Prefabricated Structures: Prefabricated Components

Definition
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:

Conventional method of building a house - transport material to the site and begin construction.
Prefabricated construction only the foundations are constructed on site, other are transported to
the site lifted into place and bolted together.
Uses of Prefabrication:
The most widely used from of prefabrication is the use of prefabricated concrete & steel
sections in structures where a particulars part on form is repeated.
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.
Prefabricating steel sections reduces on site cutting and welding costs as well as the
associated hazard's.
The technique is also used in office blocks, warehouses and factory buildings.
Prefabricated Steel and glass sections are widely used for the exterior of large buildings.
Prefabricated bridge elements and systems offer bridge designers & Contractors
significant advantages in terms of construction time, safety environmental impact
construct liability and cost.
Prefabrication can also help minimize the impact from bridge building.
Radio bowers for mobile phone and other service often consist of multiple prefabricated
sections.
 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 :
Reduction in formwork and scaffolding.
Construction time is reduced.
Congestion on site is minimized.
Enforcing of quality control on assembly line is easier than construction site.
Prefabrication can be located where skilled labour is more readily available and costs of
labour, power, materials, space and overheads are lower.
Time spend in bad weather or hazardous environments at the construction site is
minimized.
Disadvantages of Prefabrication:
Careful handling of Prefabricated components is required.
Attention to strength and corrosion-resistance at joining and sections to avoid failure.
Similarly, leaks can form at joints in prefabricated components.
Transportation costs.
Large Prefabricated Structures require heavy-duty cranes & Precision measurement and
handling to place in position.
Monotonous nature when employed enmass.
Local jobs are last.
Principles:
The main reasons to choose precast construction method over conventional method.
Economy in large scale project with high degree of repetition in work execution.
Special architectural requirement in finishing.
Colysistonay in structural quality control.
Fast speed of construction.
Constraints in availability of site resources ce.g.materials & labour etc..
Other space & environmental constraints.
 Overall assessment of some or all of the above factors which points to the superiority of
adopting precast construction over conventional method
The following details gives the cost implications of precast construction & conventional in situ
method; Flooring / Roofing system, Precast Beams and Columns, Precast wall panels, Precast
Slabs.

Classification of prefabrications:
Small Prefabrication:
Elements used in that construction for e.g., brick are prefabrication. That the degree of
precast element is very low.
Medium Prefabrication:
Suppose the roofing systems and horizontal members are provided with pretested
elements those constructions are known as medium prefabricated construction. Here the
degree of precast elements are moderate.
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 are
high.
Cast - in - site prefabrication: OFF - site (factory) prefabrication:
One of the main factors which affect the factory prefabrication is transport. The width of
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 cast in site
prefabrication is preferred
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, fittings and other fixing are done on site. This type of
construction is known as open system of prefabrication.
Closed system of prefabrication:
In this system the whole things are casted with fittings and erected into position.
 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 take
time due to erection of form work the completion of the building is delayed and hence
this method is restored. In most of the building sites this method is more popular.
This method is efficient when the elements are readily available when the building
reached the roof level. The delay caused due to erection of formwork, delay due to
removal eliminated completely in this method of construction Suitable for any type of
building provided lifting and erection equipment are available.
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 depends 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 considered the
space availability for establish such facilities though it is temporary.

The choice of the method of construction also depends on the following;

Type of equipment available for erection and transport.
Type of structural scheme (linear elements or panel)
Type of connections between elements.
Special equipment devised for special method construction.
Prefabricated Materials:
Some of the commonly used prefabricated building materials are aluminum steel, wood,
fiberglass and concrete.
Prefabricated metal buildings use galvanized steel and galvalume as the chief materials
for building. Galvalume is a form of Steel coated with aluminum Zinc. This is to protect
the building against corrosion rust and fire. Almost all the components of a metal
building such as beams, frames, columns, walls & roofs are made of steel.
Synthetic materials are used for the walls & roofs. To provide enhanced security a
combination of both metal and cloth materials are used. Plastic flooring materials can be
quickly assembled and are very durable
 Using Prefabricated materials one can make durable water and fire resistant and cheap
prefabricated buildings. Most of the prefabricated building materials are eco-friendly &
affordable.
Precast structure Installation (Assignment)
The following steps to be followed to erect the precast structure:
Planning for precast installation
Installation process.
Installation using big canopy
Installation construction Management.
Mishandling of precast panels.
Common defects in precast panels.
Precast failures.
Modular Coordination
Modular coordination means the interdependent arrangement of a dimension based on a primary
value accepted as a module. The strict observance of rules of modular coordination facilitated,

