INTRODUCTION

UNIT - I

Topics

Need for Prefabrication

Principles
Materials
Modular Coordination
Standardization Systems
Production
Transportation
Erection

Prefabrication

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 form of prefabrication in building and

civil engineering is the use of Prefabricated Concrete &
prefabricated steel sections in structures where a particular
part or form is repeated many times.
Pouring Concrete section in a factory brings the advantages
of being able to re-use moulds and the concrete can 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 hazards.
Prefabrication techniques are good in the construction of
apartment blocks and housing developments with repeated
housing units.
The technique is also used in office blocks, warehouses and
factory buildings.

Uses of Prefabrication
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.
Radio towers for mobile phone and other service often
consist of multiple prefabricated sections.
Prefabrication 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

Advantages of
Prefabrication

Self supporting readymade components are used. So, the

need for work shuttering and scaffolding is greatly reduced.
Construction time is reduced and buildings are completed
sooner allowing an earlier return of the capital invested.
On site construction and congestion is minimised.
Quality control can be easier in a factory assembly line
setting than a construction site setting.
Prefabrication can be located where skilled labour is more
readily available and costs of labour, power, materials,
space and overheads are lower.
Time spend in bad weather or hazardous environments at
the construction site is minimized.

Disadvantages of
Prefabrication

Careful handling of Prefabricated components such as concrete

panels or steel and glass panels is required.
Attention has to be paid to the strength and corrosionresistance of the joining of prefabricated sections to avoid
failure of the joint.
Similarly, leaks can form at joints in prefabricated components.
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.
Large Prefabricated Structures require heavy-duty cranes &
Precision measurement and handling to place in position.
Large group of buildings from the same type of Prefabricated
elements tend to look drab and monotonous.
Local jobs are lost.

Principle

The Main reasons to choose Precast

Construction method over conventional in
method.
Economy in large scale project with high degree of
repetition in work construction.
Special requirement in finishing.
Consistency in structural quality control.
Fast speed of construction.
Constraints in availability of site resources(e.g.
materials & Labour )
Other space & environmental constraints.

Prefabricated Materials

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 materials are aluminium, steel,
wood, fiber glass and concrete.
Prefabricated metal buildings use galvanized Steel and
galvalume as the chief material for building. Galvalume is a
form of Steel coated with aluminium Zinc. This is to protect
the building against corrosion rust and fire. It also provides
a steady and protective covering to the prefabricated
building. Almost all the components of a metal building
such as beams, frames, columns, walls & roofs are made of
steel. Most prefabricated military buildings use steel or
aluminium frames.
Synthetic materials are used for the walls & roofs. To
provide enhanced security a combination of both metal and
cloth materials are used. Plastic flooring materials can be

Prefabricated Materials
are cheaper building materials and are eco-friendly & affordable
than regular brick and concrete buildings. Materials like steel,
fiber glass, wood and aluminium are used as prefabricated
building materials for sports buildings. These materials provide
flexibility and are preferred for making structures and
accessories like stands and seats for stadium and gyms.
For making low cost housing, prefabricated materials like straw
bale, Ferrocement, calcium silicate. Products, composites and
other cheap wood based materials are currently being used.
Calcium silicate bricks are strong and durable. Ferro cement
consists of a cement matrix reinforced with a mesh of closelyspaced iron rods or wires. In this type of construction, the
techniques used are simple & quick.
Using Prefabricated materials one can make durable water and
fire resistant and cheap prefabricated buildings.

