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SUBMITTED BY-
RAJAT SINGH
MOHAK JAIN
SIDDHARTH ATREYA
MEHJABEEN SULTHANA
MOHIT RAJ
NITESH KANNAUJIA
RISHABH KAUSHIK
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Pre-Fabrication
It 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.
Pre-Fabricated Construction
A construction method relying primarily on the use of standardized
manufactured components; consists largely of assembling these
parts rather than fabricating them at the site.
Pre-Fabricated House
A house assembled from components cut to size at a factory,
or assembled from building modules shipped to the
construction site.
Pre-Fabricated Masonry Panel
A wall panel fabricated of masonry units which are bonded
together at a manufacturing plant and then transported to the
job site as a construction unit, ready for erection.
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HISTORY
Buildings have been built in one place and reassembled in
another throughout history. the first advertised prefab house was
the Manning Portable Cottage.
A London carpenter, Henry Manning, constructed a house that
was built in components, then shipped and assembled by British
emigrants.
In Barbados the Chattel house was a
form of prefabricated building which
was developed by emancipated
slaves who had limited rights to build
upon land they did not own.
As the buildings were
moveable they were
legally regarded as
chattels.
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In 1855 during the Crimean War, after
Florence Nightingale wrote a letter to The
Times, Isambard Kingdom Brunel was
commissioned to design a prefabricated
modular hospital.
In five months he designed a 1,000
patient hospital, with innovations in
sanitation, ventilation and a
flushing toilet.
Prefabricated housing
was popular during
World War II due to the
need for mass
accommodation for
military personnel. The
United States used
Quonset huts as
military buildings, and
in the United Kingdom
prefabricated buildings
used included Nissen
huts and Bellman
Hangars.
HISTORY
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McDonalds uses prefabricated
structures for their buildings, and set a
record of constructing a building and
opening for business within 13 hours on
pre-prepared ground.
In the UK, the major supermarkets have
each developed a modular unit system
to shop building, based on the systems
developed by German cost retailers Aldi
and Netto.
HISTORY
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Fabricated Unit
Fabricated are typically made of extruded or
poured metal (aluminum or steel) The units
range in scale from a small fasteners to steel
bridge trusses. For the consideration of
construction and design logics, metal
fabricated components from the single stud to
the 300-0 bridge truss are in this category.
Panel System
Panel systems contain integrated systems
within one component. Often included are
structural, thermal/waterproofing, electrical,
mechanical systems. Made up of a sandwich of
complementary materials. How the panels are
handled on site is dependent on the weight and
size of each piece.
Precast Concrete
Precast concrete is fabricated in a multitude
of sizes. Precast components are comprised
of an internal steel rebar framework and high
tolerance concrete. Concrete is meant to
withstand transport to and movement on site.
Units are limited in weight and dimensions
based on the smallest unit of transportation
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Steel Frame Construction
Fabricated Units compose the structural framing.
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Panelized construction minimizes on-site
construction. Construction materials typically
fastened on-site are compiled into a component
constructed in the controlled factory environment.
Most common type of panel system is SIPs,
structural insulated panels.
SIPs are comprised of a thick layer of insulation
between two layers of OSB, oriented strand board. A
basic SIPs panel is composed of both structure and
insulation layer.
Panel systems may increase material cost by up to
50% but on-site labor cost can potentially decrease
by 50%. The benefit exists in the precision of factory
controlled construction with isolation from problems
that exist at the site.
Installation of the panels is based on methodology
developed for the specific system.
Panel Installation Sequence
Different systems will have
different advantages: whether the
panel is lightweight or resistant to
weather, earthquakes, winds,
insects, debris.
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Precast concrete construction is most readily
seen within the city as infrastructure. It is a
versatile construction type.
Composition of Precast
Materials and Accessories
Rebar concrete: portland cement, water,
air, aggregate
Formwork:
positive/negative connection keys
Epoxy cementitious grout:
between precast segments/ components.
Structural Components
Slabs
length factor by function of service
width by transportation restriction
Beams
depth is dependent on length
length is function of capacity load
Columns
height is dependent on the width
1. Solid
2. Hollow Core
3. Single Tee
4. Double Tee
5. Rectangular
6. Inverted Tee
7. L-shaped
8. Round|Rectangle
9. Square
10. Double Height
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Advantages of Prefabrication
High capacity- enabling the realization of important projects
Factory made products
Shorter construction time- less than half of conventional cast in situ construction
Independent of adverse weather conditions during construction
Continuing erection in winter time until -20 C
Quality surveillance system
Opportunities for good architecture
Healthy buildings
Reduced energy consumption
Environmentally friendly way of building with optimum use of materials, recycling of
waste products, less noise and dust etc.
Cost effective solutions
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Disadvantages of Prefabrication
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 sections require heavy-duty cranes and precision
measurement and handling to place in position.
