PRE-FABRICATION

BUILDING CONSTRUCTION
AND MATERIALS (AR-802)

SUBMITTED BY:-
KANIKA JAIN
B.ARCH- VIII SEM
R.No. 17163020002

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CONTENTS: -
A. DEFINITION
B. CHARACTERSTICS
C. USES
D. PROCESS
E. COMPONENTS
F. ADVANTAGES
G. DISADVANTAGES
H. MATERIALS USED IN PRE-FABRICATION
I. PRINCIPLES BEHIND PRE-FAB HOUSES
J. DIFFERENCE BETWEEN PRE-FAB TECHNIQUE AND TRADITIONAL ON-
SITE CONSTRUCTION TECHNIQUE
K. PRECASTE SYSTEMS
L. JOINTS and CONNECTIONS
M.PRE-FAB COMPONENTS MANUFACTURES
1. VME-GROUP
2. LLYOD INSULATIONS (INDIA) LIMITED

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DEFINITION: -
• It may be defined as the assembly of buildings or their components at a location other
than the building site.
• The method controls construction costs by economizing on time, wages, and materials.
• Prefabricated units may include doors, stairs, window walls, wall panels, floor panels, roof
trusses, room-sized components, and even entire buildings.
• It ensures the strength, economy and environmental performance of the structures and
hence is preferred over the onsite construction.
• It is learnt that this construction technique exists from prehistoric times and has not been
evolved recently.
• “The Stonehenge” is a prominent example as it was also completed in different stages.
• Concentric rings are made by the arrangement of columns standing in height. To ensure
the stability of structure Tenon and Mortise joints were used.

INSTALLATION OF PRE-FABRICATED WALLS

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CHARACTERISTICS OF PRE-FABRICATION: -
Following are the characteristics of pre-fabrication method: -

 Easy availability,
 Light weight for easy handling and transport, and to economies on sections and sizes of
foundations,
 Thermal insulation property,
 Easy workability
 Durability in all weather conditions,
 Non-combustibility,
 Economy in cost and
 Sound insulation.

USES: -
1. The most widely used from 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 lines.
2. Pouring Concrete section in a factory brings the advantages of being able to re-use molds
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.
5. The 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.
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9. Radio bowers 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.

PROCESS OF PRE-FABRICATION: -
The Prefabrication as defined will be done in two stages: -
 Manufacturing at factory condition and
 erection of components at the required location.

This requires certain stages of preparation. They are Casting, Curing, Transportation and erection.
1. Casting: - Precast components are casted with controlled cement concrete in moulds of
required shape and sizes. The vibrator is used to vibrate concrete and this removes any
honeycombing inside the components.
2. Curing: - After 24 hours of casting, the casted components are released from the mould
and transported to curing tanks. Certain special components like railway sleepers where
high strength is required are steam cured.
3. Transportation and erection: - After complete curing is done the components are
transported to the site with heavy trucks and erection will be done using cranes with
skilled labor force.

PREFAB BUILDING COMPONENTS: -

Some of the prefab building components are as follows: -
1. Columns: – A column is a vertical member carrying the beam and floor loadings to the
foundation. It is a compression member and therefore the column connection is required
to be proper. The main principle involved
in making column connections is to ensure
continuity and this can be achieved by
a variety of methods.

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2. Beams: – Beams can vary in their complexity of design and reinforcement from the very
simple beam formed over an isolated opening to the more common encountered in frames
where the beams transfer their loadings to the column. Methods of connecting beams and
columns are
 A precasting concrete haunch is cast on to the column with a locating dowel or stud bolt to
fix the beam.
 A projecting metal corbel is fixed to the column and the beam is bolted to the corbel.
 Column and beam reinforcement, generally in the form of hooks, are left exposed. The two
members are hooked together and covered with insitu concrete to complete the joint.