Modular Coordination

Modular
coordination
means
the
interdependent
arrangement of a dimension based on a primary value
accepted as a module. The strict observance of rules of
modular coordination facilitated,
Assembly of single components into large components
Fewest possible different types of component
Minimum wastage of cutting needed

Modular coordination is the basis for a standardization of a

mass production of component. A set of rules would be
adequate for meeting the requirements of conventional and
prefabricated construction. These rules are adaptable for,

Modular Coordination

The planning grid in both directions of the horizontal plan shall be

3M for residential and institutional buildings,
For industrial buildings,

15M for spans up to 12m

30M for spans between 12m and 18m
60M for spans over 18m

The centre lines of load bearing walls shall coincide with the grid
lines
In case of external walls the grid lines shall coincide with the
centre line of the wall or a line on the wall 5 cm from the internal
face of the wall.
The planning module in the vertical direction shall be 1M up to and
including a ht of 2.8M.
Preferred increments for the still heights, doors, windows and
other fenestration shall be 1M.
In case of internal columns the grid lines shall coincide with the
centre lines of columns. In case of external columns, the grid lines
shall coincide with the centre lines of the columns in the storey or
a line in the column from the internal face of the column in the top

Modular Coordination

A basic module can be represented as module and for

larger project modules are represented as a Mp.
For eg: For a project module in horizontal coordination, the
component can be of 30cm and for vertical component size
be of 10cm.
The storey height is fixed between finished floor levels as
2.8m and if the thickness of slab is <15cm storey height is
fixed as 2.7m. The centre distance between the load
bearing walls can be chose from a set of modules. The use
of other dimensions is not allowed.
In the design of a building, modular grid can be used
consisting of parallel line spaced at a value of module M or
Mp and a grid line chosen as a base for setting out a part of
a building becomes a modular axis. In the fig (a),, a typical
grid is chosen for load bearing walls without duct. The
interior walls are placed so that their centre lines coincide

Systems of Prefabrication

System is referred to a particular method of construction of

buildings using the prefabricated components which are inter
related in functions and are produced to a set of instructions.
With certain constraints, several plans are possible, using the
same set of components, the degree of flexibility varies from
system to system. However in all the systems there is a certain
order and discipline. The system of prefabricated construction
depends on the extend of the use of prefab components, their
characteristics to be considered in devising a system:

Intensified usage of spaces

Straight and simple walling scheme
Limited sizes and numbers of components
Limited opening in bearing walls
Regulated locations of partitions
Standardized service and stair units
Limited sizes of doors and windows with regulated positions
Structural clarity and efficiency
Suitability for adoption in low rise and high rise blocks
Ease of manufacturing storing and transporting
Speed and ease of erection
Simple jointing system

Systems of Prefabrication

a) Based on Disuniting of member

b) Based on the construction
Based on Disuniting of member:

1. System consisting of linear member disunited at joints

2. System for prefabricates of entire rigid frame
3. System consisting of I,T,U of straight members disunited at points of minimum
moment.
4. Two hinged and three hinged arches

Systems of Prefabrication
A) System consisting of linear member disunited at joints:
Advantage:
Disuniting at joints gives linear member. This means that a great
advantage and facilitates from the view point manufacture and
assembly.

Disadvantage:
Joints are at corners i.e. at points of maximum moment values, so
forming the joint is difficult.
2. Joints must be over dimensioned to cope with in-situ concreting. And
one alternate solution to replace moment resistant joints by hinged
connection.

Systems of Prefabrication
B) System for prefabricates of entire rigid frame:
In this system, to reduce the no of joints and to precast larger numbers
I one piece leads to the prefabrication of entire frame. Production of the
frames does not cause any particular trouble but the hoisting is more
difficult and requires careful preparation.
The stress distribution of straight members during hoisting is in general
statistically determinate.

Advantage:
It is ideal for site prefabrication.
Small number of joints so rapid prefabrication work is possible.
Suitable for long walls consisting of great number of uniform frames.

Systems of Prefabrication
C) System consisting of I,T,U of straight members
disunited at points of
minimum moment:
Another method of disuniting of structures is by division into different
membranes at points where the moments are thin or smallest. This method
is called as lambda method. Using this method hinge joints are made.

Advantage:
Functions are made at points of minimum moments or at points of contra
flexure.
Disuniting the main girder in this manner makes the application of different
skylights possible.

