BMC - Prefabrication - Lecture 1

BUILDING MATERIALS & CONSTRUCTION VIII
BC – TOPIC 04: PREFABRICATED HOUSING CONSTRUCTION

Why the Concept of Prefabrication Evolved?
• Fast growing population
• Requirement of more residential space
• Lower cost & construction in less time (fast production)
• Better & smoother finishes

Definition of Prefabrication
"Prefabrication" is an industrialized, mechanized construction method

/ technique, whereby the building components are mass-produced,
precast either in factories or in temporary plants established in the
site, then precast, mass-produced components are transported to the
site and hoisted & assembled to erect the complete structure with the
aid of cranes and other lifting and handling appliances.
Concept of Prefabrication
The work of building is carried out in two stages:
1) Manufacture of the components in the factory or workshop

2) Erection on the site.
Prefabricated structural components made of concrete, are referred to

as "Precast units" ("Precast members" or precast elements" are terms
alternatively used), signifying that they are cast in advance and given
time to harden and acquire strength before being taken to the actual
construction site for erection.
Construction methods which make use of prefabricated components

are collectively referred to as "Prefabricated construction".
Advantages of Prefabricated Construction
• The construction time is shortened, since structural work on the site

is confined to constructing the foundations and erecting the pre
fabricated components.
• Because of the low moisture content the building dries out more
rapidly than a building of conventional construction and is sooner
ready for service.
• The quantities of materials required are reduced, as formwork and

scaffolding are largely eliminated. Favorable weight-saving structural
sections (hollow concrete block sections) can be used, so that less
concrete and steel is needed and the weight of the building as a whole
is reduced.
Advantages of Prefabricated Construction
• Production of precast units in large series makes it practicable to use

machines whereby the required amount of manual labor is substantially
reduced. Besides the units can be manufactured in the most convenient
position on the casting bed.
• Less man power is needed, since the precast units are manufactured in a
factory or, at any rate, under factory conditions on the building site. Instead
of skilled labor, unskilled workmen can be used, who do not have to travel
around from site to site.
• Better quality of the products is obtained as a result of manufacture under

factory conditions with constant Quality control, the use of machines, and
the better Working environment provided by the factory.
• Construction can proceed almost independently of weather conditions,

since the units can be manufactured in covered buildings which can be
heated and erection of the units can also carried out in winter.
Issues in Prefabricated Construction
• Transportation of heavy and large prefabricated components from

the factory to the construction site.
• Erection & interconnection of prefabricated components to form the

final structure.
• Labor safety during erection of prefabricated elements.

Classification of Prefabricated Construction
Prefabrication is classified in terms of degree of precast construction:
1. Small prefabrication
2. Medium prefabrication
3. Large prefabrication
4. Cast-in-site prefabrication
5. Off-site / factory prefabrication
6. Open system of prefabrication
7. Closed system of prefabrication
8. Partial prefabrication
9. Total prefabrication
Prefabrication Elements
• Flooring / Roofing system
• Precast beams
• Precast columns
• Precast wall panels

• Flooring / Roofing system –
This system consists of RC. planks supported over a partially precast

RC. Joist.
The joists are supported with the main beam through channels which
are provided at the necessary spacing.
To provide 'Tee' beam effect with the joist, the planks are made partly
3cm and partly 6cm thick. Remaining thickness of planks is filled with
in-situ concrete with necessary anchorage reinforcements.
• Precast beams –
The reinforcements are tapered for 300mm on either side to provide

better connection with another beam.
Shear keys are provided on either face of the column to get better
anchorage. The top corners of the beam on either side are hunched to
provide good accessibility to the in-situ concrete at the connections.
Channel sections are provided at a regular spacing to connect the
joists.
• Precast columns –
The special types of columns are used to hold the wall panel in
position.
These types of special columns having high load carrying capacity and
moment carrying capacity than the conventional types of columns.
The ribs will act as a temporary support for the beam having erection.
• Precast wall panels –
Cellular concrete of 75mm thick blocks are sandwich by a layer M25

grade concrete for thickness of 37.5mm on either face.
A minimum area of reinforcements is provided on the side face

concrete.
To withstand the handling and erection stresses RC.C. ribs are

provided around the wall panel.
Door and window frames are done simultaneously while casting the
wall panels.
Advantages of Prefabricated Elements over Conventional
Elements of Construction
• This R.C. plank and joist system provides good Tee beam effect,
because of the in-situ concrete and anchorage reinforcements.
• In this system triangular shaped stirrups are used to provide better

anchorages between the in-situ concrete and joist.
• In this system slender sections are used for planks and joists, for the
same loading condition as in the conventional buildings, so
considerably the quantity of steel and concrete is reduced. Dead
weight of the roof floor system also considerably reduced.
Advantages of Prefabricated Elements over Conventional
Elements of Construction
• Because of the less weight, the plank and joist can be transported
and erected easily.
• The bottom surface of the planks is very smooth due to pre-casting.

So, no need of special ceiling plastering.
• Cellular concrete is used as a filler material in the middle core of the

wall panel. Wall panels are smooth due to pre-casting with M25, grade
concrete. No need for special plastering. with the use of cellular
concrete the weight of wall panel is considerably reduced, and it is
easy to transport and erect in position.
Connection Details
• Wet connections – joints are filled up with in-situ concrete
• Dry connections – joints are welded / bolted
The connection should satisfy technical, economical, and if required -

aesthetical aspect.
Considerations for Choice of Connection
• Structural requirement – connection should comply with

transmission of forces, bending moments or rotation.
• Aesthetical requirement - The connection remains completely or in-

part exposed.
• Finishing requirement – With regard to corrosion protection, fir

resistance and maintenance.
• Manufacture – should be technically and economically viable.

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BUILDING MATERIALS & CONSTRUCTION VIII

BC – TOPIC 04: PREFABRICATED HOUSING CONSTRUCTION

• Fast growing population

• Requirement of more residential space

• Lower cost & construction in less time (fast production)

• Better & smoother finishes

"Prefabrication" is an industrialized, mechanized construction method

The work of building is carried out in two stages:

1) Manufacture of the components in the factory or workshop

Prefabricated structural components made of concrete, are referred to

Construction methods which make use of prefabricated components

• The construction time is shortened, since structural work on the site

• The quantities of materials required are reduced, as formwork and

• Production of precast units in large series makes it practicable to use

• Better quality of the products is obtained as a result of manufacture under

• Construction can proceed almost independently of weather conditions,

• Transportation of heavy and large prefabricated components from

• Erection & interconnection of prefabricated components to form the

• Labor safety during erection of prefabricated elements.

Prefabrication is classified in terms of degree of precast construction:

• Flooring / Roofing system

• Precast wall panels

• Flooring / Roofing system –

This system consists of RC. planks supported over a partially precast

The reinforcements are tapered for 300mm on either side to provide

• Precast wall panels –

Cellular concrete of 75mm thick blocks are sandwich by a layer M25

A minimum area of reinforcements is provided on the side face

To withstand the handling and erection stresses RC.C. ribs are

• In this system triangular shaped stirrups are used to provide better

• The bottom surface of the planks is very smooth due to pre-casting.

• Cellular concrete is used as a filler material in the middle core of the

• Wet connections – joints are filled up with in-situ concrete

• Dry connections – joints are welded / bolted

The connection should satisfy technical, economical, and if required -

• Structural requirement – connection should comply with

• Aesthetical requirement - The connection remains completely or in-

• Finishing requirement – With regard to corrosion protection, fir

• Manufacture – should be technically and economically viable.

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