CIV 367

PREFABRICATION
AND
MODULAR CONSTRUCTION

Akshat Mahajan
Prefabrication
Prefabrication, 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.

The concept and practice of prefabrication in one form or another has been
part of human experience for centuries; the modern sense of
prefabrication, however, dates from about 1905.

In Pre-fab construction, building components are pre-fabricated in yards

and brought to construction site of installation. In traditional
construction all components are casted at situations. Pre-fab are fast to
complete the construction as many components are casted together in
advance and installed at site without delay
 Prefabrication
Prefabrication is the practice of assembling components of a structure in a factory or
other manufacturing site, and transporting complete assemblies or sub-assemblies to
the construction site where the structure is to be located. The term is used to distinguish this
process from the more conventional construction practice of transporting the basic
materials to the construction site where all assembly is carried out.
The term prefabrication also applies to the manufacturing of things other than structures
at a fixed site. It is frequently used when the fabrication of a section of a machine or any
movable structure is shifted from the main manufacturing site to another location, and the
section is supplied assembled and ready to fit. It is not generally used to refer to electrical
or electronic components of a machine, or mechanical parts such as pumps, gearboxes
and compressors which are usually supplied as separate items, but to sections of the
body of the machine which in the past were fabricated with the whole machine.
Prefabricated parts of the body of the machine may be called 'sub-assemblies' to distinguish
them from the other components.
Prefabricated Components
 Prefabrication : When it Started
Actually started from the countries where there was a challenge of
construction throughout the year. So the engineers started the
production of elements (beams, slabs, columns, etc) in the factories
when it was not possible to work in open due to adverse weather
conditions. For, then those pre-fabricated elements were erected on
site. certain months when the weather used to be clear

Majorly this was the reason that precast construction technology came
into existence
Aims of Prefabricated Construction
Advantages of Prefabricated Construction.
Mitigating the labor shortage

Contractors already have difficulty finding labor, but construction still

needs to happen. When on-site construction proceeds piecemeal, it
reduces labor productivity even further. Prefabrication, therefore, helps
companies speed up timelines, make the most of the labor they have on-
site, increase productivity, and compete in the marketplace

Cost-effectiveness:

Moving partial assemblies from a factory often costs less than moving
pre-production resources to each site.

Plus, as labor productivity rises, costs associated with personnel fall.

Advantages of Prefabricated Construction.
Time savings
According to Brandt, “A modular building can go up as much as 50%
faster than traditional construction, taking a project from
conception to completion quickly and easily—reaching that coveted
return on investment fast.” This is especially important on heavy civil
projects that can be very weather-dependent. When you’re racing a
rainy season, time is of the essence and prefabrication can help you
maintain tighter timelines
Quality control

When compared to repeated construction on-site, factory tools can offer

added quality assurance. Moreover, the consistent indoor
environments of factories eliminate most impacts of weather on
production, while the streamlined manufacture and assembly processes
improve job site safety on the whole.
Advantages of Prefabricated Construction.
Lower environmental Impact

Constructing pieces quickly offsite results in reduced pollution and

disturbance of jobsites. This protects nearby wetlands or protected
areas and minimizes disruption of local flora and fauna. The
controlled, dry environment of modular construction saves on water
usage and enables the recycling of scraps and other materials. Plus,
with less on-site traffic and streamlined transportation, fossil fuel
consumption plummets.

Better safety and security

By reducing the timeframe of a construction-site, you concurrently

reduce the amount of time that site is vulnerable to vandalism or theft.
Because prefab, modular or manufactured pieces arrive in much
larger “chunks,” the building itself goes up faster, and you can secure
it that much sooner.
 Advantages of Prefabricated Construction.
•Easy Assembly
The foremost speciality of prefabricated construction is that each component can be
manufactured separately and then transported to the site of construction, So easy to
Assembling.

•Sustainable construction
Extra balance of materials after the prefabricated building construction can be recycled or
reuse instead of thrown away.

•Quality
Prefabrication parts are manufactured in a controlled industrial environment, and there
must be a standard of quality that has to be followed.
The quality of the work will be better as everything is done in a controlled industrial
environment
Prefabricated buildings are more budget-friendly when compared with on-site
construction.

•Eco Friendly
prefabricated materials are constructed in a factory, extra materials can be recycled in-hous
Advantages of Prefabricated Construction.
•Wastage
Prefabricated structures reduce material wastage.

•Faster construction
prefabrication takes less than half the time approximately when compared to old
construction types.

