Course: Modern Construction Technology

Chapter-3:
Prefabricated Construction System

Instructor: Mehari S.
 Introduction
Prefabrication is the Practice of assembling components of a structure in
a factory or other Manufacturing site and transporting complete
assemblies to the construction site where the structure is to be located.
Process of Prefabrication:
 An example from house building illustrates the process of
prefabrication. The Conventional method of building a house is to
transport bricks timber, cement, sand, Steel and construction aggregate
etc., to the site, and to construct the house on site from these materials.
 In prefabricated Construction only the foundations are constructed in
this way while sections of (walls, floors, roof are Prefabricated with
window & door frames included) transported to the site lifted into place
by a crane and bolted together.
 Uses of Prefabrication
1. The most widely used of prefabrication in building and civil
engineering is the use of Prefabricated Concrete & prefabricated
steel sections in structures where a particulars part on form is repeated
many line.
2. Pouring Concrete section in a factory brings the advantages of being
able to re-use moulds and the concrete cab be mixed on the spot
without having to be transported to and pumped wet on a congested
construction site.
3. Prefabricating Steel sections reduces on site cutting and welding costs
as well as the associated hazards.
4. Prefabrication techniques are wood in the construction of apartment
slacks and housing developments with repeated housing units.
[Link] technique is also used in office blocks, warehouses and factory
buildings.
6. Prefabricated Steel and glass sections are widely used for the exterior
of large buildings.
7. Prefabricated bridge elements and systems offer bridge designers &
Contractors significant advantages in terms of construction time, safety
environmental impact construct liability and cost.
8. Prefabrication can also help minimize the impact from bridge building.
9. Radio powers for mobile phone and other service often consist of
multiple prefabricated sections.
10. Prefabricated has become widely used in the assembly of aircraft and
space craft with component such as wings and fuselage sections after
being manufactured in different countries or states from the final
assembly site.
 Advantages of Prefabrication
 Self-supporting readymade components are used. So the need for work
shuttering and scaffolding is greatly reduced.
 Construction time is reduced and buildings are completed sooner
allowing an earlier return of the capital invested.
 On site construction and congestion is mini mixed.
 Quality control can be easier in a factory assembly line setting than a
construction site setting.
 Prefabrication can be located where skilled labour is more readily
available and costs of labour, power, materials, space and overheads are
lower.
 Time spends in bad weather or a hazardous environment at the
construction site is minimized.
 Disadvantages of Prefabrication
[Link] handling of prefabricated components such as concrete panels
or steel and glass panels is required.
[Link] has to be paid to the strength and corrosion-resistance of the
joining of prefabricated sections to avoid failure of the joint.
[Link], leaks can form at joints in prefabricated components.
[Link] costs may be higher for Voluminous. Prefabricated
sections than for the materials of which they are made, which can often
be packed more efficiently.
[Link] Prefabricated Structures require heavy-duty cranes & Precision
measurement and handling to place in position.
[Link] group of buildings from the same type of prefabricated elements
tend to look drab and monotonous.
[Link] jobs are last.
The Main reasons to choose Precast Construction method
over conventional in method.
 Economy in large scale project with high degree of repetition in work
construction.
 Special requirement in finishing.
 Consistency in structural quality control.
 Fast speed of construction.
 Constraints in availability of site resources (e.g. materials & Labours)
 Other space & environmental constraints.
 Overall assessment of some or all of the above factors which points to
the superiority of adopting precast construction over convention method.
 Large groups of buildings from the same type of prefabricated elements tend
to look drab and monotonous/repetitive.
Prefabrication Elements:
1. Flooring / Roofing system.
2. Precast Beams
3. Precast Columns
4. Precast wall panels.
5. Precast Slabs.
Classification of prefabrications:
The Prefabrication is classified as follow from the view of degree of precast construction.
1. Small prefabrication
2. Medium Prefabrication
3. Large Prefabrication
4. Cast in Site Prefabrication
5. Off-Site (or) factory Prefabrication
6. Open system of prefabrication
7. Closed system of prefabrication
8. Partial prefabrication
9. Total prefabrication
1. Small Prefabrication:
 The first 3 types are mainly classified according to their degree of precast
elements using in that construction for eg.:brick is a small unit precast and used
in building.
 This is called as small prefabrication. That’s the degree of precast element is
very low.
2. Medium Prefabrication:
 Suppose the roofing systems and horizontal members are provided with
pretested elements those construction are known as medium prefabricated
construction here the degree of precast elements are moderate.
3. Large Prefabrication:
 In large prefabrication most of the members like wall panels, roofing / flooring
Systems, beams and columns are prefabricated. Here degree of precast elements
is high.
