UNIT I

Introduction
Prefabrication 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. 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 term prefabrication also applies to the manufacturing of things other than structures at a fixed
site. It is frequently used when fabrication of a section of a machine or any movable structure is shifted
from the main manufacturing site to another location, and the section is supplied assembled and ready to
fit. It is not generally used to refer to electrical or electronic components of a machine, or mechanical
parts such as pumps, gearboxes and compressors which are usually supplied as separate items, but to
sections of the body of the machine which in the past were fabricated with the whole machine.
Prefabricated parts of the body of the machine may be called 'sub-assemblies' to distinguish them from the
other components.

The process and theory 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 and roof are prefabricated
(assembled) in a factory (possibly with window and door frames included), transported to the site, lifted
into place by a crane and bolted together.
. Prefabrication techniques are used in the construction of apartment blocks, 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 to those that live in them. The
technique is also used in office blocks, warehouses and factory buildings.
Prefabricated bridge elements and systems offer bridge designers and contractors significant
advantages in terms of construction time, safety, environmental impact, constructibility, and cost.
Prefabrication can also help minimize the impact on traffic from bridge building. Additionally, small,
commonly-used structures such as concrete pylons are in most cases prefabricated.
Radio towers for mobile phone and other services often consist of multiple prefabricated sections. Modern
lattice towers and guyed masts are also commonly assembled of prefabricated elements.

Advantages of prefabrication
1. Self-supporting ready-made components are used, so the need for formwork, shuttering and
scaffolding is greatly reduced.
2. Construction time is reduced and buildings are completed sooner, allowing an earlier return of the
capital invested.
3. On-site construction and congestion is minimized.
4. Quality control can be easier in a factory assembly line setting than a construction site setting.
5. Prefabrication can be located where skilled labour is more readily available and costs of labour,
power, materials, space and overheads are lower.
 6. Time spent in bad weather or hazardous environments at the construction site is minimized.
7. Less waste may

Disadvantages
1. Careful handling of prefabricated components such as concrete panels or steel and glass panels is
required.
2. Attention has to be paid to the strength and corrosion-resistance of the joining of prefabricated
sections to avoid failure of the joint.
3. Similarly, leaks can form at joints in prefabricated components.
4. 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.
5. Large prefabricated sections require heavy-duty cranes and precision measurement and handling
to place in position.
6. Larger groups of buildings from the same type of prefabricated elements tend to look drab and
monotonous.
7. Local jobs are lost

Modular Coordination in Construction Industry

What is Standard MS 1064?
MS 1064 is a guide line towards the usage of Modular Coordination (MC) in building
constructions which consists of Part 1 to Part 10 under the general title, "Guide to Modular
Construction in Buildings".

It provides the general principles, room and storey heights, coordinating sizes and preferred sizes
for various building components, dimensions of elements, components and spaces in the planning and
design of building.

Modular Coordination (MC) is a concept for coordinating dimension and space for which buildings
and components are dimensionalised and positioned in basic units or modules. MS1064 introduces a
certain geometric discipline using practical approaches which relate to set-up coordination and
measurement of components and spaces in the building design. The standard specifies that the module
basic M = 100mm as the basic unit to be used in a square of M.

The introduction of MC in the industry is to improve productivity and quality in building

construction construction as well as to act as a tool towards rationalization and industrialization of the
building industry.

MC has been introduced in Malaysia since 1986, but has not been widely implemented in the
building industry. The main factors limiting the uses of MC in building industries is lack of knowledge on
MC concept and it requires precision dimensioning and proper planning.
The characteristic of MC are:
1. The basic module is small in terms of odd size in order to provide design flexibility, yet large
enough to promote simplification in the components' variation in sizes.
2. Industry friendly features that not only cater for manufacturing but also the transportation and
assembly requirements.
3. Ergonomically designed to promote efficiency
4.Internationally accepted to support international market

MC Concept

MC may be applied to the design, manufacture and assembly of buildings, its components
and installations. It also affects the work positioning and dimensioning during construction. At the
work level, MC allows for relative independence in decision making with the common
dimensional language. The concept of MC is based on:
The principal objective of implementing MC is to improve productivity through the
reduction of wastages in the production, installation process, to improve quality in the construction
industry and to encourage an open system. With Open System approach, building components
could combine in a variety of individual building projects while ensuring the architect freedom in
their designs.
MC is an important factor in application of Industrialized Building System by way of
standardization of components ad dimensions such as reduce time of production and installation of
components, achieving repeatability and able to construct building at lower cost.

Shear wall
In structural engineering, a shear wall is a wall composed of braced panels (also known as shear
panels) to counter the effects of lateral load acting on a structure. Wind and earthquake loads are the most
common loads braced wall lines are designed to counteract. Shear walls are a type of structural system
that provides lateral resistance to a building or structure. They resist "in-plane" loads that are applied
along its height. The applied load is generally transferred to the wall by a diaphragm or collector or drag
member. They are built in wood, concrete, and CMU (masonry).
Shear walls are the main vertical structural elements with a dual role of resisting both the gravity
and lateral loads. Wall thickness varies from 140 mm to 500 mm, depending on the number of stories,
building age, and thermal insulation requirements. In general, these walls are continuous throughout the
building height; however, some walls are discontinued at the street front or basement level to allow for
commercial or parking spaces. Usually the wall layout is symmetrical with respect to at least one axis of
symmetry in the plan.
Standardization
Standardization is concerned with the use of common components, products, or processes to satisfy
heterogeneous needs. It necessitates designing an overly robust product or the use of a robust process
(often a more flexible process). Different aspects of standardization have been discussed in the literature.
Tarondeau [18] argued that standardization results in higher productivity, larger lot sizes, decrease in the
number of reference points to be managed, decrease in the stock level, and the reduction of complexity of
a manufacturing system. The unnecessary cost of robustness may be balanced by increased productivity
and decrease in product and process control.