•Budget friendly
Prefabricated buildings are more budget-friendly when compared with on-site
construction.

•Eco Friendly
prefabricated materials are constructed in a factory, extra materials can be recycled
in-house.
Characteristics to be considered for
Prefabrication
• Easy Availability
• Light weight for easy handling and Transport and to economize
on sections and sizes of foundations
• Thermal Insulation Property
• Easy Workability
• Durability in all weather Conditions
• Non-Combustibility
• Economy in Cost
• Sound Insulation
Need for Prefabrication
• Prefabricated construction is obtained in places where it is not
suitable for normal construction Practise such as Hills.

• Prefabricated construction is adopted in places where

materials are not Locally available.

• In order to achieve speed in construction

• In order to obtain high-quality of work with a higher degree

of precision.
Need for Prefabrication

• If there is a lack of space in the construction site.

• If there is bad weather conditions in the construction site.

• Non- availability of local workers near to construction site.

• If there is mass construction practice.

Principles of Prefabrication
• To improve quality of work, as it is manufactured under improved

and controlled conditions.

• To speed up the construction, since no curing is necessary

• To achieve a good quality of construction with minimal cost.

• To use materials that possess innate characteristics such as

lightweight, sound insulation, thermal conductivity etc…

• To use locally available materials with required characteristics

• Use of reusable materials in construction

Principles of Prefabrication
• Design for flexibility and adaptability.
• Simplify and standardize building systems.
• To provide safety working platform during deconstruction.
• To minimize complexities in building design.
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Advantages of Prefabrication
1. Self-supporting readymade components are used, hence use of
scaffolding and shuttering is greatly reduced.
2. Speeder construction than normal one
3. Quality control can be easier in factory than in construction site
4. Quality obtained in prefabrication process is higher than normal one
5. Prefabricated construction is independent of bad weather conditions
in the construction site.
6. Onsite construction and congestion is eliminated
7. Provides safer working platform for labourers
8. There is minimization of noise and dust in the construction site
9. Prefabrication mode is economical than conventional methods
10. Lesser expansion joints are required
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Disadvantages of Prefabrication
• Careful handling of prefabricated panels are required.
• If the joints are not properly sealed there may be problem of
leakages
• Cost of transportation may be high
• Transport of high voluminous materials requires larger road width
• Traffic congestion is the big issue during mass transportation
• Large prefabricated structure requires heavy duty crane, high
precision measurement and proper placing of components
• Attention has to be paid towards strength and corrosion resistance
of sections while joining in order to avoid failures
• Local jobs may be lost
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Modular Coordination
Modular coordination is a concept of coordination of dimension and
space, in which buildings and components are dimensioned and
positioned in a term of a basic unit or module, known as ‘1M’ which is
equivalent to 100 mm.

• It is internationally accepted by the International Organization for

Standardization (ISO) and many other countries.

• Thus, the modular coordination can facilitate the achievement of

greater productivity in the building industry by virtue of its ability to
discipline the dimensional and spatial coordination of a building and its
components.
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Modular Coordination
Modular Coordination is a useful design tool that provides useful design
principles and rules which combine freedom in architectural planning
and free choice of construction method, with the possibility of
incorporating standardized modular components in the project.
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Modular Coordination
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Modular Coordination
The standard specifies that the module basic M =100mm as the basic unit
to be used in a square of M. The introduction of MC in the industry is to
improve productivity and quality in building construction as well as to
act as a tool for rationalization and industrialization of the building
industry.

MC has been introduced in Malaysia since 1986, but has not been widely
implemented in the building industry. The main factors limiting the uses
of MC in building industries is lack of knowledge on MC concept and it
requires precision dimensioning and proper planning
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Modular Coordination
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Modular Coordination
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Benefits of Modular Coordination

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Benefits of Modular Coordination

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Characteristics of Modular Coordination

• The basic module is small in terms of odd size in order to provide

design flexibility, yet large enough to promote simplification in
the components variation in sizes.
• Industry friendly features that not only cater for manufacturing
but also the transportation and assembly requirements.
• Ergonomically designed to promote efficiency.
• Internationally accepted to support international market
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Characteristics of Modular Coordination

• The use of modules (basic Modules, multi-modules and Sub
Modules).
• A reference system to define coordinating spaces and zones for
building elements and for the components which form them.
• Rules for locating building elements within the reference system.
• Rules for sizing building components in order to determine their
work size.
• Rules for defining preferred sizes for building components and
coordinating dimensions for building.
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Objective of Implementing Modular Coordination