4. Cast – in – site prefabrication:
 One of the main factor which affect the factory prefabrication is transport. The
width of mad walls, mode of transport, vehicles are the factors which
prefabrication is to be done on site on factory.
 Suppose the factory situated at a long distance from the construction site and
the vehicle have to cross a congested traffic with heavy weighed elements the
cost in side prefabrication is preferred even though the same condition are the
cast in site prefabrication is preferred.
5. OFF – site (factory) prefabrication:
 When number of houses and more for small elements the conveyance is easier
with normal type of lorry and trailers. Therefore we can adopt factory (or) OFF
site prefabrication for this type of construction.
6. Open system of prefabrication:
•In the total prefabrication systems, the space framers are casted as a single
unit and erected at the site. The wall fitting and other fixing are done on site. This
type of construction is known as open system of prefabrication.
7. Closed system of prefabrication :
•In this system the whole things are casted with fixings and erected on their
position.
8. Partial prefabrication:
•In this method of construction the building element (mostly horizontal)
required are precast and then erected. Since the costing of horizontal elements
(roof/floor) often takes there time due to erection of from work the completion of
the building is delayed and hence this method is restored.
9. Total Prefabrication:
•Very high speed can be achieved by using this method of construction. The
method can be employed for frame type of construction or for panel type of or the
total prefabrication can be on site or off-site.
•The choice of these two methods depend on the situations when the factory
produced elements are transported and erected site we call if off-site prefabrication.
If this method is to be adopted then we have a very good transportation of the
products to site. If the elements are cast near the building site and erected, the
transportation of elements can be eliminated, but we have consider the space
availability for establish such facilities though it is temporary.
The choice of the method of construction also depends on the following;
1. Type of equipment available for erection and transport.
2. Type of structural scheme ( linear elements or panel)
3. Type of connections between elements.
4. Special equipment devised for special method construction.
Prefabricated Materials:
•Prefabricated building materials are used for buildings that are manufactured
off-site and shipped later to assemble at the final location same of the commonly
used prefabricated building materials are aluminium steel, wood, fiberglass and
concrete.
Precast structure Installation (Erection):
• The following steps to be followed to erect the precast structure:
[Link] for precast installation
[Link] process.
[Link] using Big canopy/covering
[Link] construction Management.
[Link] of precast panels.
[Link] defects in precast panels.
[Link] failures.
Planning for precast installation:
Planning co-ordination:
•It is important to have the precast erector / installer and builder working together to achieve
best performances.
Site Access and storage:
i. Check for site accessibility and precast panels delivery to site especially low bed trailers.
[Link] whether adequate space for temporary storage before installation and ground
conditions firm ground & levelled)
[Link] ground will cause overstress & crack panels.
Planning crane Arrangement:
• Plan the crane capacity and lifting gears based on
[Link] weight of precast panels.
[Link] heights.
[Link] radius.
[Link] of crane in relation to final location.
 Plan other equipment’s
[Link] lift and scissor lift for unhooking installed panels.
[Link] gears.
Skilled personnel’s:
[Link] crane operators.
[Link]
[Link] etc.
General consideration for crane selection:
1. Total lifting weight.
2. Crane Model
3. Crane safe working load (SWL)
4. Lifting and swing radius.
5. Crane counters weight.
6. Crane boom length is relation to the vertical and horizontal clearance from
the building.
 7. Installation process.
8. Installation of vertical components.
9. Verification of delivered panels.
10. Check the panels delivered for correct marking liftinglook and position
etc.
11. Surface finishing conditions.
12. Reinforcement provision
13. Architectural detail compliance.
Setting out:
[Link] the panels delivered for marking lifting hook and condition.
[Link] the reference lines & grids.
[Link] starter bars for vertical components before hoisting for installation.
Setting out quality control points.
[Link] correct offset line.
[Link] ‘Shim Pad’/plate level and firm.
[Link] gasket/liner property secured.
[Link] external wall / column place backer rod.
Hoisting, Rigging and installation:
[Link] tilting provide rubber pad to avoid chip off.
[Link] and rig the panel to designated location.
[Link] the panel in position and secure.
[Link] of space adding items with balanced center of gravity.
[Link] horizontal alignment correct.
[Link] panel vertically to correct plumb.
[Link] panel to panel gap consistency.
[Link] stability of prop before releasing hoisting cable.
Grouting/filling works:
[Link] and apply non shrink mortars to seal gap
[Link] corrugated pipe sleeve or splice sleeve pour or proprietary grouts into pipe
sleep.
[Link] installed panels undisturbed for 24 yrs.
[Link] joint widths are consistent before grouting.