Disadvantage:
Hosting and temperature bracing of L joined asymmetric frame members is
particularly complicated.
Temperature resting of frame member on each other necessitates the use
of cantilevers having half depth and proper forming of this cause difficulty.

Systems of Prefabrication
D) Two hinged and three hinged arches

Arched structures are normally two hinged and three hinged arches. Arched
structures are normally used for bridging span more than 20-25m. Their
production and placing is more difficult than straight members. Arch can be
two hinged and three hinged but they can also be fixed at footings and can
be constructed with or without tie.
These members are generally precast and assembled in statistically
determinant three hinged variance and middle hinge is only eliminated
after placing is finished. The reinforcing bars protruding both sides are
welded together and the joint between the members is filled in with In-situ
concrete.
Arch structure can be precast in either vertical or horizontal positions. In
the first case,
shuttering made of timber or concrete is required having the same
curvature s the arch itself.
The prefabrication of larger arches in the horizontal position is found to be
more economical.
The construction of arch
trusses can be properly
carried out in the horizontal
position only.

Production

Site prefabrication - for large prefabricates

Plant prefabrication - large scale production

Site prefabrication:

The RC members are produced t the site in the open air chiefly in the
open air or in the temporary sheds
The difficulties in construction in general are felt in this
mechanization can case.
Mechanization can not be of such high degree as site PF is done for
smaller duration of time.
When the pre fabricates are of large size it is difficult to transport the
pre fabricates to the site.
In comparison with plant prefabrication transportation of the
members are not needed. As large members are not transported the
design and weight of the prefabricates are not limited.

Production
Plant prefabrication

The members produced are to be transported t the place of

construction this accounts for about 10-15% of the cost of production
and assembling.
Certain restriction is made in the dimension of prefabrication leading
to restraints in the design and development of prefabrication.
Prefabrication is appropriate for mass production for manufacture of
standardized members.
Needs costly materials for batching and production.
This method is most suited in the case of small prefabricates which are
to be prefabricated in very large number.
Plant prefabrication is done under permanent plant or factories. It is
done under the covered roof so the effect of weather does not affect
the work. So the quality and strength of the members can be improved
considerably. Plant prefabrication reduces the cost of prefabrication if
the number of prefabricate needed is more.

Production
Dimensions of prefabricate:
There are 3 commonly known dimension for the prefabricates.
The design of the erection dimension governing the dimensional
coordination of the prefabricates.
Theoretical dimension
The actual dimension of the element when delivered the design
dimension should be a multiple of a basic module size m or of a
module lmp.

Production of prefabricates:
Production techniques involved are

Stand method
Conveyor method or line method
Aggregate method

Production
Stand Method:
In this method, the prefabrication mature where they are moulded while the
production teams moves to successive stands. The bed on which
prefabricates are cast may be fixed or movable. Tilting forms are often used
and in this method steam curing is generally done.
Conveyor belt method:
The whole production is split up in to series operations carried out at
separate successive and permanent points served by specialized teams. The
movement of the mould or prefabricate one point to other vary by means of
conveyor belt trolleys. The rigid steel forms are assembled at station 1 where
they are mould, oiled to reduce the adhesion of concrete. The conveyor
moves from 1 to 2 where prestressing wires are fixed & in the next station
anchoring of the wires is carried out. The prepared mould is then carried to
the station 4 i.e. casting station. After casting ,it is shifted to the vibrating
table & finally stacked @ station 5 for setting. After that it is passed through
tunnel autoclave for curing. After steam curing move to station 7 for
demoulding & is finally stacked @ 8.

