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(3) Prefabricated System(a)Precast concrete panel (b)Precast concrete frame (c)Precast steel frame
Solid Block
Hollow Block
Interlock Block
Precast Panel
Precast Brick
advantages over cast in-situ construction. These include mass production of units, cost and time reduction, improved quality of units, etc. prefabricated method involves casting structural building elements within site before erecting to actual location. Offsite prefabricated method involves transferring building operations from site to factory. Prefabrication allows a component to be built whenever convenient, so long as it is delivered on time.
infilled wall, bathrooms, staircase, etc and are placed for incorporation into main units, column and beams, which are usually, cast in-situ.
KLCC
Pekeliling Flats
LRT Station
KL Tower
Characteristics of IBS
1.3.1 Five Characteristics of IBS are : a) Industrial production of components though prefabrication b) Reduced labour during prefabrication of components and site works c) Modern design and manufacturing method using CAD/CAM d) Systematic Quality Control i.e ISO 9000
This can contributes : Messy Sites, High Wastage, Labour Intensive, Low Quality and Delays
Benefits
a)Reduction of site labour b)Minimal Wastage c) Less site material d)Cleaner environment e)Controlled quality f) Neater and safer sites g)Faster project completion h)Lower total construction costs due to the above
Case Study
(a) frame system, (b) panel system, (c) box system, (d) formwork system, (e) block system
Frame System
Frame System
Frame system consists of main structural element
columns, beams, frames or trusses made of plain concrete, prestressed concrete, or steel.
Their important characteristics are the capacity to
Frame System
Frame System
THE STRUCTURAL SCHEME A multi-storey building includes the following structural components
Frame System
Figure 2.2: Typical linear prefabricated elements: (a)-(d) beams; (e), (h) joists; (f), (g) girders; (i), (j) columns; (k), (l) footings (Allen, 1999)
is spread on a concrete bearing to provide a uniform load distribution over the connected surface. The grout normally between 20-30mm thick and consists of a 1:3 cement-tosand mix with a stiff consistency.
consists of elastomeric materials (neoprene), laminated fabric, synthetic fibers, and other materials, which allow a certain degree of freedom of movement to supported members.
Bearing Pad
This pads permit a smooth and uniform transfer of load
and abutment.
angles. Steel plates are embedded into concrete elements during casting. Then steel plates between two concrete elements are either welded or bolted. These types of connection, however induce additional stress due to the nature of fixed connection.
Figure 2.3: Typical connections between frame elements: (a), (b) column to footing; (c) column to column; (d), (e) beam to column; (f) beam to girder
Connections [Figure 2.3 (d) and (e)] for the joint between
column and beam. Both elements are fixed together through a dowel sleeve entry or welding of steel fixtures. Furthermore, a corbel supported connection is preferred structurally and is mostly applied in industrial buildings.
Beam connections
A projecting concrete haunch is cast on to the column
There are three basic solutions: 1. bolted connections, 2. Projecting reinforcement 3. Pockets joint
4. 5.
In the bolted connection, the column base plate is fixed to the foundation bars with nuts. With projecting reinforcement, projecting bars from the foundation or from the column are fixed into grouted openings in the columns or in the foundation respectively. In the case of pockets, the column is fixed into the pocket with grout or concrete.
6.
CONNECTIONS
Precast columns are fixed to the foundations with pockets, projecting reinforcing bars or holding down bolts. The first solution is mainly used for foundations on good soil; the second and third in the case of foundation piles.
POCKET FOUNDATIONS
Precast pocket foundations realize the site-work faster and cheaper. Indeed, site-cast pockets need rather complex molding and reinforcement, and the working conditions are more unfavorable. The industry has developed a series of pocket foundations for different column sizes. The precast pocket foundations may only be used in conditions of firm and level ground. The pockets are positioned by means of leveling bolts. The baseplate is cast on site.
POCKET FOUNDATIONS
Column-to-column splices Column-to-column splices are made either by bolting mechanical connectors
anchored in the separate precast components or by the continuity of the reinforcement through a grouted joint.
