PREFABRICATION

The concept of precast (also known as prefabricated) construction includes

those buildings where the majority of structural components are
standardized and produced in plants in a location away from the building,
and then transported to the site for assembly. These components are
manufactured by industrial methods based on mass production in order to
build a large number of buildings in a short time at low cost. The main
features of this construction process are as follows:
1. The division and specialization of the human workforce
2. The use of tools, machinery, and other equipment, usually automated, in
the production of standard, interchangeable parts and products
This type of construction requires a restructuring of the entire conventional
construction process to enable interaction between the design phase and
production planning in order to improve and speed up the construction. One
of the key premises for achieving that objective is to design buildings with a
regular configuration in plan and elevation.

ADVANTAGES OF PREFABRICATION
High quality product
Labor related savings
Savings in time
Overall efficiency is greatly increased
Mass production is easier and quick
Protected and controlled production environment
Potential for lower production costs and other cost savings
Independence of climatic conditions
The disruption of traffic is avoided
Ensures high degree of Safety





OPEN PREFABRICATION SYSTEMS
In view of the limitations inherent in the closed system, an open system
which allows greater flexibility of design and maximum coordination
between the designer and precasted has been proposed.
This system is plausible because it allow the precasted to produce a limited
number of elements with a predetermined range of product and at the
same time maintaining architectural aesthetic value.
In spite of many advantages inherent in an open system, its adoption
experiences one major setback. For example, joint and connection
problem occur when two elements from different system are fixed
together.
This is because similar connection technology must be observed in order
to achieve greater structural performance.
Partial prefabrication can be usefully employed for practically every part of
a building - foundations, walling systems, doors and windows, roofing
systems, lintels and staircase elements. Costs of a roof being one of the
major components of the construction outlay in any building project, one of
the thrust areas has been the prefabrication of roofing elements
Partial Prefabrication
Open prefab systems based on an appropriate production level and small,
easily to handle elements with rationalized production methods have
attracted the attention of housing experts as an important option for
arresting the rapidly rising escalation in the costs of material and labor.
Building Centers in different regions of India have been instrumental in
propagating several of these prefab systems at the grass-root level.
These are of two types:
1. Partial open prefabrication system
2. Full open prefabrication system
Large Panel Prefabrication System
The designation large-panel system refers to multistory structures composed of
large wall and floor concrete panels connected in the vertical and horizontal
directions so that the wall panels enclose appropriate spaces for the rooms within a
building. These panels form a box-like structure. Both vertical and horizontal panels
resist gravity load. Wall panels are usually one story high. Horizontal floor and roof
panels span either as one-way or two-way slabs. When properly joined together,
these horizontal elements act as diaphragms that transfer the lateral loads to the
walls.
Depending on the wall layout, there are three basic configurations of large-panel
buildings:
Cross-wall system. The main walls that resist gravity and lateral loads are placed in
the short direction of the building.
Longitudinal-wall system. The walls resisting gravity and lateral loads are placed in
the longitudinal direction; usually, there is only one longitudinal wall, except for the
system with two longitudinal walls developed in Kazakhstan.
Two-way system. The walls are placed in both directions.
Thickness of wall panels ranges from 120 mm for interior walls to 300 mm for exterior
walls. Floor panel thickness is 60 mm. Wall panel length is equal to the room length,
typically on the order of 2.7m to 3.6 m. In some cases, there are no exterior wall panels
and the facade walls are made of lightweight concrete.
In this system, vertical wall panel connections are accomplished by means of groove
joints, which consist of a continuous void between the panels with lapping horizontal
steel and vertical tie-bars. Horizontal joint reinforcement consists of dowels projected
from the panels and the hairpin hooks site-welded to the dowels; the welded length of
the lapped bars depends on the bar diameter and the steel grade. Vertical tie bars are
designed for tension forces developed at the panel intersections.
The techniques to be adopted depend upon the needs of the client and the level of the
economy to be achieved
Large panelled buildings are also built very fast and this is one of the methods of solving
the housing problem in the country.
Large panel partial prefabricated system is much more economical than full prefabricaed
system
Lateral stability of a large-panel building system typical is provided by the columns
tied to the wall panels. Boundary elements (called bulbs) are used instead of the
columns as stiffening elements (Stiffeners)at the exterior, as shown in Fig. The
unity of wall panels is achieved by means of splice bars welded to the transverse
reinforcement of adjacent panels in the vertical joints. Longitudinal dowel bars
placed in vertical and horizontal joints provide an increase in bearing area for the
transfer of tension across the connections.
METHODS OF PREFABRICATION
INDIVIDUAL MOULD METHOD
In this method each components of building
made in individual mould.
Like : wall, beam, roof, pile, etc.
BATTERY METHOD
In this walls are made and
spaces used for curing.
STACK METHOD
In this horizontal module are made. Like slab.
TILTING METHOD
PRE-STRESSED LONG LINE METHOD
EXTRUSION METHOD
Unlimited length.
Used self consolidation.
No vibrator.
CURING
This was the process to hardening.
It is artificial curing method which in turn will allow the elements to be demoulded much
earlier permitting early re-use of the form.
STEAM CURING
Steam curing may be done under high pressure and high temperature in an autoclave.
This technique is more suited to smaller elements.The temperature having around 80
degree cel.
BY HEATING THE AGGREGATE AND WATER BEFORE
MIXING THE CONCRETE.
By heating of the aggregates as well as water to about
70 degree cel. to 80 degree cel. before making the
concrete mix and placing the same in the moulds,
sufficiently high earlier strengths are developed to
allow the elements to be stripped and transported.
Steam injection during mixing of concrete.
In this method low pressure saturated steam is injected
into the mixer while the aggregate are being mixed.