• The principal objective of implementing MC is to improve
productivity through the reduction of wastages in the production,
installation process, to improve quality in the construction industry
and to encourage an open system.
• With Open System approach, building components could combine in a
variety of individual building projects while ensuring the architect
freedom in their designs.
• MC is an important factor in application of Industrialized Building
System by way of standardization of components and dimensions
such as reduce time of production and installation of components,
achieving repeatability and able to construct building at lower cost.
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Modules
Module Standard unit size used to coordinate the dimensions of buildings and
components MODULES

Basic module (M = 100 mm)

The basic module is the fundamental unit of size in modular co-ordination).
The unit ( of length ) of modular co-ordination, the size of which is selected in order to
achieve dimensional co-ordination of building elements and of general purpose
building components with maximum flexibility and convenience, and shall be denoted by
letter ‘M’

Multi-Module 2M, 3M :

Multimodule are selected multiples of the basic module;

different multimodule will suit particular applications.
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Modules
• Sub-Module M/2, M/4
For sizing of components requiring increment smaller than M.

NOTE - This is the international

standardized value.

IS: 10316:1986

The contents of this standard are

equivalent to those given in the
following standards published by the
International Organization for
Standardization ( IS0 ).

IS0 1005-1973 Modular co-ordination -

Basic module.

IS0 6514-1982 Building construction -

Modular co-ordination - Sub-Modular
increments.
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Sub Modular Increments

4.2.1 Sub-modular increments shall be used where there is a need for an
increment smaller than the basic module.
4.2.2 Sub-modular increments shall not be used for determining the distance
between modular reference planes of a modular grid.

4.2.3 Sub-modular increments may be used for:

a) determining the co-ordinating sizes of building products and components
smaller than 1 M ( for example: certain types of ceramic tiles and nominal drops
in floors ); and
b) determining the co-ordinating sizes of building components and products
larger than 1 M which need to be sized in increments smaller than 1 M ( for
example bricks, tiles, thickness of walls, floors and sub-floors, and the sizing and
location of pipes, etc ).
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Reference System
REFERENCE SYSTEM The reference system is a system of points,
lines and planes to which the sizes and positions of building
components or assemblies relate.

A reference system should be used during the design stage, and may
also form the basis of the system of lines from which
measurements on site are set out.

MODULAR SPACE-GRID
A modular space-grid is a three-dimensional system of planes within
which a building and its components are located. The distance
between the planes in such a system is equal to the basic module, or
to a multimodule.
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Reference System

Multi Modular System

The grid in which the spacing of the consecutive parallel lines is equal
to n times the Basic Module.
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Standard and Recommended Modular

Dimensions
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Standardization of Components
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Standardization of Components
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Types of Prefabrication:

1.Conventional prefabrication construction is the most traditional

construction method where all the construction activities are in-situ
practices on site.

2. Semi-prefabrication divides as two sub-categories: system formwork

and nonstructural semi-prefabrication, involving a part of in-situ
construction activities and a part of prefabrication. Normally, the non-
structural semi-prefabrication is applied on façade, curtain walls, lost
form systems etc.
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Prefabrication Types

3. Comprehensive prefabrication involves a structural part and pre-

finished construction. Examples of applications of structural
comprehensive prefabrication include staircases, slabs, columns and
beams.

4. Volumetric off-site fabrication encloses usable space but does not

constitute the whole building. Volumetric off-site fabrication is mainly
used for ‘facilities’ and includes solutions on office washrooms, plant
rooms, building services risers and lifts.
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Materials Used for Pre Fabricated Construction

1. Galvalume
Protecting steel from oxidation is a must for many projects. While
applying a zinc coating to (known as galvanizing) steel is one
common method to prevent corrosion, another material type,
known as Galvalume.
Galvalume is a coating consisting of zinc, aluminum and silicon
that is used to protect a metal (primarily steel) from oxidation.
Galvalume is a suitable match for applications that demand high
corrosion resistance and heat reflectivity.

The main difference between galvanizing and Galvalume is that

galvalume is a combination of zinc, aluminum, and silicon, while
galvanizing is 100% zinc. The makeup of the three elements in a
Galvalume coating is just over 50% aluminum, just under 50% zinc,
with trace amounts of silicon.
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Advantages/ Properties of Galvalume

• Excellent resistance to corrosion:
When the zinc starts to degrade, the aluminium will form a thick
alumina layer which prevents further corrosion of the materials inside.
Its corrosion resistance is 3 times that of galvanized sheet.

