CE6016 PREFABRICATED STRUCTURES LTPC

 
UNIT I INTRODUCTION 9
Need for prefabrication – Principles – Materials – Modular coordination – Standarization –
Systems – Production – Transportation – Erection.
 UNIT II PREFABRICATED COMPONENTS 9
Behaviour of structural components – Large panel constructions – Construction of roof and floor
slabs – Wall panels – Columns – Shear walls
 UNIT III DESIGN PRINCIPLES 9
Disuniting of structures- Design of cross section based on efficiency of material used –
Problems in design because of joint flexibility – Allowance for joint deformation.
 UNIT IV JOINT IN STRUCTURAL MEMBERS 9
Joints for different structural connections – Dimensions and detailing – Design of expansion
Joints
 UNIT V DESIGN FOR ABNORMAL LOADS 9
Progressive collapse – Code provisions – Equivalent design loads for considering abnormal
effects such as earthquakes, cyclones, etc., - Importance of avoidance of progressive collapse.

TOTAL: 45 PERIODS
PREFABRICATED STRUCTURES

UNIT I
INTRODUCTION
 DEFINITION
 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 where the structure is to be
located.
 It is combination of good design with modern high
performance components and quality controlled
manufacturing procedures.
 This work is carried out in two stages,
manufacturing of components in a place other than
final location and their erection in position.
• "Prefabricated building is a type of building that
consists of several factory-built components or
units that are assembled on-site to complete the
unit. “Prefabricated” are built in:

 Components (panels)
 Modules (modular homes)
 Transportable sections (manufactured homes)
 Mobile homes (houses on wheels)
 NEED FOR PREFABRICATION
• For sites which are not suitable for normal construction
(Hilly region)
• Repeated structures (Mass housing)
• Increased Speed
• Areas in which lack of space prevails
• Proper utilization of space
• Quality
• Control over material
• Mass production of materials
• Safety
• Sustainability
• Cost – saving in manpower and material
• Time for change
 ADVANTAGES
• 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 in a

controlled environment in factories .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.
• High transport cost

• Need of erection equipment

• Skilled labour and supervision is required.