1. Assembly of single components into large components.

2. Fewest possible different types of components.
3. Minimum wastage of cutting needed.
Modular coordination is the basis for a standardization of a mass production of component. A set
of rules would be adequate for meeting the requirements of conventional and prefabricated
construction. These rules are adaptable for,
a. The planning grid in both directions of the horizontal plan shall be
3M for residential and institutional buildings,
For industrial buildings, 15M for spans up to 12m; 30M for spans between 12m and 18m;
60M for spans over 18m. The center 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. In
case of external columns, the grid lines shall coincide with the centre lines of the columns in the
storey or a line in the column from the internal face of the column in the top most storey.

The storey height is fixed between finished floor levels.

The centre distance between the load bearing walls can be chose from a set of modules. The use
of other dimensions is not allowed.
In the design of a building, modular grid can be used consisting of parallel line spaced (at a value
of module M or Mp) and a grid line chosen as a base for setting out a part of a building becomes
a modular axis. In the fig (a), a typical grid is chosen for load bearing walls without duct. The
interior walls are placed so that their centerlines coincide with the modular axis.
Systems of prefabrication:

System is referred to a particular method of construction of buildings using the prefabricated

components which are interrelated in functions and are produced to a set of instructions. With
certain constraints, several plans are possible, using the same set of components, the degree of
flexibility varies from system to system. However, in all the systems there is a certain order and
discipline. The system of prefabricated construction depends on the extent of the use of prefab
components, their characteristics to be considered in devising a system:

i. Intensified usage of spaces

ii. Straight and simple walling scheme
iii. Limited sizes and numbers of components
iv. Limited opening in bearing walls
v. Regulated locations of partitions
vi. Standardized service and stair units
vii. Limited sizes of doors and windows with regulated positions
viii. Stuctural clarity and efficiency
ix. Suitability for adoption in low rise and high-rise blocks
x. Ease of manufacturing storing and transporting
xi. Speed and ease of errection
xii. Simple jointing system

a) Based on Disuniting of member

b) Based on the construction
A Based on Disuniting of member:
1. System consisting of linear member disunited at joints
2. System for prefabricates of entire rigid frame
3. System consisting of I,T,U of straight members disunited at points of minimum moment.
4. Two hinged and three hinged arches

1 System consisting of linear member disunited at joints

Advantage:
Disuniting at joints gives linear member. This has advantage in manufacture and assembly.
Disadvantage:
1. Joints are at corners i.e. at points of maximum moment values, so forming the joint is
difficult.
2. Joints must be over dimensioned to cope with insitu concreting. And one alternate
solution to replace moment resistant joints by hinged connection.

2 System for prefabricates of entire rigid frame:

In this system, to reduce the number of joints and to precast larger numbers I one piece leads to
the prefabrication of entire frame. Production of the frames does not cause any particular trouble
but the hoisting is more difficult and requires careful preparation.
Advantage:
1. It is ideal for site prefabrication.
2. Small number of joints so rapid prefabrication work is possible.
3. Suitable for long walls consisting of great number of uniform frames.

3 System consisting of I,T,U of straight members disunited at points of minimum moment:

Another method of disuniting of structures is by division into different membranes at points
where the moments are thin or smallest. This method is called as lambda method. Using this
method hinge joints are made.
Advantage:
1. Functions are made at points of minimum moments or at points of contra flexure.
2. Disuniting the main girder in this manner makes the application of different skylights
possible.
Disadvantage:
1. Hosting and temperature bracing of L joined asymmetric frame members is particularly
complicated.
2. Temperature resting of frame member on each other necessaitates the use of canilevers
having half depth and proper forming of this cause difficulty.
4 Two hinged and three hinged arches
Arched structures are normally two hinged and three hinged arches. Arched structures are
normally used for bridging span more than 20-25m. Their production and placing is more
difficult than straight members. Arch can be two hinged and three hinged but they can also be
fixed at footings and can be constructed with or without tie.