HEATED AIR METHOD.
The concrete elements are kept in contact with hot
air with a relative humidity not less than 80 percent.
This method is specially useful for light concrete products.
ELECTRICAL METHOD
The passage of current through the concrete panels
generates heat through its electro-resistivity and
accelerates curing. In this method, the concrete is
heated up by an alternating current ranging from
50 volts for a plastic concrete and gradually increasing
to 230 V for the concrete.
CONSOLIDATION BY SPINNING.
Such a method is generally used in the centrifugal moulding of pipes and such units. The
spinning motion removes excess water, effects consolidation and permits earlier
demoulding.
ASSEMBLY OF ELEMENTS: JOINT DETAILS
Dry Assembly: Direct Bearing

When concrete rests directly on concrete (the load is transferred mainly by the
stiffer constituentsthe pieces of coarse aggregate in the concrete Dry assembly
means that no mortar is used and therefore the joint is not waterproof. Only
compressive forces can be transmitted, although a certain amount of lateral force
can also be resisted as a consequence of friction. The magnitude of the frictional
resistance depends on the magnitude of the vertical load. A simple pin connection is
sometimes used Pins are necessary for structures which include inclined elements.
The points to be noted when using pin connections are:
(i) Avoid the use of two pins wherever possible These tend to restrain the
deformation and to cause cracks.
(ii) Grouting may be needed to protect a steel pin from corrosion. Small steel
projections may sometimes be sufficient to act as pins.


Dry Assembly: Use of Layers
Dry mortar, bituminous felt, plastics and sheet lead are some of the various materials used to provide an
even bearing surface. The application of a glue, epoxy-based or polyester-based, is a recent development;
up to the present time this has only been used in special cases.
Wet Assembly
Joints of cement mortar, 10-20 mm thick, between the elemen canbe used to transmit compression and
certain amount of shear A joint with lapped reinforcement bars is able to transmit both compression and
tension, and also some shear. Temporary formwork is required while the joint is cast. In cold climates care
should be taken to ensure that this additional concrete does not freeze; in hot dry climates, on the other hand,
precautions should be taken to ensure that the water in the concrete does not evaporate causing the joint
material to suffer excessive shrinkage. The main disadvantage of wet assembly is its delaying effect on the
construction programme. Time must always be allowed for the connection to gain its necessary strength.

