BUILDING CONSTRUCTION

AND MATERIAL-VII

TOPIC - COMPONENTS OF PREFABRICATION

SUBMITTED TO - AR DAMANDEEP KAUR

SUBMITTED BY - MANLEEN KAUR (1700532)

SHRUTI VERMA (1731685)
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CONTENTS
Table of Contents ........................................................................................... Page No.

Part I – Introduction ...................................................................................... (3)

1.1 Introduction ................................................................................................. (3)
1.2 Definition ..................................................................................................... (3)
1.3 Materials used in prefabrications…………………………………………. (3)

Part II – Components of prefabrication ........................................................ (4)

2.1 Flooring ........................................................................................................ (4)
2.2 Roofing......................................................................................................... (5)
2.2.1. Roof slabs
2.2.2 Roof truss
2.2.3 Roof Panels
2.2.4 Roofing Materials
2.3 Column…………………………………………………………………. (7)
2.3.1 Column to foundation
2.3.2 Column to beam
2.3.3 Column to column
2.4 Beam……………………………………………………………………… (9)
2.4.1 Types of beams
2.4.2 Beams connections
2.5 Walls……………………………………………………………………… (11)
2.5.1 Cladding or curtain walls
2.5.2 Load-bearing wall units
2.5.3 Shear walls
2.5.4 Formwork for cast-in-place concrete
2.6 Lintels……………………………………………………………………… (13)
2.6.1 Pre- cast lintels
2.7 Stairs……………………………………………………………………… (14)
2.7.1 Benefits of precast stairs

Part III – Details of prefabrication............................................................... (16)

Bibliography…………………………………………………………………. (18)

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 PREFABRICATION

Prefabrication is the method of construction which includes assembling components of a

structure in a manufacturing or production site, transporting complete assemblies or partial
assemblies to the site where the structure is to be located. It is combination of good design
with modern high-performance components and quality-controlled manufacturing
procedures.
This work is carried out in two stages, manufacturing of components in a place other than
final location and their erection in position.
Prefabricated sections are produced in large quantities in a factory and then shipped to
various construction sites. This procedure may allow work to continue despite poor
weather conditions and should reduce any waste in time and material at the site.

This requires certain stages of preparation -casting, curing, transportation and erection.
• Casting: – Precast components are casted with controlled cement concrete in moulds of
required shape and sizes.
• 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.
• 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.

MATERIAL TO BE USED IN PREFABRICATION

• Concrete
• Steel
• Treated wood
• Aluminum
• Cellular Concrete
• Light weight Concrete elements
• Ceramic products

COMPONENTS OF PREFABRICATION
• Flooring
• Roofing
• Column
• Beam
• Wall
• Staircase
• Lintel

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 FLOORING

A floor slab (also called plate slab or filigree slab) is reinforced concrete slab with a
minimum thickness of 5–6cm.

Depending on the concrete covering and reinforcement, it can be up to 7cm thick. The
floor slab is a semi- precast component that includes the lower floor slab reinforcement that
is required for structural reasons.

The floor slab is precast in the precast concrete component factory under ideal conditions,
and contains the torsion ally stiff reinforcement (truss) that is required to give stiffness
once installed, as well as the flexural tension reinforcement, lengthways and
crossways, that is required for assembly and the final state.

The floor slab is made into a solid and monolithic reinforced concrete floor by using mix-in-
situ concrete that is poured at the construction site. The thickness of the finished floor slab
is between 12 and 30 cm, depending on the span and the loading.

Apart from some differences in the measurement of the pushing force, the floor slab can be
regarded from a structural point of view as being the same as a floor that has been
produced on site with concrete poured into casing.

The floor slab thus combines the major advantages of prefabrication with the advantages of
floors that have been produced on site with concrete poured into casing.

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 ROOFING

• Roof slabs
• Roof truss
• Roof Panels
• Roofing Materials

Roof slabs
A Roof slab would be a concrete slab (either in-situ or pre-cast) which functions as a roof
(i.e. the overhead element in a building which encloses the interior space at the top and acts
as a barrier between the inside and outside).
A Concrete slab is a common structural element of modern buildings, consisting of a flat,
horizontal surface made of cast concrete. Steel-reinforced slabs, typically between 100 and
500 mm thick, are most often used to construct ceilings. It can be prefabricated off-site and
lowered into place

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Types of slab
i. Flat slab - This is a typically a reinforced slab supported directly by columns or caps,
without the use of beams. This type of slab is generally easy to construct and requires
little formwork.
ii. Conventional slab - This type of slab is supported with beams and columns, with the load
transferred to those elements. A conventional slab is classified as either:

a) One-way
b) Two-way

iii. Waffle slab - This type of slab contains square grids with deep sides, resembling a waffle
shape, often used where large spans are required without the interference of columns.
Waffle slabs can be capable of supporting a greater load than conventional slabs.
iv. Composite slabs - They are typically constructed from reinforced concrete cast on top of
profiled steel decking.

