with insitu concrete to complete the joint.
 This is as shown in the figure.
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P
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WAFFLE UNIT FOR FLOORING/ROOFING: P
 The saving achieved is not much. Also Shuttering are complicated and costly.
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 Time consumption for construction is less. E
 These are suitable for roofs / floors spanning in two directions. F
 They are laid in a grid pattern. A
 These units are cast in moulds. B
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 P
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SLAB TO BEAM CONNECTION N
THANK YOU