Unit 4: Prefabricated Construction

– Part 2

Structural System and Design - V

 Contents
• Uses of prefab construction
• Methods of prefab construction
• Classsification of prefab construction
• Modern day use in Prefab housing and other fields
 Uses
• Prefabricated components speed up construction time, resulting
in lower labor costs.
• Prefabrication allows for year-round construction
• Work is not affected by weather delays (related to excessive
cold, heat, rain, snow, etc.)
• The mechanization used in prefabricated construction ensures
precise conformity to building code standards and greater quality
assurance
• There are less wasted materials than in site-built construction
• There is less theft of material/equipment (and less property
damage due to vandalism)
 Uses
• Materials are protected from exposure to the elements during
construction
• Worker safety and comfort level are higher than in site-built
construction
• Computerization of the production process permits a high degree
of customization, at an affordable cost
• Quality control and factory sealing and design can ensure high
energy efficiency
• Cost savings through prefabrication can reduce the income
required to qualify for a high ratio mortgage by upto one third
compared to a conventionally built home of the same size.
 Methods of prefabrication
Plant prefabrication
• Plant fabrication is adopted for large scale production.
• The members produced are to be transported at 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
restraint 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.
 Methods of prefabrication
Plant prefabrication
• 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.
Methods of prefabrication
 Methods of prefabrication
Site prefabrication
• Site prefabrication is adopted for large scale prefabricates.
• The RC members are produced at the site chiefly in the open air or in the
temporary sheds.
• The difficulties in construction in general are felt in this mechanization case.
• Mechanization can not be of such high degree as site prefabrication is done for
smaller duration of time.
• When the prefabricates are of large size it is difficult to transport them to the
site.
• 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.
Methods of prefabrication
Methods of prefabrication
 Classification of Prefabrication
• Small prefabrication
• Medium prefabrication
• Large prefabrication
• Cast in Site prefabrication
• Off-site or Factory prefabrication
• Open system of prefabrication
• Closed system of prefabrication
• Partial prefabrication
• Total prefabrication
 Classification of Prefabrication
Small prefabrication
• Elements using in the construction for e.g. Brick is a small precast
unit and used in building. This is called as small prefabrication.
The degree of precast element is very low.
 Classification of Prefabrication
Medium prefabrication
• Suppose the roofing systems and horizontal members are provided
with pretested elements for construction, they are known as
medium prefabricated construction. Here the degree of precast
elements are moderate.
 Classification of Prefabrication
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.
 Classification of Prefabrication
Open prefabrication
• In the open prefabrication system, the space framers are casted as a
single unit and erected at the site.
• The wall fitting and other fixing are done on site.
 Classification of Prefabrication
Closed system of prefabrication
• In this system the whole things are casted with fixings and erected
on their position.
 Classification of Prefabrication
Partial prefabrication
• In this method of construction the
building elements (mostly horizontal)
required are precast and then erected.
• Since the costing of horizontal
elements (roof / floor) often take time
due to erection of formwork, the
completion of the building is delayed
and hence this method is restored.
• Use of double tees, cored slabs, slabs
etc., are some of the horizontal
elements.
 Classification of Prefabrication
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. The total prefabrication can be on site or off-site.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication
• One of the main factor which affect the factory prefabrication is
transport. The width of walls, mode of transport, vehicles are the
factors which decide whether prefabrication is to be done on site
or 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 off-site prefabrication is
preferred even though it is challenging.
• Cast in site prefabrication is preferred only when number of
houses is small and conveyance of precast elements is easier
with normal type of lorry and trailers.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication
• 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. It
is suitable for any type of building provided lifting and erection
equipments are available.
• The manufacture of the components can be done in a factory for
the commercial production established at the focal point based on
the market potential or in a site-precasting yard set up at or near
the site of work.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication
• Factory prefabrication is restored in a factory for the commercial
production for the manufacture of standardized components on a
long-term basis.
• It is a capital-intensive production where work is done
throughout the year preferably under a closed shed to avoid
effects of seasonal variations.
• High level of mechanization can always be introduced in this
system where the work can be organized in a factory-like manner
with the help of a constant team of workmen.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication
• Cast-in-site prefabricated components is normally adopted for a
specific job order for a limited period.
• Semi-mechanized
• The work is normally carried out in open space with locally
available labour force. The equipment machinery used may be
minor in nature and moulds are mobile or stationary in nature.
• Fully mechanized
• The work will be carried out under shed with skilled labour.
• The equipments used will be similar to one of factory production.
This type of precast yards will be set up for the production of
precast components of high quality, high rate of production.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication
• Though there is definite economy with respect to cost of
transportation, this system suffers from basic drawback of its
non-suitability to any high degree of mechanization and no
elaborate arrangements for quality control.
• Normal benefits of continuity of work are not available in this
system of construction.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication
• The choice of these two methods depend on the situations when
the factory produced elements are transported and erected on site
we call it off-site prefabrication.
• If this method is to be adopted then there should be 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 the space
availability for establishing such facilities should be considered
even though it is temporary.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication

• The temporary supporting props to • The transportation of precast

hold the precast façade in position. facades.
This prevents any movement of the
panel and allows final adjustments to
be made.
 Cast-in-site prefabrication vs. Off-site
(factory) prefabrication

• Lifting precast slab into position

• The worker is laying the services pipes and service conduits.

Prefabricated Construction – An
overview
Prefabricated Construction – An
overview
Assembly of Precast Members
Prefabricated Construction – Assembly
Manufacturing Process
 Standardization
• It is defined as the process of adoption of generally accepted
uniform procedures, dimensions, materials or parts that directly
affect the design prefabricated product or a facility.
• Examples: Modular Bathroom, Standard kitchen cabinet, Prison
cell etc.
Advantages of Standardization
• Easier in design as it eliminates unnecessary choices
• Easier in manufacture as there are limited number of variants
• Makes repeated use of specialized equipments in erection and
completion
• Easier and quicker
 Factors influencing Standardization
• To select the most rational type of member for each element from
the point of production, assembly, serviceability and economy.
• To limit the number of types of elements and to use them in large
quantities.
• To use the largest size of the extent possible, thus resulting in less
number of joints.
• To limit the size and number of prefabricate by the weight in
overall dimension that can be handles by the handling and
erection equipment and by the limitation of transportation.
• To have all these prefabricates approximately of same weight
very near to the lifting capacity of the equipment.
 Production Systems

• Line up System (conveyor belt system) • Stand System

• Aggregate System
Materials used for handling
 Stacking – Dos and Don’ts
• Stacking method and packers for support spacers vary according
to the type of precast elements.
• Horizontal stacking – beams, slabs and columns
• The storage support position for beams and slabs – within 300
mm from the lifting points.
 Stacking – Dos and Don’ts
• Do not use more than two support points in particular pack for
prestress elements like hollow core slab
 Stacking – Dos and Don’ts
• The packers or support spacers should not be misaligned as as
shown.
 Stacking – Dos and Don’ts
• Wall panels should always be stored vertically and braced in
position by A – frames or racking systems
Precautions during transport
 Erection and installation of
prefabricated elements

• Temporary strengthening of panels with opening is necessary

 Erection and installation of
prefabricated elements

Precast Beam
• The lifting points should be designed and located to limit the bending
moments within the beam element.
• As a general guide, they should be located at about one fifth of the beam
length measured from the edge.
 Erection and installation of
prefabricated elements

Precast Wall
• For wall panels, it is recommended to lift the panel in vertical position for
installation so that turning is not required.
• Hoisting method adopted for demoulding of wall panels that are cast
horizontally.
 Erection and installation of
prefabricated elements

Precast Plank/ Slab

• Wherever necessary multiple lifting points can be designed and located to
minimize undue stresses within the slab elements, in particular for slender
panels such as precast planks.
Erection and installation of
prefabricated elements
Precast Column
• Columns are usually
first handled in
horizontal position.
Slings are attached to
the inserts at the top to
facilitate the rotation of
the elements to vertical
position before hoisting
and placing to their
designated location.
Hoisting of prefabricated elements