 PRINCIPLES OF PREFABRICATION
• The prefabrication will be done in two stages.
1)Manufacturing at factory condition.
2)Erection of components at required location.
• This requires certain stage of preparation. They are
i)Casting
ii)Curing
iii)Transportation and erection.
 Contd..
• 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 labor force.
Casting
Curing
Transportation and Erection
 MATERIALS
• Structural Insulated Panels (SIPs)
• Insulating Concrete Forms (ICFs)
• Prefab foundation system
• Steel framing
• Concrete framing
• Large modular system
Structural Insulated Panels (SIPs)
• Structural insulated panels (SIPs) are a high performance
building system for residential and light commercial
construction.
• The panels consist of an insulating foam core
sandwiched between two structural facings, typically
oriented strand board (OSB). 
• SIPs are manufactured under factory controlled
conditions and can be fabricated to fit nearly any
building design.
• The result is a building system that is extremely strong,
energy efficient and cost effective. Building with SIPs will
save you time, money and labor.
Insulating Concrete Forms (ICFs)
• Insulating concrete forms (ICE) are a prefab construction
material consisting of hollow EPS (Extended
Polystyrene) foam blocks that are stacked and glued
together on-site , creating the form that is filled with
reinforcing bars and concrete.
Prefab Foundation
 Steel Frames
• Prefabricating all of the structural steel and metal
components of the building in the factory eliminates
the materials waste common in traditional construction,
saving materials cost and also being more
environmentally friendly.  (Any excess materials waste
at the factory is 100% recyclable steel.)
26
 MODULAR COORDINATION
• Modular coordination is a concept of coordination of
dimension and space, in which buildings and
components are dimensioned and positioned in a term
of a basic unit or module, known as ‘1M’ which is
equivalent to 100 mm.
• It is internationally accepted by the International
Organization for Standardization (ISO) and many other
countries.
• The principle objective of modular coordination is to
improve productivity in the building industry through
industrialization.
 Establishment of Modular Coordination
• In 1936, Albert Farnell Bernis proposed a module for
mass-produced building with size of 4 inches during
world war II.
• In 1953, “ European Productivity Agency – E.P.A. ”
launch a systematic study of modular coordination and
the general agreement reached in 1955 with the
Munich Convention, called for the adoption of a module
with base M = 10cm, as common denomination for
correlating the dimensions of all elements involved in
architecture and building.
• In 1972, Malaysia adopted metric system of measure
and only in April 1986, modular co-ordination was
introduced in building industry in Malaysia.
 Advantages
• Modular coordination make single component in to
larger combinations
• Cutting wastages are minimum in the components.
• Base for standardization of mass production of
components.
 BASIC MODULE
• The fundamental module used in modular coordination,
the size of which is selected for general application to
building and its components.
• It is denoted by ‘M’.
• The value of basic module ‘M’ has been chosen as
100mm for maximum flexibility and convenience.
• The different modules are
i)Basic Module: M
ii)Multi modules: 3M, 6M etc.,
iii)Sub-module: M/2,M/4.etc.,
• In prefabricated industry a larger modular unit is called
as a project module(Mp)
 OBJECTIVES OF MODULAR COORDINATION
a)Major Objective:
• The principal objective of modular coordination is to
assist the building design, construction professionals in
building industry by standardization in such a way that
building components fit with each other, with other
components and with building assembly on site,
thereby improving the economics of building.
b)Specific Objectives:
Modular coordination
• Facilitates cooperation between building designers,
manufacturers, distributors, contractors and authorities.
• Enables building to be dimensionally coordinated so
that they can be erected with standard components
without undue restriction on freedom design.
• Permits a flexible type of standardization which
encourages the use of number of standardized building
components for the construction of different types of
building.
• Optimizes the number of standard sizes of building
components.
• Encourages as far as possible the interchangeability of
components , whatever the material form or method of
manufacture.
 MODULAR AXIS
• In the design of buildings, the modules are made as a
grid which consists of parallel lines spaced at the value
of module, M or project module (Mp).
• A grid line taken as the base for setting out the given
part of the building is called as modular axis.
• In prefabricated industry the practice is as follows
i)The horizontal co-ordination based on the project
module (Mp)=30cm.
(Note: Larger module unit is called project module)
ii)Vertical coordination based on basic module, M = 10cm.
iii)Floor height in multi storeyed building is fixed as 2.8m.
But for buildings having floor less than 15 cm, it may be
reduced to 2.7m.
iv)The c/c distance ‘L’ b/w the load bearing walls are
selected from the following i.e.,
nMp=2.7,3,3.3,3.6,3.9,4.5,5.1,5.4,5.7,6 m
v)The width of staircase measured b/w centre line of walls
is fixed as 2.7m.
vi)In large multiple projects, the dimensions are used
which are the multiples of the project module,
Mp=30cm
 Dimensioning of Prefabricates
• The three basic types of unit dimensions are
i)Design or Erection dimension(lm)
ii)Theoretical dimension(l)
iii)Actual dimension(lw)
• The production discrepancy is defined as difference
between the theoretical dimension(l) and actual
dimension (lw).
• If l<lw, the production discrepancy is positive.
• If l>lw, the production discrepancy is negative.
• In drawings (working drawings), the theoretical
dimensions of the units and the joints b/w them are
mentioned.
 Coordination of Prefabricates
i)Three dimensional coordination
- Prefabricates are connected to its neighbors in 3
directions (l,b,h).
- Eg: Wall panel
ii)Superficial coordination
- Unit is joined to other unit in 2 direction only
- Eg: l, b of a roof panel
iii)Linear coordination
- Unit is connected in one direction only.
- Eg: length of beam
 Diversity of Prefabricates