[Link] used should be same grade of components and self-compacting to
prevent cracking.
[Link] test cube sample for testing for critical elements or load bearing
elements.
Connecting joints:
[Link] in situ joints, install rebar’s as required
[Link] up forms for casting joints.
[Link] connecting.
[Link] forms after sufficient strength.
[Link] external connections welding as required.
Installation of Horizontal Elements:
Setting out:
1. Set reference line / offset line to required alignment and level of slab / beam
during installation.
2. Put temporary prop to support the precast slab / bear elements.
3. Before hoisting check dimensions.
4. Check level and stability of shim.
Specified tolerances to prevent any obstruction during the erection process
Hoisting installation
1. Put temporary props to support slab or beam.
2. Lift and rig the elements to designated location
3. Align and check the level before placement
4. The beams shall prop at least two locations
5. Check level of precast elements
Connection and jointing
1. Precast with cast-in-situ joints place the lap rebar’s as required.
2. Set formwork for casting joints
3. Remove formwork after concrete strength is achieved
4. Supporting beams shall be designed to form part of formwork joints
5. The connecting or lapping rebar’s tied and secured
6. Same grade of concrete to be used that of panel
Transportation and Hosting of refabricates:
[Link] cranes
[Link] cranes
[Link] cranes
[Link] cranes
[Link] mast cranes
1. Truck cranes:
Truck cranes consist of chassis including mortar and pivoting upper part. These
cranes are mobile and a travel on their own needs. Different features are:
[Link] of the crane while travelling is 31.8 tonnes
[Link] height of hoisting hook is 36.6m
[Link] can rotate through 360º.
Disadvantage:
•Needs firm and compact soil.
2. Gantry Cranes:
 These cranes are used mainly to serve the operation of manufacturing and
storing areas in prefabrication plants.
 Capacity 5T, Total weight 4.5T
 Horizontal distance between 2 tracks is 7.8m
 Maximum height is up to 11m
 Mast height 10.9m and it can hoist up to 20 tonnes in operation.
3. Mast Cranes:
•These are wide spread hoisting devices, simple and cheap. Operation requires great skill and
practice. Useful in hoisting prefabricates in vertical direction. Suspension load can be slightly moved
forward by slackening the rear staying cable. Hoisting load is done by a winch.
4. Derrick cranes:
 Highly efficient lifting machines
 It is stable or movable
 Capacity 20-40T
 Suitable for prefabrication halls
 These cranes have booms which can move in horizontal directions
5. Twinned mast cranes:
 It is used for hoisting member to great height. It consists of two steel column assembled from
sections and connected at top by bridging structure.
 Hoisting capacity using two cranes each of 35-70T
 Operation of the crane required minimum 16 workers.
 The crane can be transferred but takes 1-2 days and is suitable for high lifting but difficult to
operate.
 These are now a day replaced by 30T mast cranes hinged in 2 directions.
Methods of prefabrication:
A. Site prefabrication- for large prefabricates
B. Plant prefabrication- large scale production
A. Site prefabrication:
[Link] RC members are produced to the site in the open air chiefly in the open air
or in the temporary sheds
[Link] difficulties in construction in general are felt in this mechanization can
case.
[Link] cannot be of such high degree as site PF is done for smaller
duration of time.
[Link] the pre fabricates are of large size it is difficult to transport the pre
fabricates to the site.
[Link] comparison with plant prefabrication transportation of the members are not
needed. As large members are not transported the design and weight of the
prefabricates are not limited.
B. Plant prefabrication
[Link] members produced are to be transported the place of construction this
accounts for about 10-15% of the cost of production and assembling.
[Link] restriction is made in the dimension of prefabrication leading to
restraints in the design and development of prefabrication.
[Link] is appropriate for mass production for manufacture of
standardized members.
[Link] costly materials for batching and production.
[Link] method is most suited in the case of small prefabricates which are to be
prefabricated in very large number.
 Plant prefabrication is done under permanent plant or factories. It is done
under the covered roof so the effect of weather does not affect the work. So
the quality and strength of the members can be improved considerably. Plant
prefabrication reduces the cost of prefabrication if the number of
prefabricate needed is more.
Production of prefabricates:
•Production techniques involved are
[Link] method
[Link] method or line method
[Link] method
1. Stand Method:
•In this method, the prefabrication matures where they are moulded while the
production teams moves to successive stands. The bed on which prefabricates are cast
may be fixed or movable. Tilting forms are often used and in this method steam
curing is generally done.
2. Conveyor belt method:
•The whole production is split up in to series operations carried out at separate
successive and permanent points served by specialized teams. The movement of the
mould or prefabricate one point to other vary by means of conveyor belt trolleys.
