EFABRICATED CONSTRUCTION

SHUBHAANG GOELA | 4TH YEAR (SECTION B)

Prefabricationis
the
practice
of
assembling
components
of
astructurein
afactoryor
othermanufacturingsite,
andtransportingcomplete assemblies or sub-assemblies to theconstructionsite where the structure is to be located.
The term is used to distinguish this process from the more conventional construction practice of transporting the basic materials to the
construction site where all assembly is carried out.
The use of prefabrication can be traced back to 3800BC where prefabricated timber sections were used in England.

CURRENT USES OF PREFABRICATION IN BUILDING CONSTRUCTION

DIS ADVANTAGES OVER IN SITU

ADVANTAGES OVER IN SITU

The most widely used form of prefabrication in building andis the use of prefabricatedconcreteand prefabricatedsteelsections in
structures. Pouring concrete sections in a factory brings the advantages of being able to re-use moulds and the concrete can be mixed on
the spot. Prefabricating steel sections reduces on-site cutting andweldingcosts as well as the associated hazards.
Prefabrication techniques are used in the construction ofapartmentblocks, and housing developments with repeated housing units. The
quality of prefabricated housing units had increased to the point that they may not be distinguishable from traditionally built units.
Prefabrication saves engineering time on the construction site in civil engineering projects. This can be vital to the success of projects
such as bridges and avalanche galleries, where weather conditions may only allow brief periods of construction. Additionally, small,
commonly used structures such asconcrete pylonsare in most cases prefabricated. Radio towers for mobile phone and other services
often consist of multiple prefabricated sections
Factory
made
products
Accuracy
Shorter construction time Leaks can form at
less than half of in situ
Independent
joints in prefabricated
of
adverse
components.
weather conditions
Transportation
Quality surveillance system
costs
Opportunities
may be higher for
for
good
voluminous
architecture
prefabricated.
Healthy buildings
Large
Reduced energy consumption
prefabricated
Environmentally friendly way
sections
require
heavy-duty cranes and
of building with optimum use
precision
of materials, recycling of
measurement.
waste products, less noise
Larger
groups
of
and dust, etc.
Cost effective solutions
buildings
from
prefabricated
Safety in construction
elements tend to look
Increase in the quality of
monotonous.
construction
Skilled
Reduction
labour
is
ofPREFABRICATED
construction
CONSTRUCTION
required to assemble
waste and labour costs
or
erect
parts

Prefabrication is a 2 step process requiring manufacture in factory and erection in-situ. This is done by:
Casting: Precast components are casted in desired shapes and sizes in various moulds. Honeycombing and other defects in concrete are
removed mechanically.
Curing: After 24 hrs of casting, steam curing is done on components.
Transportation and Erection: Transportation is done via trucks and Erection(including assembly) is carried out by cranes using skilled
labour.
PRECAST
PRECAST BEAMS
TYPES
OFCOLUMNS
PRE FABRICATED STRUCTURAL COMPONENTS
Precast Concrete Columns
can be circular, square or
rectangular.However,
these columns come in a
specific
height
span,
hence acquire vertical
joints within.
It
is
a
compression
member and therefore
the column connection is
required to be proper. The
main principle involved in
making
column
connections is to ensure
continuity

Rectangular beams: used as

overlap beams and overlap with a
small span length.
T-section beams: used as overlap
beams with a medium and large
span length
L-section beams: used as outer
(front) overlapping beams
I-section beams: used for roofs
and overlapping with a large span
length

PREFABRICATED CONSTRUCTION

PRECAST SLABS
FLAT SLAB: Flat slabs are highly versatile elements widely used in construction,
providing minimum depth, fast construction and allowing flexible column grids.
Precast flat slabs are typically between 75 and 100mm thick. Special thicknesses (up
to 175mm) can be provided. Width is fixed at 8ft and span could range from 10ft to
32ft.
HOLLOWCORE SLAB: Hollow core slabs derive their name from the voids or cores
which run through the units. The cores can function as service ducts and significantly
reduce the self-weight of the slabs, maximising structural efficiency.
TEE SLAB: Double Tee (TT) slabs are two symmetrically placed beams interacting
with a slab forming in one section with a double tee shape made in precast,
prestressed concrete. Double tee slabs are resistant to moisture and corrosion. double
tee and single tee slabs with standard width of 2400 mm/ 1200 with span from 8 to 32
meters, 2 production lines, 150m long each, depths: 400, 500, 600, 700, 800, 900 and
1,000 mm.

HOLLOWCORE SLAB

DOUBLE TEE SLAB

PREFABRICATED CONSTRUCTION

AMPRAPALI DREAM VALLEY (GREATER NOIDA,UTTAR PRADESH)

Precast Elements can be quickly erected on the job site and precast thermal mass can also save energy and increase comfort. Major
reasons and Advantages to Adopt this technology are structural stability, speedy and Quality Construction, Flexibility, Wastage Control and
Less Manpower requirement. Other than this, The strength of this technology is, Low Maintenance, Seismic Resistance and Universal
application. This technology have been incorporated initially in two of our mega projects named Amrapali Verona Heights and Amrapali
Dream Valley at Greater Noida-West, which consists of custom designed precast concrete components like roof slabs, beams, columns,
wall panels etc. and offers flexibility in shape and size with a variety of surface finishes and colors.
These components are manufactured / casted in strictly controlled environment with state of the art machineries and are erected at site
with the help of tower cranes. The components are then joined to each other as per specification with grouts and screed to provide
monolithicity, rigidity and requisite strength to the structure. Amrapali Group did extensive research on the technology and its suitability in
Indian context and we found that this technology precast concrete can contribute to sustainable Design in many ways.

STEPS OF CONSTRUCTION (ON S

PREFABRICATED CONSTRUCTION

D) WALL CONNECTION DETAIL

A) FOOTING CONNECTION DETAIL

B) COLUMN SPANDREL CONNECTION DETAIL

C) HOLLOW CORE SLAB DETAIL

PREFABRICATED CONSTRUCTION

Flyover Pillar detail (Column reinforcement)

PREFAB CONSTRUCTION - PROCESS

PREFABRICATED CONSTRUCTION