• Large prefabricated units have 3 degrees of diversity

i)I Degree of diversity
- Differ from each other in basic shape, cross section of
material and their production demand which seperate
form work and technology
- Eg: wall & floor panel.
ii)II Degree of diversity
- Different length or width but can be cast by same
methods and using same form work.
- Eg:16 module wall panel and 18 module floor panel
iii)III degree of diversity
- Difference between the units lies only in the internal
details but size or production unit is not effected.
- Those are window openings, service holes, surface
treatment etc.,
• I degree and II degree of diversity affect the capital
expenditure.
• III degree of diversity affects the basic size, production
method and erection.
• Normally larger units are made in industry.
• If units are large then less work will be on the site and
number of joints will also be less.
 STANDARDIZATION
• It is defined as the process of adoption of generally
accepted uniform procedures, dimensions, materials or
parts that directly affect the design prefabricated product or
a facility.
Advantages of standardization:
• Easier in design as it eliminates unnecessary choices.
• Easier in manufacture as there is limited variants.
• Makes use of specialized equipments easier and quicker for
erection and completion.
Factors influencing standardization
• To select the most rational type of member for each
element from point of production, assembly, serviceability
and economy.
• To limit the number of types of elements and to use
them in large quantities.
• To use the largest size to extent as possible , thus
resulting in less number of joints.
• To limit the size and number of prefabricate by weight
in overall dimension so that it can be handled well by
handling and erection equipment and can be
transported easily.
• To have all prefabricates approximately of same weight
very near to the lifting capacity of the equipment.
 SYSTEM FOR PREFABRICATES
• It is a method of construction of buildings by using
prefabricated components which are inter-related in
functions.
• The degree of flexibility varies from system to system.
• However in all the system, there is a certain order and
discipline.
• The various prefabrication system are
i)Open prefab system
ii)Large panel prefab system
iii)Frame systems
iv)Lift slab systems
v)Box type system
i)Open Prefab System
- This system is based on the use of basic structural
elements to form whole or part of building. The
standard prefab concrete components which can be
used are prefabricated slabs, prefabricated beams,
columns, precast lintels and sunshades etc.,
- Foundation for the columns could be prefabricated or
conventional cast in-situ depending upon the soil
condition and load.
- The columns may have hinged or fixed base connections
depending upon the type of components used and
method of design adopted
• Two types of open prefab system are
a)Partial prefab open system
b)Full prefab open system
a)Partial prefab open system
- This system emphasizes the use of prefabricated
roofing and flooring and other minor elements like
lintels, sunshades, kitchen sills in conventional
building construction.
b)Full prefab open system
- All structural components are prefabricated
ii)Large panel prefab system
- Based on use of large panel prefab system.
- Components used are prefabricated large panels for
walls, floors, roofs, staircases etc.,
- It is a box like structure.
- Both horizontal and vertical members are load bearing.
- The prefabricated large panel walls can be classified as
a)Cross wall system
b)Longitudinal system
a)Cross wall system
- Cross walls are load bearing and facade walls are non load
bearing.
- Suitable for high rise buildings
b)Longitudinal wall system
- Cross wall is non load bearing and longitudinal walls are
load bearing.
- Suitable for low rise buildings.
Prefabricated floors
- Depending upon the composition prefabricated floors are
classified as
a)Homogeneous floor
b)Non homogeneous floor
- Depending upon the way loads are transferred, the
prefabricated floors are classified as
a)One way system
b)Two way system