Joints Between Wall Panels

The joint faces may be straight or may have shear keys.
Examples of both are shown in Sealing strips are inserted in
the joints, to provide tolerance during the erection of the wall
panels.
Vertical joints
Horizontal joints
Wall panels can be positioned by means of levelling
bolts fixed to the wall panels of the storey below. The
gap between the wall and floor panels is filled with
mortar with a minimum strength of 15N/mm
2
. This
process calls for precision in alignment, especially
during the placing of the units.
JOINTS

Joints, and particularly horizontal joints, require very careful attention if they are to
remain watertight for a number of years. The placing and packing of watertight
mortar has proved to be markedly less efficacious than has often been assumed in
the past, since the facade elements are subject to deformations due to temperature
changes from bright sunlight and heavy rain on one face. A better form of
construction may prove to be of the type shown in, with a cavity in the central part
of the joint; in this, small amounts of moisture penetrating through the joint
material can be allowed to evaporate or drain off into the cavity. This type of joint
has been indicated .If the prevailing direction and force of the wind are such as to
make water penetration more severe, a double sealing system may be needed. No
single solution exists, since there is no single type of climate. A number of possible
solutions are superimposed in Fig. 6.16, which is not intended as an example of
belt, braces, and crossed fingers.

TYPES OF CONCRETE ADMIXTURE
water reducing/plasticizing
high-range water reducing/superplasticizing
water retaining (Note: this type is intended to
reduce bleeding from concrete; it is little used
in the UK)
water resisting (Note: this type is frequently
known as waterproofing admixture);
air entraining;
set accelerating;
hardening accelerating;
set retarding;
*set retarding/water reducing/plasticizing;
*set retarding/high-range water reducing/
superplasticizing;
*set accelerating/water reducing/plasticizing.
Admixtures are now widely accepted as materials that contribute to the production
of durable and cost-effective concrete structures. The contributions include
improving the handling properties of fresh concrete, making placing and
compaction easier, reducing the permeability of hardened concrete, and providing
freeze/thaw
resistance.
Admixtures
Examples of other admixture types
corrosion inhibiting
shrinkage reducing
for use in underwater concrete
for use in precast concrete.
For designed concrete, admixtures are frequently used to help achieve the
following properties:
compressive strength
consistence
density
air content
strength development
retarded stiffening
resistance to water penetration
other special properties (e.g. accelerated
stiffening, high early strength development).
Admixtures will normally be used in designed and designated concrete. The
concrete producer should be left to select the most appropriate admixture to
contribute to achieving the specified concrete properties.
Designed and designated
concrete
Prefabrication in slab columns and beam
Prestressed rectangular beam

Variable width :from 15cm to 60cm,
variable height from 15cmto 70 cm.

It is compatible with all slab
including the
prestressed slab in the market ,
namely the hollow core slab,
the prestressed ribs and blocks ,
the predalle and the conventional
insitu cast slabs.
Therefore , It is is provided with a
double strip on top to
insure the proper level to the slab
components.
Advantages
Large span up to 17.00m,higher
fire resistance up to 4 hours
A smooth finishing with chamfered angles
quick erection
Withstand higher load
it could be manufactured with high concrete resistance up to 50 MPa

Design code and quality control
The structural and seismic design are to French code BPEL 91.
The Fire resistance is also to French code DTU 1987.
The quality control is carried out in our factory material laboratory on daily basis .
The client will be provided with the test results on the ordered products.
Standard box dimensions: 6.00m x 3.60m x height 2.40m
or 2.80m