Column connections
The main principle in constructing column connections is to ensure
continuity.
Dowel connection
For simple connection - dowel placed at the upper or lower column - If continuity of reinforcement is required the reinforcement from upper and lower column are welded or lapped before completing the connection with in situ concrete.
BEAMS
PURLINS
Purlins are used as secondary beams for roof structures with light roof cladding. The distance between the portal frames is maximum 12 to 16 m. The units are in prestressed concrete.
Purlins are mainly used in industrial storage buildings where light roof coverings such as steel sheet decking,corrugated slabs, cellular concrete slabs, etc. are used.
Purlins Connections
very large spans of up to 30m and used mostly in heavy industry buildings.
Frame system elements such as columns provide
considerable flexibility in partitioning the layout into functional spaces compared to precast panels.
Panel System
framing, panel systems can be used as non-loading bearing space enclosure functions.
to 5.5m. The width of slabs can be up to 3.6m if transported horizontally and up to 4.0m if transported vertically.
Panel Systems
(a)room-size slabs on cross walls (b)modular slabs on cross walls (c)modular slabs on exterior walls (d)slabs on beams and column
Thicknesses of 4", 6" and 8" Spans up to 25-0" Standard panel width = 4-0"
Slab
Lattice Girder
Half Slab
Half Slab
Half Slab
(h) Storage and curing PHCS Hollow core floor slabs are can be used for span up to 15.0m with thickness of up to 300mm.
Figure 2.8: Precast floor elements (a) double-tee (b) single tee; (c) cassette slab; (d) support detail
Technical Highlights:
1.One unit of 600mm x 3000mm panel (75mm & 100mm
Full-height partitions are installed in one operation; maximum height of blockwork to be laid in one day is 1.5 meters. Also, installation rates are significantly faster than masonry alternatives.
The lightweight nature of the finished partitions leads to savings in cost and time in the construction of building foundations and frames. These gains are made while retaining the solid concrete feel to finished partitions.
The innate toughness of concrete in combination with a thin finish coat yields a very high level of durability. Water saturation whether by condensation, leaks or flood will have no deleterious long-term effect on the panels.
Water resistance
With panels custom-made for each project and the small amounts of mortar and plaster required, waste is reduced to a minimum. Furthermore, the lightweight nature of the panels reduces the burden of transportation.In-use benefits of the wall systems are also significant
Box System
Different arrangements of box system: (a) separate units; (b) checkerboard pattern; (c) framed units
Box System
Box systems consist of concrete walls and floor slabs
that form together to act as structural building element. They can either be cast in box moulds or assembled in the plant from panel elements. Normally, box elements contain a substantial amount of finish works such as electrical wiring and conduits, painted, glazed doors and window frames, plumbing pipes and fixtures, and cupboards before transporting the module to an erection site.
Box Systems
Box Systems
Box Systems
Box system
Box System
Formwork Systems
Formwork systems are also referred to as
industrialisation onsite where the structural elements consist of horizontal slabs supported on a series of parallel cross wall spaced at a equal interval.
These walls and slabs are cast in-situ with steel or
aluminum mould forming them. The remaining interior and exterior walls are built conventionally or made of precast elements. The common type of formwork system are as follow.
Formwork Systems
Tunnel Forms
walls and horizontal table form for floor slabs. In addition, the two elements are cast in two separate operations.
First, the wall forms are installed and cast, followed by
removal of the forms after setting. Then, the slab table forms are erected and positioned for further horizontal slab casting.
Wall Form
Block System
Modular coordination or MC is a dimensional system. It
is a dimension and space coordination concept in which building and components are placed at their designations based on the unit or basic module known as "1M" that equals to 100 mm.
Modular System
To strengthen the wall against "bowing" in due to lateral pressure (earth, wind, seismic)
Shapes: ladder & truss Materials: Steel with various finishes and gauges
Ladder
Truss
steel rebar into open cores of the wall, then filling those cores solid with a concrete-like grout
Cell Reinforcing
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