3. Waffle unit for flooring / roofing: – These are suitable for roofs / floors spanning in two
directions. They are laid in a grid pattern. These units are cast in moulds. The saving
achieved is not much. Also Shuttering are complicated and costly. Time consumption for
construction is less

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ADVANTAGES OF PRE-FABRICATION: -
Following are the advantages of pre-fabrication technique: -
 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 labor is more readily available and costs of
labor, power, materials, space and overheads are lower.
 Time spend in bad weather or hazardous environments at the construction site is
minimized.
 Installation of building services and finishes can be done immediately.
 Independent of weather condition.
 Components produced at close supervision .so quality is good
 Clean and dry work at site.
 Possibility of alterations and reuse
 Correct shape and dimensions and sharp edges are maintained.
 Very thin sections can be entirely precast with precision.

DISADVANTAGES OF PRE-FABRICATION: -
Following are the disadvantages of pre-fabrication technique: -

 Careful handling of Prefabricated components such as concrete panels or steel and glass
panels is required.
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  Attention has to be paid to the strength and corrosion-resistance of the joining of
prefabricated sections to avoid failure of the joint.
 Similarly, leaks can form at joints in prefabricated components.
 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.
 Large Prefabricated Structures require heavy-duty cranes & Precision measurement and
handling to place in position.
 Large group of buildings from the same type of Prefabricated elements tend to look drab
and monotonous.
 Local jobs are last.
 They are to be exactly placed in position, otherwise the loads coming on them are likely to
get changed and the member may be affected.
 High transport cost
 Need of erection equipment
 Skilled labor and supervision are required.

MATERIALS USED IN PRE-FABRICATION: -

Several materials are used in prefab homes, such as concrete, timber, and metals
CONCRETE
 It is possible to achieve sturdy structures with very intricate profiles through the use of
moulds.
 Precast concrete panels can also be used in larger multi-storey constructions that can
constitute the building blocks.
 The materials themselves can be formulated to meet certain requirements, such as
lightweight (there are concrete formulations that can float on water) and resistance to
temperature fluctuations.
 Additives such as graphene oxide can be added to concrete to make it a more sustainable
material.

WOOD
 Wood is another commonly used material in prefab homes.

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  It can be used as-is, in the form of “heavy timber”, which refers to column and beam
structures, or in the form of “mass timber”, which refers to its use as panel systems (a
combination of wood and other materials).
 Bamboo is a common building material that can be adapted for use in prefab homes, as
well.
 Examples of such wood materials include cross-laminated timber (CLT), glued laminated
lumber (GLULAM), and laminated veneer lumber (LVL).

STEEL
 Steel is a common building material used as support frames (I-beams and columns), floors,
and walls for modular buildings.
 It may be used in conjunction with materials or as the bulk of the building materials, such
as in the adaptation of shipping containers.
 Advantages of steel are its relatively low weight-to-strength ratio, ease of transportation,
and recyclability.
 In contrast, its drawbacks include poor insulation, subpar acoustic performance, and the
fact that using steel for this purpose potentially takes it out of the recycling loop.

GLASS
 Glass is a highly customizable material for several building functions.
 Several types of glass are used in construction, including tempered glass, laminated glass,
heat-strengthened glass, and wire glass.
 Glass can bring about useful properties, such as high strength, insulation, chemical
resistance, and fire resistance.
 Glass also has a unique aesthetic quality and is fully recyclable, a common theme of prefab
houses.

RECYCLED AND RECLAIMED MATERIALS

 Recyclable materials include some of the traditional building materials, such as concrete,
gypsum wallboard, and steel.
 They also include other materials, like cellulose insulation, ceiling tiles, plastics, ceramic or
porcelain tiles, and fiberglass insulation.

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  The challenge of using these materials is that some of them do not have a steady supply
and cannot be relied upon for consistent use.
 Some of these materials may also be toxic or harmful to residents over the long term and
so must be carefully studied if they would fit the purpose.

PRINCIPLES BEHIND PRE-FAB HOUSES: -

The driving principles behind prefab houses are:
1. INDUSTRIALIZATION AND MASS PRODUCTION
 Prefab homes can be mass-produced since the components can be constructed relatively
faster than on-site building.
 This would represent a shift in the focus and infrastructure of building from producing raw
materials such as cement, sand and I-beams, to producing modular components such as
precast panels and plywood.