Roof truss
A truss is a structure with straight pieces forming triangles to support a load. The members
of the triangles are placed under tension and compression but do not bend.
A joint framed structure that sustained the inclined, vertical or horizontal loads. A truss
consists of angles, channels, plates and eye bars.

Timber roof truss -

i. A timber roof truss is a structural framework of timbers designed to bridge the space
above a room and to provide support for a roof.
ii. Pre-fabricated wood trusses offer advantages in building construction through machine-
made accuracy and tend to use less timber

Steel Roof Truss

iii. When the span exceeds 10 m, timber trusses become heavy and uneconomical. Steel
trusses are more economical for larger spans.Steel trusses are fabricated from rolled steel
structural members such as channels, angles, T-sections and plates.
iv. Prefabricated steel trusses offer a high-strength, light-weight roof system that can be
installed quickly.

• Roof Panels
Prefabricated structural panels are a form of building product that can be manufactured
off-site and assembled on-site, providing an alternative to traditional site-based
construction.

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 Types of prefabricated panels

i. Concrete insulated panels – These comprise a robust insulated concrete with a brick outer
leaf, and can be manufactured with external windows and doors. They are designed to
have a service life of more than 60 years.

ii. Structural insulated panels – Structural insulated panels are a form of sandwich panel
system that incorporates insulation, predominantly used for residential and light
commercial construction

• Roofing Materials
Roofing material is the outermost layer on the roof of a building, sometimes self-
supporting, but generally supported by an underlying structure. A building’s roofing
material provides shelter from the natural elements.
1. Metal Roofing sheets
2. Polycarbonate roofing sheets
3. Corrugated sheeting

COLUMN

Columns are typically used to support beams and spandrels in applications such as parking
structures and precast concrete structural systems of all types.

They generally are designed as multilevel components ranging from a single story to six
levels or more. Sizes and shapes can vary to satisfy both architectural and structural
requirements.
Typical shapes: Square or rectangle
Typical sizes: From 12 by 12 in. to 24 by 48 in.
Precast concrete columns may be single or double storey height. The method of connection
to the foundation and to the column above will vary with manufacturer.
Designer should be conversant with various connection methods:
• Column to foundation
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• Column to beam
• Column to column

Column to Foundation – The connection can be through reinforcing the bars which
protrude from the column ends and passing into sleeves that are then gout-filled.
Alternatively, the columns can be connected to the foundation through a base plate linked
to the column.

Column to Column – The connections can be achieved by joining threaded rods using
appropriate connectors (Collins n.d.). During the process, the cement mixture is
consequently, cast round to the column’s cross-sectional dimension resulting in thin
stitches between the columns

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Column to Beam – Columns are provided with sufficient supports for the end of the cast
beams. In addition to the support, some form of connections is also provided for column-
beam continuity and moment connections. The connection may be through holes for the
passage of the reinforcement bars from one beam to another(interior). However, for edge
columns, some form of sockets or brackets are necessary.

BEAMS
.
Beams are horizontal components that support deck members like double tees, hollow-
core, solid slabs, and sometimes other beams.
They can be reinforced with either pre-stressing strand or conventional reinforcing bars
Typical depths: 16 to 40 in.
Typical widths: 12 to 24 in.
Typical span-to-depth ratios: 10 to 20-

Beams are typically considered structural components and are made in one of three key
shapes:

• Rectangular
• Inverted Tee Beams
• L-Beams

Beams can be designed as either full, semi or shell sections depending on the fabrication,
joining details, handling and delivering and lifting capacities of the crane.
• Design consideration:
• Section properties
• Construction methods
• Sequence of the loads applied to the beams
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 • Beam behavior at the serviceability and ultimate limit state

Types of beams
i. RCC beams – RCC beams are structural elements designed to carry transverse external
loads that cause bending moment, shear forces, and in some cases torsion across their
length. It can be classified as per size into- rectangular, T-Beam, I-Beam, Circular Beam
and L-Beam.
ii. Pre-stressed beams – FRP-prestressed beams are greater than those of steel-prestressed
beams. It is very easy to install with reduced on-site labor needs and costs
iii. Shell beams – Shell beams are commonly used with precast floor systems to streamline
building programs and reduce on-site labor. Pre-stressed shell beam units, with the
addition of a reinforcing cage and on-site concrete.