Larger groups of buildings from the same type of prefabricated elements
tend to look drab and monotonous.
Local jobs may be lost, if the work done to fabricate the components being
located in a place far away from the place of construction. This means that
there are less locals working on any construction project at any time,
because fabrication is outsourced
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EXAMPLES of Prefabrication
NAKAGIN CAPSULE TOWER
T30A HOTEL TOWER
GFRG Demo Building at IIT Madras
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LOCATION: TOKYO, JAPAN
BUILDING STATISTICS-
SITE AREA: 442 SQUARE METRES BUILDING
AREA: 430 SQUARE METRES TOTAL FLOOR
AREA: 3,091 SQUARE METRES.
STRUCTURE DETAILS: STRUCTURAL STEEL
FRAME PARTLY ENCASED IN CONCRETE MAX
OF 140 CAPSULE UNITS (PREFABRICATED) 11-
13 STORIES INCLUDING 1 BASEMENT
MATERIAL DETAILS: CAPSULE EXTERIOR:
STEEL WITH SPRAYED PAINT FINISH CAPSULE
INTERIOR: STEEL CAPSULE WITH CLOTH
CEILING AND FLOOR CARPET TOWERS:
CORTEN STRUCTURAL STEEL FRAME LOWER
LEVELS: FAIR-FACED REINFORCED CONCRETE
.
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Methodology: Japanese Metabolism,
physical objects are never eternal,
celebrates individualism, response to
long commutes.
Units of Prefabrication: Capsules
arrive from factory completely
prefabricated, ready to be lifted by
crane and bolted onto the
superstructure.
Structure: Steel frame with light-
weight concrete shaft which houses
vertical circulation, mechanical shafts.
Delivery: Dense urban surroundings
meant that capsules were delivered
from factory to site on the same day it
was attached to the superstructure
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THE STRUCTURE :
REPUTED TO BE THE WORLDS FIRST STRUCTURE
THAT IMPLEMENTED THE INNOVATIVE IDEA OF
CAPSULE ARCHITECTURE, KISHO KUROKAWA
DESIGNED THE NAKAGIN CAPSULE TOWER BASED
OFF OF HIS SUSTAINABILITY CONCEPT CALLED
METABOLISM.
THE NAKAGIN CAPSULE TOWER IS A MIXED-
SYSTEM STRUCTURE, UTILIZING BOTH
TRADITIONAL ARCHITECTURE WITH MODERN
TECHNOLOGY WITHIN ONE ENTITY. IT IS MADE OF
TWO REINFORCED CONCRETE AND STEEL FRAME
PILLARS OF ASYMMETRIC HEIGHTS, BOTH HOUSING
PUBLIC UTILITIES SUCH AS STAIRS, ELEVATORS,
PLUMBING, AND ELECTRICAL SYSTEMS .
THE 14-STORY HIGH TOWER HAS 140 CAPSULES
STACKED AT ANGLES AROUND THE CENTRAL CORE.
KUROKAWA DEVELOPED THE TECHNOLOGY TO
INSTALL THE CAPSULE UNITS INTO THE CONCRETE
CORE WITH ONLY 4 HIGH-TENSION BOLTS, AS WELL
AS MAKING THE UNITS DETACHABLE AND
REPLACEABLE.
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THE CAPSULE :
THE STEEL FRAME CAPSULES (WHICH
HAVE BEEN DESIGNED TO BE
REPLACEABLE, REMOVABLE, AND
TRANSPORTABLE) WERE PREFABRICATED
IN SPECIALIST FACTORIES AND
ASSEMBLED AT A PLANT BEFORE BEING
DELIVERED TO THE SITE. EACH ONE WAS
LIFTED BY MECHANICAL CRANES AND
WERE ATTACHED TO THE TOWER SHAFTS
USING 4 HIGH-TENSION BOLTS
THE CAPSULE INTERIOR WAS PRE-
ASSEMBLED IN A FACTORY THEN HOISTED
BY CRANE AND FASTENED TO THE
CONCRETE CORE SHAFT.
DETAIL OF SYSTEM OF CAPSULE JOINING TO SHAFT
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THE CAPSULE :
Capsule Axonometric
1. Plumbing, Electrical, & Waste Lines
2. Vertical Plug-In Service Fin
3. Air Conditioning Duct
4. Air Conditioning Register
5. Prefabricated Bathroom
6. Built-In Desk
7. Moveable Chair
8. Built-In Bed
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Typical Capsule Plan
1. Capsule Entrance
2. Prefabricated Bathroom
3. Air Conditioning Chase
4. Interior Finish Surface
5. Welded Light-Weight Steel Truss Member A
6. Welded Light-Weight Steel Truss Member B
7. Built-In Bed
8. Circular Window
The capsules contained a built-in bed and
drop-in bathroom unit. They were outfitted off
site and hoisted into place by crane, latching
onto the fourteen-story superstructure and its
concrete shaft of vertical circulation. All
capsules were driven in by truck the same
day they were to be plugged-in. A stop-over
happened on the outskirts of Tokyo where
the capsules got transferred to smaller
trucks.