2. SPEED AND AFFORDABILITY

 Prefab homes are cheaper than regular homes due to the amount of time and effort saved
compared to traditional construction.
 The time consumed is more often concentrated in making the components rather than in
assembling them.

3. CUSTOMIZATION AND SUSTAINABILITY

 The design of prefab houses needs the components to fit in a way that allows for a
reasonable degree of customizability.
 Furthermore, the processes employed in the construction and assembly need to have as
little environmental impact as possible.


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 PRE-FAB CONSTRUCTION TECHNIQUE TRADITIONAL ON-SITE CONSTRUCTION
METHOD
Weather doesn’t affect the speed at which Weather conditions affect the speed of
construction is completed. progress.
It is able to be transported. Only raw materials can be transported.
It offers significantly faster timelines to Construction time is much more.
consumers.
Quality control measures produce great Quality gets affected due to cheap material
results. quality.
Modular construction minimizes waste. Waste production is comparatively more.
Communities are less interrupted with pre- Noise production from machinery etc.
fabricated construction. interrupts the community.
Modular construction produces airtight Some gaps or holes may get left due to poor
commercial buildings. workmanship.
Pre-fabricated construction reduces overall Energy usage is more.
energy use.
Once a modular construction project begins, Changes can be made after construction
changes can’t be made to the plans. begins.
It requires extremely detailed planning Easily renovate or add on to an existing
before building. structure.
Customization of modular construction Customization of design details is limitless.
projects is limited.
COMPARISON BETWEEN PRE-FAB AND TRADITIONAL ON-SITE
CONSTRUCTION METHOD: -

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PRECAST SYSTEMS: -
In order to understand the construction of precast concrete structure, different precast systems
shall be known. There are four major types of precast systems which are classified based on the
on the load bearing structure:

1. LARGE PANEL SYSTEM

 Large panel systems are useful for the construction of apartments and hotels.
 It consists of large walls and floor concrete panels connected in the vertical and horizontal
directions.
 Both horizontal and vertical panels withstand gravity loads.
 There are three arrangements of large panel system based on wall layouts which include
cross-wall system, longitudinal-wall system, two-way system.

Large Panel Precast Concrete System Construction

2. FRAME SYSTEM
 It is suitable for the construction of car parks, stadia, and offices.
 Precast frames can be constructed using either linear elements or spatial beam-column
sub assemblages.
 Precast beam-column sub-assemblages have the advantages that the connecting faces
between the sub-assemblages can be placed away from the critical frame regions.

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  However linear elements are generally preferred because of the difficulties associated with
forming, handling and erecting spatial elements.

Precast Concrete Frame Structure erected within four weeks

3. SLAB- COLUMN
SYSTEM WITH SHEAR
WALL

 In this system, gravity loads supported by slab-column structure whereas shear walls
withstand lateral loads.
 There are two types of slab-column system with shear walls namely; lift slab system with
walls and pre-stressed slab-column system.

Precast Column-slab System

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ELEMENTS IN PRECAST CONCRETE BUILDING SYSTEMS: -
Precast concrete members are manufactured in factory under controlled conditions to keep
standard dimensions and tolerances. Structural elements used in the construction of precast
concrete buildings include:
1. Precast concrete wall (Panels),
2. Precast Slabs,
3. Precast Beam and Girders,
4. Precast Columns,
5. Precast Stairs

PRECAST CONCRETE CONSTRUCTION CONSIDERATIONS: -

1. Erection Sequence
Precast concrete members shall be erected according to preplanned sequence. The erection plan
is commonly prepared drawings If it is important for structural stability and for access to
connections at specific location. The erection sequence shall avoid multiple handling of elements.
Finally, a trial erection operation should be considered to identify any unforeseen erection
difficulties.

2. Erection Safety
Safety during the handling and erection of precast concrete elements is substantially important.
Therefore, all machines and equipment employed precast concrete element handling and
erection need to be maintained to a high standard, load tested, and be suited to the intended
utilization.

3. Erection Tolerances
Generally, the precast unit should be erected in accordance with the tolerances provided by
applicable codes, unless other tolerances are used in the design and specifications.