These members are generally precast and assembled, and middle hinge is only eliminated after
placing is finished. The reinforcing bars protruding both sides are welded together and the joint
between the members is filled in with insitu concrete.
Arch structure can be precast in either vertical or horizontal positions. In the vertical case,
shuttering made of timber or concrete is required having the same curvatures the arch itself.
The prefabrication of larger arches in the horizontal position is found to be more economical.
The construction of arch trusses can be properly carried out in the horizontal position only.
Transportation and Hosting of prefabricates:
Truck cranes, Gantry cranes, Mast cranes, Derrick cranes, Twinned mast cranes,
Truck cranes: are mobile and can travel on their own needs. Different features are:
1. Weight of the crane while travelling is 31.8 tonnes
2. Maximum height of hoisting hook is 36.6m
3. Crane can rotate through 360.
Disadvantage: Needs firm and compact soil,
Gantry Cranes: These cranes are used mainly to serve the operation of manufacturing and
storing areas in prefabrication plants.

Features – 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.
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.

Twinned mast cranes: It is used for hoisting member to great height. It consists of two steel
columns assembled from sections and connected at top by bridging structure.
Features: Hoisting capacity using two cranes each of 35-70T, Operation of the crane requires
minimum 16 workers. The crane can be transferred but takes 1-2 days and is suitable for high
lifting but difficult to operate.
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.

Sequence of erecting Prefabricated structures

Structure units- external load bearing walls, columns, etc.
Non structure units- internal walls, partition, walls, etc.
Floor panels, balconies, stair units
Specialized prefabricated units- chimney flumes. Ventilators, sanitary installation.
If the external walls are hand laid from small blocks or bricks, all necessary materials should be
hoisted by crane and stacked near the ultimate position. The masonry work is begun after the
floor immediately above is laid.
Accuracy of all installations is monitored and verified by means of surveying instruments
during/after all joints are connected or erected.

Hosting of Columns:
The hoisting machine for small column is less than five tones. First of all, pick up gear must be
assembled on to the column and the column is then under pinned. Thereafter the column is
lowered temporarily on to a sheep shoe assembled at the foot and the roller track is pushed under
the shoe. When column is hoisted the pick-up points moves vertically and bottom resting on the
roller tracks shifts towards the footing. When the column is lifted to the required height, the
retaining cable is used to decrease and finally stop the swinging motion of the column.
The hoisting and fixing up of the beams:
1. Pick up and hoisting
Beams in general are lifted at two points depending on the weight and dimensions as well as the
load bearing capacity of hoisting machines. The hoisting grider which is heavy to a great can be
executed with hydraulic jacks. The jacks are lowered and the beam is placed to the required
position to the column.
Suspension:
For lifting up of trusse and large beams of length 25-30m. care is taken to lift the rocker in
uniform rate with two hoisting machines otherwise the beams would be subjected to distortion
during the lifting leading to cracks.

Methods of prefabrication:
Site prefabrication- for large prefabricates
The RC members are produced at the site in the open air chiefly in the open air or in the
temporary sheds
The difficulties in construction in general are felt in this mechanization can case.
Mechanization cannot be of such high degree at site if it is done for smaller duration of
time.
When the pre fabricates are of large size it is difficult to transport and hence reason for
onsite prefab.
In 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.
Plant prefabrication- large scale production
The members produced are to be transported t the place of construction this accounts for
about 10-15% of the cost of production and assembling.
Certain restriction is made in the dimension of prefabrication leading to restraints in the
design and development of prefabrication.
Prefabrication is appropriate for mass production for manufacture of standardized
members.
Needs costly materials for batching and production.
 This 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.
Dimensions of prefabricate:
There are 3 commonly known dimension for the prefabricates.
1. Theoretical dimension
2. The design of the erection dimension governing the dimensional coordination of the
prefabricates.
3. The actual dimension of the element when delivered. The design dimension should
be a multiple of a basic module size.

Production of prefabricates:
Production techniques involved are: Stand method, Conveyor method or line method, Aggregate
method
Stand Method: the prefabrication mature 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. The stand
technique is the most flexible one. It is used in varying degrees of mechanization, in all kinds of
prefabricate factories. It is simple & less capital is required. It can be used for field prefabricate
also.
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.
The rigid steel forms are assembled at station 1 where they are mould oil to reduce the
adhesion of concrete. The conveyor moves from 1 to 2 where prestressing wires are fixed & in
the next station anchoring of the wires is carried out. The prepared mould is then carried to
the station 1 i.e., casting station. After casting ,it is shifted to the vibrating table & finally stacked
at station 5 for setting. After that, it is passed through tunnel autoclave for curing. After steam
curing move too station 7 for demoulding & is finally stacked at 8.
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 for
large scale productionin which case number of machineries is required.