Hello Learners,

In the previous video we have observed about Monolithic concrete construction using
Aluminium formwork. i.e Mivan technology. Normally If we want to take copy of any
paper, we used to take with the help of photocopying machine. But People used to tell
colloquially as Xerox. You might have absorbed the same in the photocopying shops too as
“Xerox will be taken here”. Actually taking a copy is photocopying, Machine is
photocopying machine. But, “Xerox” is the company name. This company introduced the
photocopying machine first into the market. So the copying process is named as Xerox. Same
way this monolithic concrete construction using aluminium formwork named as Mivan
technology. Mivan is a company who manufactured the aluminium formwork. Similar kind
of system is Mascon system. The Monolithic concrete construction was discussed in our
previous video.
In this video we are going to discuss about prefabricated structures.
Cast-in situ construction is the main way of traditional construction and the cost of this
construction method is relatively low. But there are a lot of drawbacks in this method, such as
more labour required, affected by environment, low efficiency, cause noise and dust pollution
etc. These do not satisfy the demands of green requirement, low carbon and sustainable
development requirements
Prefabricated housing system is a green environmental protection energy-saving building,
extensively used in residential, commercial construction projects. This method overcomes the
deficiencies of the traditional construction mode. In addition, this prefabricated system
provides good quality structure, reduces the construction period, saving the materials, and
also free from noise and dust pollution.
What is precast building? Each and every conventional building is having components like
slab, beam, column, wall, footing, staircase etc. The precast or prefabricated buildings also
having components similar to the conventional building. But all the components except
footings are manufactured in a factory under controlled environment and transported to the
site for the Erection, Connection and commissioning.

Precasting technology demands proper planning, detailed design & coordination before start
of the project, to minimize the changes at site. Prior planning is essential to ensure the
location of plumbing and electrical fixtures. Because while prefabricating the wall panels, the
electrical conduits, switch boxes will be embedded. Proper connection between the panels
have to be provided with ultimate care.
Work Cycle
While making a footing, the dowel bars will be extended to support wall panels. The wall
panels will be having holes at bottom to accommodate the dowel bars which projected from
the foundation. After the erection of wall panels, the holes will be grouted. Then proper
connection will be made between wall panels. Wherever required the beam will be placed
over the corbel. After this, the slab panels will be erected. Each and every wall panels will be
having screed bar and dowel bars. Above the slab, reinforcement will be placed and
connected with the screed bar which projected from the wall, to make proper connection
between slab and wall. Electrical conduits will be provided. Then screed concrete will be
placed for 60mm thickness. Then same way it will be extended for the next floor.

Let us compare Precast concrete with conventional concreting system

Method
The precast elements made by pouring concrete in reusable mould and cured in a plant. Then
transported to the site for erection.
But in the conventional system, cast in situ concreting will be done. Formwork will be made
at the site and Concreting will be done in the site itself and then cured.
Casting
Casting of elements like beam, column, slab and walls will be done in advance
Whereas in conventional system casting will not be done in advance
Speed of construction
The prefabricated system takes less time. Because the fabricated panels have to lift
and erect at site and requires minimum propping. No need of any formwork and no need to
wait to gain its strength. Hence requires less time.
Where as cast in situ method requires more time. Because concrete requires minimum 28
days to achieve 99% of strength of its total strength. Only after seven days new element can
be created. Because concrete gains 65% of its total strength in 7 days.
Curing Conditions
In a factory, High early strength can be achieved due to accelerated curing. common method
of curing in the factory are steam curing, warm water curing, boil water curing and
Autoclaving. Hence no need of curing on site.
Where as in case of cast in situ concrete, accelerated curing is difficult and not worth. So we
have to give room for actual curing period which extend the project duration.

Quality
In case of precast concrete, members are made in factory. So quality will be maintained
easily.
Whereas in cost in situ, quality is mainly depends upon the workman ship.
Labours
In case of prefabricated, Less number of labours and less number of skilled labours are
sufficient.
The cast in situ method involves mixing concrete, shuttering, pouring concrete, curing and
deshuttering. So more skilled labours are required
Effect of weather condition
Unexpected weathering condition will not affect the fabrication of precast elements. Because
it is made in the factory
Where as in case of cast in situ system, if there is a rain, the casting work will be affected. If
concreting is done in cold weather, that may require more time for curing.
Cost
In case of prefabricated, same type of component can be produced faster which increase the
productivity and reduce the cost. In addition, shuttering and deshuttering is not required by
the precast elements which also reduce the labour cost. Especially for large scale production
the precast components are almost 20% cheaper than the conventional concrete system.
Where as in situ concrete system cheaper for small scale project. Shuttering, deshuttering,
plastering and curing need to be done at site which required more labour. So it will not be
cheaper for large scale production.
Material Wastage
In case of precast concrete, the wastage of material is negligible.
Where as in case of cast in place system, wastage will be more.
Reusage
Precast elements can be reused and refitted.
But in case of cast in place concrete system, cannot be reused.
Storage of material
In case of precast, no need of storage space or less storage space is sufficient. Because the
panels are manufactured in factory and transported to the site.
But in case of cast is situ, more space is required to store cement, aggregates and also
shuttering materials.
Onsite test
Strength test will be done in the factory itself for the precast. So no need of onsite test.
But in case of cast in situ, onsite test is essential to monitor the quality. So quality control lab
will be available at site.
We have seen the benefits of precast while comparing with the cast in situ system. Let us
have a look on the demerits of the precast or prefabricated system.
1. The moulds that are used for casting the precast panels are little costly, so the
construction will be economical when lot of members are produced.
2. In country very few factories are required. If distance of the construction site is more
from the factory, then transportation cost will escalate.
3. Some members may be broken and wasted during the transportation from the
factory to the construction site.
4. Careful attention is needed to provide proper connections between the
components. So skilled technicians are required.
Hello learners,
So far we have discussed about prefabricated construction system, steps involved in the
prefabrication construction process, merits and demerits of this system.
Tamil Nadu Slum Clearance board is constructing 540 tenements for EWS – economically
weaker section at Athipattu, North Chennai under Pradhan Mantri Awas Yojana (Urban) –
Housing for all mission. Wherein the precast panels are used. The construction is in progress.
We have visited the site and captured the videos for your better understanding. That will be
played in next video.
Stay tune
Thank you.