4. Rigging
A rigging system for handling and erecting precast elements requires careful and thorough
preplanning. It may be necessary to equalize loads between lifting points on certain precast
elements, such as beams or flat slabs. Lifting accessories may be in the form of slings/cables,
hooks or shackles. The selection of such components should take into consideration the forces
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due to all operations involved in the handling and erection of the precast units. Headroom
availability and maneuverability during erection may also have an impact on the type of rigging
system selected.

5. Temporary bracing
Precast concrete elements must be adequately braced and supported during all phases of
erection to ensure proper alignment and structural integrity until permanent structural
connections are completed.

6. Leveling shims
Leveling shims should be formed from a suitably durable material and should have adequate
strength to carry the full imposed loads. Leveling shims carry the full construction load of the
precast element and must provide adequate support to prevent movement until the element is
incorporated in the main structure.

7. Propping
All temporary propping requirements must be shown on the erection drawings. The design of
temporary propping systems should be in accordance applicable codes. Temporary propping
should provide full support for all construction loads.
6.

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JOINTS: -
 A joint is a designedly gap between adjoining elements or between an element and some
other portion of the structure where the action of forces takes place (e.g., Compression,
 Tension and Shear etc.).
 Joints may be horizontal, vertical or inclined.
 The function of a joint between precast elements is to provide physical separation
between the components of the structure.

CONNECTIONS: -
A connection is an assembly consisting of one or more interfaces and parts of the adjoining
components, designed to resist the action of forces or moments.

Purpose and importance of joints and connections in Precast concrete buildings

The Design & Construction of Joints & Connections is the most important consideration in Precast
Concrete Structures/Buildings.
The purpose of Connection and Joint is:
1) To transmit forces between structural components
2) To provide overall stability
3) To provide strength to the structure
4) To prevent from external leakages

In addition to this the joint is to be designed to resist unpredictable loads due to

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1)Fire
2)Impact
3)Explosion
*Failure of one joint should not affect the stability of the structure, there must be always
alternate path must be available for transfer of loads.

Different types of joints and connections

Two kinds of joints can be distinguished
a) Dry Joints: Joint accomplished by simple placing of two members by means of welding or
fastening,
b) Wet Joints: Joint requires not only casting with cement but also concreting and grouting
material.

Different types of connection between the precast components of a structure

 Column to foundation
 Wall to foundation
 Wall to wall
 Wall to column
 Wall to beam
 Column to column
 Beam to column
 Beam to slab
 Wall to slab
 Stairs to wall

Failure of joints and connections

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As the stability and strength of precast concrete building depends on connections and joints
between the components. So, it is necessary to study the reasons causing the failure of
connections and joints.
Here are the few reasons due to which connections and joints fails:
 Improper Detailing of reinforcement in elements
 Inadequate Design of Precast element
 Type of concrete use and its mix design
 Low quality of material used at the time of production
 Lack of concrete continuity
 Low quality connecting loops provided
 Low quality of grouting material
 Usage of weather sensitive connections
 Inappropriate lapping of steel (locker Bars) in connection
 Inappropriate water to powder ratio of grouting material
 Unprofessional workmanship at the time of execution
 Ignorance in supervision

Issues with Joints and Connections

 Adequate number of joints should be provided to transfer the forces.
 The joints and connection between core structure and components should be strong
enough to transfer the different kinds of loads.
 Joints must have adequate strength to transfer gravity and lateral load between the
precast elements.
 If joints and connection are not well finished and accomplish its results in leakage.

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 124, Eraiyur Road, Vallam (A) Village, Sriperumbudur,
Kanchipuram - 602105,
Tamil Nadu, India
Phone: +91 9840041400
E-mail: [email protected]

VME Precast is a diversified unit of the VME Group which is primarily involved in planning,
execution and transfer of specialized projects in the field of construction like road over bridges,
railway bridges and such other structures, besides highway enhancement.

VME Precast has set up India’s first state-of-the-art precast plant in Oragadam, one of the fastest
growing industrial centers. Backed by Finnish expertise, VME Precast’s in-house structural
designing team takes up turn-key projects right from the structural design stage right up to the
erection of precast elements.