3. Aggregate method:
 In the aggregate method, aggregate describes large complex permanently installed
machines & mechanical appliances which carry out most of the separate operations
involved in the casting of the concrete composition. The stand is operated by a
permanent team & the only move the prefabricate makes is to the maturing point.
 Aggregate method is used in the production of multi duct hollow floor panel in
Poland. At production point the reinforcement is fixed in the form & remote
controlled aggregate (machine) inserts the duct formers, cast& vibrates the concrete,
floats @ the top of the floor. The prepared prefabricate then move to the autoclave
chamber in which hardening of concrete is accelerate. In many factories combined
technology are employed when complex prefabricate are required.
Advantages:
1. The stand technique is the most flexible one. It is used in varying degrees of
mechanization, in all kinds of prefabricate factories.
2. It is simple & less capital is required. It can be used for field prefabricate also.
3. Aggregate method is used for large scale production in which case number of
machineries is required.
Joints of different structural connections:-
[Link] of column to footing
[Link] of column to beams on top of column.
[Link] of column to beam at an intermediate
[Link] of columns
[Link] of beams
F. Forming of joints of arched structures
[Link] of joints of post tensioned structures.
[Link] of precast to monolithic reinforced concrete structures.
Different stages in precast reinforced members:
1)The structure is divided into no of units.
2)The different units are precast in permanent plants.
Permanent prefabrications - plant prefabrication. Temporary
plants (sheds) - Site prefabrication
3)Transported to the site
4)Hoisted and put into their places
Uses of pre-fabrication construction methods:-
[Link] or total saving of material used for scaffolds.
[Link] use of structuring
[Link] of far more accurate and better work transits.
[Link] sections more advantages from the new point of stream
[Link] time can be shortened.
[Link] expansion joints are required.
[Link] in concreting can be omitted.
[Link] work can be carried out with a high degree of mechanization.
[Link] in man power decrease.
[Link] to avoid the seasonal character of the buildings industry.
[Link] use of the members. In pre fabrication scaffolding materials
are needed as a temporary support.
Moulds:
• Moulds are the covers, which are used to casting the precast
elements in manufacturing plants.
Different types of moulds:
[Link] moulds
[Link] moulds
[Link] moulds
[Link] moulds
Types of prefabricated Structures:
[Link] less - large panelled structures - External and Internal wall
panels - Floor and roof panels (of room single)
[Link] buildings: Columns, beams & floor elements.
Stages of work in pre-casting:
Methods of manufacturing by using moulds:
•Characteristics of prefabricated members:
 Thermal insulation property.
 Easy workability
 Durability in all weather conditions.
 Non-Combustibility
 Economy in cost
 Sound insulation.
The standard prefab concrete components are:
1. Reinforced concrete channel units.
2. Hollow cost slabs
3. Hollow blocks ad patterns.
4. Precast plank and buttons.
5. Precast frosts ad tiles.
6. Cellular concrete slabs.
7. Pre stressed / reinforced concrete slabs.
8. Reinforced / pre stressed concrete beams.
9. Reinforced / pre stressed concrete columns.
[Link] lintels ad sub standby.
[Link] concrete waffle slabs /concrete panels.
[Link] / pre stressed concrete walling elements.
[Link] / pre stressed concrete trusses.
Modular Coordination:
Modules:
Modules are a standard unit of size used to coordinate the dimensions of buildings
and components.
Modules reduce the variety of components and sizes produced.
The symbol used for basic module is M.
1M =100mm

Modular coordination:
Modular coordination is a concept for coordinating dimensions and space for which
buildings and components are positioned.
Advantages of Modular coordination:
[Link] of single components into large components.
[Link] possible different types of component.
[Link] wastage of cutting needed.
The rules adopted for conventional and prefabricated constructions
inn modular coordination:
[Link] planning grid in both directions of the horizontal plan shall be
1.3M for residential and institutional buildings,
[Link] industrial buildings,
15M for spans up to 12m
30M for spans between 12m and 18m
60M for spans over 18m
• The centre lines of load bearing walls shall coincide with the grid
lines
B. In case of external walls the grid lines shall coincide with the centre line of the
wall or a line on the wall 5 cm from the internal face of the wall
C. The planning module in the vertical direction shall be 1M up to and including a
height of 2.8M.
D. Preferred increments for the still heights, doors, windows and other fenestration
shall be 1M.
E. In case of internal columns the grid lines shall coincide with the centre lines of
columns.
Types of Modular Grid:
[Link] grid
[Link] grid
[Link] of grid (or) Tartan grids
[Link] grids as neutral zone
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