Multistorey arrangement : a ground floor plus three stories. combine
this module to get several models. Standard design houses is done
Scope of use
This System is designed for villas and small constructions, such as:
commercial offices, residential houses, construction site offices,
newspaper kiosk, gasoline station, resting area on the highways,
guardian house, sentry box With the possibility of building two stories
and more.
PRACTICE FOR DESIGN AND CONSTRUCTION OF FLOORS AND ROOFS USING PRECAST
REINFORCED/PRESTRESSED CONCRETE RIBBED OR CORED SLAB UNITS
A breakthrough in housing technology is necessary to build houses at affordable cost on mass scale.
The technology of complete fabrication will greatly speed up housing construction on mass scale.
However, it may not result in cost reduction. As such. Appropriate technology based on use of
indigenous resources has to be developed.
Partial Prefabrication employing the use of prefab building components, particularly for flooring can
reduce the cost as well as time of construction.
The success can be achieved once we have traversed some part PF learning curve (after constructing few
buildings
The prefab floor slabs can rest on insitu RC frames or load bearing walls. Keeping in mind the above
parameters, an attempt has been made to study two types of precast slabs for use in

Mass Housing as well as in industrial plants.
(a) Hollow Core Slab.

(b) Inverted Tee Beams with Hollow Blocks.
Hollow Core Slabs (HCS) are favorites of both, the Structural Engineers and the
Contractors the world over.
1. The cost of HCS is comparable with that of solid slabs and is usually available off the self
in standard width of 1200 mm.
2. The HCS are produced in North America and Europe by extrusion process and are of
prestressed concrete.
3. The high cost of machinery and infrastructure prohibits the construction of HCS @ a
centralized precasting plant in India.
4. The HCS that we are proposing is of reinforced concrete, up to a maximum span of 6.0 m
and easy to mass produce at site without any special machinery or resource.
5. The code for design and construction of precast HCS units is IS 10297 - 1982. However,
our design does not wholly confirm to IS 10297.
Hollow Core Slabs
Inverted Tee Beams with Hollow Blocks

PRECAST COLUMN TO BASE CONNECTION IN A SOCKET
PRECAST COLUMN TO COLUMN CONNECTION BY WELDED STEEL BEARING FACES
Mega Homes: Residential multistory building system
Mega Homes is a comprehensive precast concrete modular
housing system designed for a ground floor+3 stories.
It is composed of single footings, ties, prestressed concrete
slab made of rectangular beams and hollow core slabs.
The ground floor is an elevated slab.
The external walls are 15cm thermally insulated precast
concrete sandwich panels.
While internal walls surrounding the stair case and
separating the contiguous apartments are solid precast
concrete.
Complementary finishing
Mechanically toweled
screened over the slab,
gypsum board partitions,
electrical works,
aluminum carpentry and
wooden carpentry,
painting, mechanical and electromechanical
Ferro-cement techniques
Ferro cement, a composite
comprising cement mortar as the
matrix and uniformly distributed
fine wire mesh as the
reinforcement.
it is a material ideally suitable for
high level prefabrication and for the
production of light weight elements
for use in the building industry.
Prefabricated ferrocement panel
Many different shapes of such elements have been explored and, among
them channel elements appear to have an enormous potential in the
development of a fully industrialized housing system.
It can be used for load bearing wall, partition wall, floor and ceiling.