VME Precast uses cutting-edge technology to create precast concrete precisely cast in a
controlled environment and properly cured. The VME Precast plant meets international
production standards and safety norms.

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ELEMENTS OFFERED BY VME-PRECAST
1. Hollow Core Slabs (HCS)
 VME Hollow Core Slabs have all the advantages of precast concrete.
 The Hollow core slab from VME Precast, is of very high quality due to its excellent concrete
compressive strength coupled with high tensile strength of steel strand.
 The Pre-stressed hollow core units are manufactured using long line extruders.
 The HCS are cast on beds having a width of 1.2 meters wide and 120 meters long.
 Based on the project requirements and capacities, the slabs are cut as per the required
dimensions.
 The factory has the capacity to produce 10000 sq. ft per day of HCS in various sizes and in
varied thickness.

HOLLOW CORE SLABS BEAMS

2. Beams
 Precast RCC/Pre-stressed beams are advantageous for fast constructions as no propping of
beams are required.
 There is no need for expensive on-site formwork and flexibility with design is also possible.
 The main advantage of a precast beam structure is that it permits less structural depth for
a given load-bearing capacity.
 Precast beams are manufactured in a variety of sizes, shapes and lengths.
 The concrete surface is smooth and the edges are chamfered.

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3. Columns
 Precast columns can be made in variety of sizes, shapes & for different loading conditions.
 Precast columns can be made for single storey/two/three storey height based on the
weight and the lifting capacity of the crane.
 Different types of connections are possible - bolted/sleeved & other proprietary
connection systems.
 Columns come with corbels to rest the beams.
4. Walls


VME Precast offers a wide variety of Precast panels for external wall, internal walls and
boundary walls, Systems for housing and apartment buildings are normally designed as
wall-frame structures.
 The walls support the vertical loads from the floors and the upper structure.
 Non load bearing walls act as separating walls.
 Sandwich elements consist of two concrete layers with an insulation layer in between.
 The external layer is generally in architectural concrete.
5. Stairs

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VME-PRECAST’s PRODUCTS
1. Compound walls

Various size of compound walls

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 LAYING PROCEDURE OF BOUNDARY WALL
1. EXCAVATION 2. PLACING

2. CONCRETING 4. BACK FILL

EXTERIOR SIDE INTERIOR SIDE

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 2.Sleek walls

 Sleek Walls are thin concrete panels made using structural steel and high strength
concrete of M 40 grade.
 Full composite action is achieved by the bonding of the concrete to the metal framing
assembly.
 These are robust and highly flexible having wide variety of applications. It can be designed
as load bearing walls, shear walls & as cladding walls.
 These walls have been designed as per the Building Code requirements, for Seismic Zones
and for high wind loads.

FULL PANEL SECTION@INSULATION SEC@RIB

Wall Outer Insulation Inner Rib Wall Wall Weight

thickness layer (OL) layer (SL) layer (IL) thickness length (L) height (H) (kg/sqm)
(T) max (BD)
100 50 0 50 120 4m 3m 250
120 30 60 30 120 6m 3m 200
125 35 60 30 120 9m 3m 205

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 Picture showing the layers of Sleek Walls

Wall finishes provided by VME-GROUP

TYPES OF FIXINGS OF PRECAST CLADDING

 Precast concrete cladding can be installed quickly on site, with just-in-time delivery, Panels
can be supported by the structural frame of a building, or self-supporting and restrained.
 Cladding panels can also be designed to be load bearing to support floors.
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  The weight of these cladding panels is only about 200kg/sqm.
 Average size of the cladding panel in commercial buildings can be about 20 sqm.
 Considering 10% of the window openings, the net area would be about 18sqm, which is
about 3.6 tons.
 This is very much lower than the conventional precast concrete. Hence the speed and cost
of erection is low.