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HE BORROWED THE CAPSULE TERMINOLOGY FROM
THE AEROSPACE INDUSTRY (ALREADY AWARE THAT
MANY SPACESHIPS HAVE IMPLEMENTED THE IDEA OF
EFFICIENT AREA-USAGE) AND RETROFITTED A
RECTANGULAR CABIN OF 8 FEET BY 12 FEET FLOOR
SPACE WITH A BUILT-IN BATHROOM, DOUBLE BED,
DESK, STORAGE SPACES, TV, TAPEDECK,
TYPEWRITER, CALCULATOR, CLOCK RADIO, AND A 2-
BURNER STOVE. IT WAS PLANNED AS A FUTURISTIC
NICHE FOR MODERN BUSINESSMEN IN TOKYO.
KUROKAWAS DESIGN CONCEPT
FOCUSES ON HOW TO MAKE
THE MOST EFFICIENT USE OF
LIVING SPACE TO
ACCOMMODATE THE EVERYDAY
ESSENTIALS OF A PERSON.
INSIDE THE CAPSULE
(2.5M X 4.5 X 2.5M) :
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Exploded Axonometric
1. Precast Concrete Shell w/ Steel Frame
2. Plug-In Service Fins
3. Lightweight Precast Concrete Floor Plates
4. Precast Concrete Lift Shaft
5. Ground Level Podium - Office Space
Armature: a framework to support the clay or other
material used in modelling.
The tower is comprised of two, interconnected towers
which serve as the framework for the capsules to rest
on. The on-site preparation work to create the armature
is the first stage.
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Components: Plan & Core
1. Typical Capsule
2. Lightweight Precast Concrete Floor Plate
3. Prefabricated Interim Bridge
4. Plug-In Service Fin
5. Precast Concrete Shell w/ Steel Frame
6. Prefabricated Lift Cage
7. Typical Floor Entrance/Exit
Aggregation: Type 1
1. Typical Side-Entry Capsule w/ Side Window
2. Typical Front-Entry Capsule w/ Side Window
3. Side Window Capsule Aggregation
Aggregation: Type 2
1. Typical Side-Entry Capsule w/ End Window
2. Typical Front-Entry Capsule w/ End Window
3. End Window Capsule Aggregation
The Aggregation & Capsule Delivery
Type 1
Type 2
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Capsule Delivery
1. Capsule Base Connections Dtail
2. Capsule Bolting Process
3. Capsule Bolting Connection Detail
4. Prefabrication - 3 Hour Assembly
5. Transportation - 500km
6. Construction - 7-8 Months
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TIME LINE
The precast concrete floor slabs that were part of the
cores structure were erected at a rate of one every two
days, alternating with the construction of the steel frame,
affording a full operational core to facilitate the periodic
construction of the framework without an external
scaffold. 144 capsules were attached to the building in
less than a month. Interestingly, the podium, which is the
most under-looked part of the project, had more
traditional construction techniques and also responsible
for much of the on-site construction time.
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T30A HOTEL TOWER
LOCATION- CHANGSHA, CHINA
HEIGHT: 99.9 meter / 328 feet
FLOORS- G+30
GROUND FLOOR AREA- 17,602 m / 189,466 ft
OWNER/DEVELOPER- BSB GROUP
(BROAD SUSTAINABLE BUILDING)
BUILDING FUNCTION- HOTEL
STRUCTURAL MATERIAL- STEEL
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A 3.915.6m main board including flooring
and ceiling, embedded shafts of ventilation,
water supply & drainage, electricity and
lighting. All needed pillars, diagonal bracings,
doors, windows, walls and even sanitary &
kitchen wares for the room installation are
placed on main board for factory shipment.
One truck can carry 120m2 main boards and
then deliver them to the construction site to
be hoisted in installation place. What all
workers need to do is just screwing bolts,
painting. Such a high-efficiency construction
mode makes on-site installation only account
for 7% of the total construction hours. This
building is 93% factory-made.
T30A HOTEL TOWER
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T30A HOTEL TOWER
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THE INSTANT SKYSCRAPER
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THE INSTANT SKYSCRAPER
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THE INSTANT SKYSCRAPER
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THE INSTANT SKYSCRAPER
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THE INSTANT SKYSCRAPER
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T30A HOTEL TOWER
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GFRG Demo Building at IIT Madras
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GFRG Demo Building at IIT Madras
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GFRG demo building at IIT Madras (1981 sq ft)
GFRG Demo Building at IIT Madras
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GFRG Demo Building at IIT Madras
TYPICAL FLOOR PLAN
BUILT UP AREA-1981.3 SQ. MT.
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