Production
Aggregate method:
In the aggregate method, aggregate describes large complex
permanently installed machines & mechanical appliances which
carry out most of the separate operations involved in the casting
of the concrete composition. The stand is operated by a
permanent team & the only move the prefabricate makes is to the
maturing point.
Aggregate method is used in the production of multi duct hollow
floor pannel in Poland. At production point the reinforcement is
fixed in the form & remote controlled aggregate(machine) inserts
the duct formers, cast & vibrates the concrete, floats @ the top of
the floor. The prepared prefabricate then move to the autoclave
chamber in which hardening of concrete is accelerated. In many
factories combined technology are employed when complex
prefabricate are required.

Transportation & Hoisting

The different cranes used for hoisting are:

Truck cranes
Gantry cranes
Mast cranes
Derrick cranes
Twinned mast cranes

Truck cranes:

Truck cranes consists of chassis including mortar and pivoting

upper part. These cranes are mobile and an travel on their own
needs. Different features are:
Weight of the crane while travelling is 31.8 tonnes
Maximum height of hoisting hook is 36.6m
Crane can rotate through 360.

Disadvantage:
Needs firm and compact soil.

Transportation & Hoisting

Gantry Cranes:

These cranes are used mainly to serve the operation

of manufacturing and storing areas in prefabrication
plants.
Capacity 5T, Total weight 4.5T
Horizontal distance between 2 tracks is 7.8m
Maximum height is up to 11m
Mast height 10.9m and it can hoist up to 20 tonnes in operation.

Mast Cranes:

These are wide spread hoisting devices, simple and cheap.

Operation requires great skill and practice. Useful in
hoisting prefabricates in vertical direction. Suspension load
can be slightly moved forward by slackening the rear staying
cable. Hoisting load is done by a winch.

Transportation & Hoisting

Twinned mast cranes:
It is used for hoisting member to great height. It consists of two steel column
assembled from sections and connected at top by bridging structure.
Hoisting capacity using two cranes each of 35-70T
Operation of the crane required minimum 16 workers.
The crane can be transferred but takes 1-2 days and is suitable for high lifting
but difficult to operate.
These are now a days replaced by 30T mast cranes hinged in 2 directions.

Derrick cranes:

Highly efficient lifting machines

It is stable or movable
Capacity 20-40T
Suitable for prefabrication halls
These cranes have booms which can
move in horizontal directions.

Transportation & Hoisting

Prefabricated structures are erected in convenient sections which when

fixed correctly should be sufficiently rigid in all directions. Normal sequence
of erection is

Structure units- external load bearing walls, columns, etc.

Non structure units- internal walls, partition walls, etc.
Floor panels, balconies, stair units
Specialized prefabricated units- chimney flumes. Ventilators,
installation.

sanitary

If the external walls are hand laid from small blocks or bricks, all necessary
materials should be hoisted by crane and stacked near the ultimate
position. The masonry work is begun after the floor immediately above is
laid.
The tolerances are comparatively strict and are normally complied with the
use of a skilled erection gang. The distance between the walls are
measured with the steel tape and the thickness of joint with rule having
mm scale. The accuracy is verified by means of surveying instruments
after all joints are connected or erected.

Transportation & Hoisting

Hosting of Columns:
The hoisting machine for small column is less than five tones. First of all
pick up gear must be assembled on to the column and the column is then
under pinned. Thereafter the column is lowered temporarily on to a sheep
shoe assembled at the foot and the roller track is pushed under the shoe.
When column is hoisted the pick up points moves vertically and bottom
resting on the roller tracks shifts towards the footing. When the column is
lifted to the required height, the retaining cable is used to decrease and
finally stop the Swinging motion of the column.
The hoisting and fixing up of the beams:
Pick up and hoisting
Beams in general are lifted at two points depending on the weight and
dimensions as well as the load bearing capacity of hoisting machines. The
hoisting girder which is heavy to a great can be executed with hydraulic
jacks. The jacks are lowered and the beam is placed to the required
position to the column.
Suspension:
For lifting up of trusses and large beams of length 25-30m. care is taken to
lift the rocker in uniform rate with two hoisting machines otherwise the

Questions