Types of Beam Connections

• Beam-to-beam connection
• Beam-to-column connection
• Beam slab connection

Beam-to-Column connection

Beam to slab connection

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 WALL

Precast wall panel is an independently supported vertical member in a prefabricated

structure using an assemblage of metal components and anchors. Joints around each of the
precast panels are usually filled with sealant.

There are generally four types of precast panels used as part of building envelopes:
• Cladding or curtain walls
• Load-bearing wall units
• Shear walls
• Formwork for cast-in-place concrete

Cladding or Curtain walls

Precast cladding or curtain walls are the most common use of precast concrete for building
envelopes. These types of precast concrete panels do not transfer vertical loads but simply
enclose the space. A Curtain wall system is an outer covering of a building in which the
outer walls are non-structural.

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Load-bearing wall
Load-bearing wall units resist and transfer loads from other elements and cannot be
removed without affecting the strength or stability of the building. Typical load-bearing
wall units include solid wall panels, and window wall and spandrel panels. Precast concrete
wall panels that act as load bearing elements in a building are both a structurally efficient
and economical means o f transferring floor and roof loads through the structure and into
the foundation.

Shear Wall
Shear walls are vertical structural components meant for resisting horizontal forces and
counter act the lateral loads acting on the structure like wind seismic forces etc.They are
designed for the strength and stiffness to resist the horizontal forces.They are designed to
provide a safe serviceable and economical solution for wind and earthquake resistance.

Materials-
• RC shear wall
• Plywood shear wall
• Mid ply shear wall
• RC Hollow concrete
• Block masonry wall
• Steel plate shear wall
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 LINTEL

A lintel is a structural horizontal support used to span an opening in a wall or between two
vertical supports. It is frequently used over windows and doors, both of which represent
vulnerable points in a building's structure.
Lintels are generally used for load-bearing purposes, but they can also be decorative.
The most common materials for lintels are timber, steel and concrete.

Precast concrete lintels - They are economical and provide robust support for structures
such as masonry over door and window openings. They are able to accept a wide range of
surface finishes.

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 STAIRS
Stairs is simply a structural member that gives vertical access from one floor to another.
Stairs are placed in a house for safe and convenient access of occupants from one floor to
other. Stair consists of small series units known as steps.

Stairs are made of concrete, stone, wood, steel or combination of any of these. They are
either build/constructed on site or are prefabricated/ precasted and placed on site. Here, we
will focus on precast concrete stairs. Concrete stairs significantly reduce noise caused by
people moving around a house. Concrete stairs and landing slabs, fitted along with
concrete floors are provided with an appropriate handrail for safe vertical access to floors.

Precast concrete stair, made up of reinforced concrete is one of the best options to
eliminate the trouble of adjusting the number of steps, rise, run and width of each stair
flight.

They are available as:

• A single precast unit containing all the flights and landings

• Separate precast flights and landings
• Parts of the flights and landings are made in one unit

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Benefits of Precast Concrete Stairs:

• Advanced mechanical connection, speeds the installation process along with

eliminating the need of propping (temporary supports).
• Precast stairs are designed and manufactured to any specific floor height and
application.
• These are durable and maintenance free.
• Eliminates the need for temporary stairs during construction.
• Safety rails and handrail can be pre-installed prior to installation.

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DETAILS OF PREFABRICATION

FOUNDATION TO WALL CONNECTION

BEAM TO COLUMN CONNECTION

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SLAB BEAM COLUMN CONNECTION

COLUMN TO COLUMN CONNECTION

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 BIBLIOGRAPHY

• www.wikipedia.org
• https://www.slideshare.net/SofiaRajesh/prefabricated-components
• https://www.slideshare.net/AbhishekM45/prefabrication-structure
• https://cbri.res.in/wp-content/uploads/2016/03/Dr.KP-Jaya.pdf
• https://www.slideshare.net/nishantpatyal/precast-and-prefabricated-
components-and-structures-and-the-connection-between-them
• https://www.sciencedirect.com/topics/engineering/prefabricated-component

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