iii)Frame System
- Components are usually linear elements.
- The beams are seated on the corbels of pillars usually
with hinged joints. (rigid connection is also carried out).
- Joints are filled with concrete at site.
iv)Lift Slab System
- Partially prefabricated in plant (pillars) and partially
precasted on site (slabs).
- It consists of one or more high pillars (max 5).
- Up to 30 storey high construction is possible.
- Consists of specially designed joints and temporary
joints.
- Slabs are casted on the ground (one on top of another)
and then lifted with cranes and elevators.
Lift-Slab Procedure:
i)Pillars and first package of slabs (Eg: 5 pieces) are
prepared at the ground level.
ii)Lifting boxes are mounted on the pillars and a single slab
is lifted to first floor level.
iii)Other boxes are sequentially raised to higher position to
enable the slabs to be lifted to their required final
position. Slabs are held in relative position (temporary)
by pinning system.
v)Box Type System
- In this system room size units are prefabricated and
erected at site.
- Toilet and Kitchen blocks could also be similarly
prefabricated and erected at site.
- This system derives its stability and stiffness from the
box units which are formed by four adjacent walls
which are joined to make rigid connection.
 PRODUCTION OF PREFABRICATES
• Stand System
• Conveyor belt or production line system
• Aggregate system
Tilting Table
Battery Mould
 TRANSPORTATION
• Transportation means taking the prefabricates in a
vehicle of wagon or truck from the prefabrication
industry to the place of site work for erection.
• In addition to railway wagons, special transporters are
used to carry the prefabricated units from the factory to
the building site.
• These are designed to suit the prefabricate dimensions
and weight and convenient method of loading.
• In some places, the lorries are used to transport large
prefabricates which are equipped or having power
operated unloading derricks.(cranes or lifting
mechanism)
• The following points should be considered for
transporting the prefabricates
i) It must be carried out with extreme care to avoid any
jerk and distress in elements and handled
/transported in the same orientation as it is to be
placed in final position.
ii) It should be properly planned and conformity with
traffic rules and regulation.
iii) The size of element decide the mode and size of
transport vehicle.
iv) Check the load carrying capacity of the bridges.
vi) Avoid excessive cantilever projection while transport.
vii) Special care should be taken while moving in curves
and uneven roads which may lead to undesirable
stresses.
viii) Before loading, proper base packing materials, proper
location and packing must be done one over the other.
Delivery:
i) Delivery of prefabricate elements should be planned
according to the general erection sequence to
minimize unnecessary site storage and handling.
ii) Prefabricate elements should be loaded and delivered with
proper supports and frames. Cushioning and tie-downs to
prevent damage during transports.
iii) Adequate packing or protection to the edges of
prefabricate elements should also be provided to minimize
the risk of damage during transport.
Handling:
i) Lifting and handling position shall be clearly defined
particularly if sections are critical.
ii) It mainly involves the removal of prefabricate elements
from mould, transportation to the storage yard and
unloading operation and erection of these element at the
job site.
iii) Prefabricate elements are demoulded and transported
to the site only when concrete reach required strength.
iv) But these elements haven’t got full design strength and
prone to damage during handling.
v) So it has to be carefully handled to avoid excessive
stress during handling.
 ERECTION
• Erection of building means keeping of prefabricated
products in proper and correct position at the site.
• Before doing the erection the setting out should be
done and carefully checked with survey instruments.
• While erection the working of the crane and the correct
layout of the crane must be checked.
• Uneveness of the ground, makes it difficult to lay a
horizontal crane truck.
• When there is steep slope, high embankment is
required and this is costly and technically difficult.
• Prefabricated buildings are erected in convenient
sections.
• Sections should be correctly fixed and should be rigid in
all directions.
• The normal sequences of erections are
i)Structural wall units.
ii)Non-structural wall units (partition).
iii)Floor panels, balconies, staircase units.
iv)Specialized pre-fabricates( chimneys, ventilation
ducts, sanitary installations).
• The materials required for construction are also lifted by
crane and stacked on the floor at the place of work.
• In large panel buildings, where two external and one
internal wall panels meet at common joint, the external
panels are erected first and the joint between them is
sealed or covered and then the internal wall panel is
placed.
ERECTION PREPARATION:
i)Check the crane access to site and erection platform to
prevent cranes or trucks damaging the concrete floors
during access.
ii)Obtain verification that the erection platform can
support the erection loads.
iii) Ensure the locating dowels and levelling shims are
correctly located.
iv)Clear the site for truck.
v)Ensure sufficient space is available for precast propping
or panel bracing.
vi)Builder must ensure that adequate temporary base
restraint is provided for any prefabricate element to
prevent sliding failure at the base.
vii)Check lifting inserts are in their correct location and
recesses are cleaned in preparation for lifting.
Types of Cranes
1)Stationary Cranes
a)Guyed derrick crane
b)Climbing crane
c)Tower crane with fixed base
2)Cranes on rails
a)Portal crane
b)Tower cranes
3)Mobile crane moving on ground
a)Truck mounted
b)Crawler mounted
a)Guyed derrick crane
• Used on framed buildings for erection of floor panel,
columns and slab strips.
Guyed Derrick Crane
Climbing Crane
Tower Crane
Portal Cranes
Tower Cranes on rail
Truck Mounted Crane
Crawler Mounted Crane