Details of ferrocement box section

Precast ferrocement jackets for brick masonry
columns
IMPORTANT POINTS.
1. A ferrocement is a thin wall of reinforced cement, where layers of continuous mesh are
covered on both sides with mortar.
2. Ferrocement elements are durable, versatile, light and waterproof.
3. A ferrocement channel (FC) is a longitudinal element of a curved section (often semi-
cylindrical). It is precast using moulds.
4. A ferrocement channel uses less cement and steel while having the same strength as the
same RCC.
5. FC are used for floors or roofs, but are bad thermal insulators.
6. A major cost reduction is achieved compared to RCC.
7. A simple and cheap manufacturing set up is needed but the areas for prefabricating and
curing need to be quite large.
8. It is easy to acquire the skill and easy to manufacture.
9. A constant quality control is needed during the manufacturing process and a proper curing
is needed for one month
10. If the channels are not manufactured on site, transportation has to
11. be organized while taking care against damage.
12. Ferrocement channels are lifted into place and can immediately be joined together in order
to provide a shelter.
13. No need of scaffoldings, shuttering, concrete mixer or vibrator.
Projects..
PRE-FABRICATED EARTHQUAKE
RESISTANT BUILDING FOR LOW
INCOME HOUSING
STRUCTURAL PERFORMANCE DURING EARTHQUAKES
General concept of earthquake resistant design
There are some general concepts or rules to prevent damage during
earthquake to minimize life losses based on the
knowledge of the building performance and damage during past
earthquakes (Boen, 1997). They are:
a. symmetry of the plan in both axes and simple shapes
b. adequate strength structures, not brittle, able to deflect or
deform a considerable amount
c. using resisting elements, i.e. bracing or structural shear walls
d. rigid joint between beams and columns
e. an integrated walls and roof with the main structure
f. well connected to foundation and the earth
g. good quality of the materials
h. fire resistance
PRE-FABRICATED BUILDING
Lower production time (parallel production, can
be produced during winter)
High quality level, constant production
conditions, not depend on local labor skill and
equipments, climate
during construction etc.
Lower production cost (reduction of cost for
formwork and false work in site)
Better finishing
Using eco friendly and recycled materials
Standard parts of the Smart Modula are:
a. Foundations are made of concrete 1:3:5 (the compressive strength about 15 MPa). Usually the shape is
trapezoid 50 cm height and 50 x 50 m2 base areas. The foundations are connected together by beams and
columns by bolts through plates.
b. Columns are made of hollow square section steel, galvanized 90 micron. They are joined or tied firmly to the
foundation and horizontal beams by bolts. The ends of the columns are connected with beams to form a rigid
frame. On the top and bottom end of the column there is metal plate.
c. Floors are made of concrete 1:3:5 or floors tiles such as ceramic.
d. Beams are made of light lips channel, galvanized 120 micron. In the top connection (connection between
columns and beams) strengthened with knee L profile.
-4-
e. Walls are made of pre-fabricated materials (strerofoam, Portland cement and cellubond mixture). Between
walls and main frame is connected or strengthened by powder coating U wall-clamps vertically and
horizontally. The U clamp is connected to the main frame by self taping screws. Between walls are connected
by powder coating H-plate.
f. Roof frame is made of Zincalume profile C-75x40x1, be tied firmly to the frame structure. Roof is made of
pre-fabricated Styrofoam tile or supplied by other products for example Zincalum 0,33 mm thick (Lysact
Ausdek)
g. Doors and windows are made of wood, aluminium, PVC or other materials. Windows have glass for lighting.
PRE-FABICATED EARTHQUAKE
RESISTANT SMART MODULA
General description of Smart Modula
Smart Modula House is kind of pre-fabrication house
that is designed to fulfill the needs of low income
groups. The
house module is easy to be installed, comfortable,
durable and strong. To build a Smart Modula house (36
m2) needs
only 2-3 days. The shape of the house can be modified
easily; even the house itself can be moved without
much
trouble. Adding accessories such as changing the door-
window frame is possible.
Numerical
analysis
a. Roof is made of light steel truss (channel
C-75, 1.0 mm thick), tied to the frame
structure, with the yield stress
fy = 550 MPa (BJ 55), Modulus of elasticity Es
= 2.105 MPa, shear modulus G = 8.104 MPa,
Poissons ratio
= 0, 3.
b. The columns are made of hollow square
section steel 60x60x2, while beams of light
lips channel C 100,
thickness t = 2 mm. They are joined by bolts,
and assumed as rigid frame. The base of the
columns is assumed
as pin.
A typical plan

a. Roof is made of light steel truss (channel C-75, 1.0 mm
thick), tied to the frame structure, with the yield stress
fy = 550 MPa (BJ 55), Modulus of elasticity Es = 2.105
MPa, shear modulus G = 8.104 MPa, Poissons ratio
= 0, 3.
b. The columns are made of hollow square section steel
60x60x2, while beams of light lips channel C 100,
thickness t = 2 mm. They are joined by bolts, and
assumed as rigid frame. The base of the columns is
assumed
as pin.
A typical plan