1. Restraint fixing 2. Loadbearing fixing

These fixing is designed to hold panels back and Each panel should have two support
transfer all horizontal forces to the structure. positions through which its weight is
transferred to the structure.
3.Retaining Wall
A Hollow core slab retaining wall is a structure designed and constructed to resist lateral soil
pressures when the desired change in ground elevation exceeds the soil's angle of repose.

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 TYPICAL CROSS SECTION OF HC SLAB HCS PLACED CAST IN-SITU CONCRETE

4.Precast Concrete Cladding Wall

 Hollow core wall panels are an excellent replacement for brick masonry walls due to its
excellent concrete compressive strength coupled with high tensile strength of steel strand.
 The pre-stressing strands are usually located in the top and bottom of the panel to give a
uniform effective pre-stress of approximately 2 MPa.

Hollow core slab cladding wall can easily cover

larger span with these vertical and horizontal
joints.

DESIGN REQUIREMENTS DOOR & WINDOW OPENING IN HCS WALL GROOVE DETAILS

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SOME PROJECTS DONE BY COMPANY: -
1. SEEMATTI SILKS, THIRUVARUR

• CLIENT – SEEMATTI SILKS & READYMADES, THIRUVARUR.

• TYPE – SHOW ROOM BUILDING

• LOCATION – THIRUVARUR.
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• PROJECT SIZE – 45,000 sq. ft, BASEMENT+ GROUND + 4 FLOORS

• VALUE – Rs. 680 lacs.

• PRECAST ELEMENTS – Hollow Core Slabs as roof elements, RCC Columns, Beams, Retaining
Walls, lift core walls, Staircase.

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DURING CONSTRUCTION PICTURES OF SEEMATTI SILKS, THIRUVARUR

PRE-CAST FOOT OVER BRIDGE

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OTHER COMPLETED PROJECTS BY VME-PRECAST

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 New Delhi (Registered Office) Plot no.2, Punj Sons Premises, Kalkaji Industrial Area, Kalkaji

New Delhi - 110019. Phone: 011 – 30882900 Email: [email protected]

As one of India’s leading companies offering End to End Industry Solutions, Lloyd Insulations have
been in the business for 51 Years...

Today, they are known as a One stop Multi-disciplinary solution providers serving a wide
spectrum of Industries on Turnkey basis

They specialize in Supplying, Contracting and Manufacturing of Insulation, Refractory, Pre-

fabricated Panels, Pre-Engineered Buildings, Metallic Profiled sheets, Fire-proofing and
Mechanical erection works.

THEIR PRODUCTS: -

 ISOLOYD Nilflame  Supercera Ceramic Fibre

 Specialized Metal Roofing & Wall Cladding Blankets
Systems  Supercera Ceramic Bulk Fibre
 Lloyd Shelter  Rockloyd Building Insulation
 Isothane EMA  Lloyd foam
 Supercera Ceramic Fibre  Lloyd Panel System
 Rockloyd Mattress  Rockwool Panel System
 Rockloyd Slab  Lloyd PU Panel System
 Rockloyd Pipe Sections  Lloyd Soler Cool
 Superfoam
 Supertherm Pipe Support
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THEIR SERVICES: -

 Thermal Insulation
 Building Insulation
 Acoustics
 Pre-Engineered Buildings
 Metal Roofing & Wall Cladding
 Pre-Insulated Sandwich Panels
 Turnkey Cold Storage / Controlled Atmosphere System
 Telecom Shelters / Pre-Fabricated Enclosures
 Water Proofing
 Electrical Heat Tracing
 Active & Passive Fire Protection
 Energy Audit
 Post-Harvest Management Projects for Perishables
 Sector Specialty Packaged Services
 Ship Building Insulation Service
 Refractory
 Auxiliary Services
 Mechanical Work
 Active & Passive Fire Protection
 Acoustic Enclosures

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THEIR PROJECTS: -

Client Name: Winwind Energy Pvt. Ltd.

Location: Chennai, Tamilnadu, India
Month & Year: 2010
Service/Specialty: Pre-Engineered Buildings

Client Name: Administrative building, Lanco

Location: Korba, Chhattisgarh, India
Month & Year: 2010

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Service/Specialty: Pre-Engineered Buildings

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