• High heat reflectivity. The thermal reflectivity of GL sheet is very high,

twice that of galvanized steel sheet, and it is often used as a thermal
insulation material.

• Heat resistance. Galvalume steel has impressive heat resistance that will
withstand temperatures that exceed 300 degrees.

• Appearance: The surface of the GL steel sheet is smooth with beautiful

and uniform spangles, and the base colour is silver white, so it can be used
as cladding.

• GL coating has good adhesion to paint film so it can be the substrate for
PPGL (pre-painted galvalume) steel.

• It has good processing performance and can be punched, sheared,

welded, etc. for other uses.
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Materials Used for Pre Fabricated Construction

2. Structural insulated panels (SIPs)
Structural insulated panels (SIPs) are high-performance insulating
panels used to construct walls, ceilings, and floors for residential
and light commercial properties. They are a type of composite
sandwich panel system that forms an insulating core.

Each panel has multiple layers that combine to resist heat transfer
efficiently. SIPs provide extreme durability, strength, and energy
efficiency compared to traditional insulation methods.

SIPs are manufactured in various dimensions and thicknesses,

generally ranging between 4 and 8 inches.

Based on the specifications of the project, SIPs can be

manufactured.
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Materials Used for Pre Fabricated Construction

Advantages of Structural insulated panels (SIPs)
• Provide healthier air quality
• Highly energy-efficient
• High design flexibility
• Provide high strength and thermal performance
• Fast fabrication and installation
• Use less energy
• Reduce waste
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Materials Used for Pre Fabricated Construction

Generalized: Structural insulated panels (SIPs) (for Understanding)
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Materials Used for Pre Fabricated Construction

Types of Structural insulated panels (SIPs)

Based on the insulating material used for manufacturing, there

are mainly three types of SIP’s:

1.Expanded polystyrene insulated panels

2.Polyurethane insulated panels
3.Compressed straw-core insulated panels
4.Insulated Concrete Formwork (ICF)
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Materials Used for Pre Fabricated Construction

1.Expanded polystyrene insulated panels

Expanded Polystyrene (EPS) panels act as insulation panel in

composite sandwich panels with Expanded Polystyrene (EPS)
insulation as core. EPS panels have multiple applications in the
construction industries. They can be used in cavity wall, duct and floor
insulation, void filling, floor raising and packaging application. High
density panels are recommended for insulation and floor raising
applications. Low density panels which has good resilience property
can be used for packaging applications .EPS panels are manufactured
using polystyrene beads that are expanded to their size through a
chemical process that uses heat.
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Materials Used for Pre Fabricated Construction

1.Expanded polystyrene
Insulated panels
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Materials Used for Pre Fabricated Construction

2. Polyurethane insulated panels
Polyurethane Insulation Panels are versatile and can be used for interior
or exterior walls, partitions, roofing, ceiling in commercial, industrial
or residential buildings, warehouses, cold rooms and clean rooms,
factory buildings, prefab containers and cabins. Polyurethane Panels
are especially highly efficient in industries like food processing,
refrigeration, pharmaceuticals and drug storage, fish and dairy, etc.
insulated partitions enable you to divide your interior space into cool
and normal temperature zones.

Polyurethane Foam
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Materials Used for Pre Fabricated Construction

Polyurethane insulated panels

Polyurethane Foam Panel

Construction using Polyurethane Foam

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Materials Used for Pre Fabricated Construction

3. Compressed straw-core insulated panels
These are manufactured using renewable and recycled waste agricultural
straw, unlike other panel materials. They are environmentally friendly and
provide excellent thermal insulation, thermal storage and sound insulation as
well as a high resistance to mold, pests and fire.

Compressed straw-core
insulated panels Construction using Polyurethane Foam
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Materials Used for Pre Fabricated Construction

4. Insulated Concrete Formwork (ICF)

Insulating concrete formwork (ICF) is a building system that uses lightweight

formwork (made from an insulating material) to support concrete walls whilst
they are being cast in-situ and which is then left in place as insulation.

Insulated concrete formwork consists of twin-walled expanded polystyrene

panels that are stacked together to create the permanent formwork used to
contain the ready-mixed concrete for the walls.
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Materials Used for Pre Fabricated Construction

Insulated Concrete Formwork (ICF)

The insulated formwork remains in place to provide complete thermal

insulation to the walls of the finished building. It also provides a
uniform surface ready for direct application of most finishes and
proprietary cladding systems.
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Materials Used for Pre Fabricated Construction

Steel framing

Steel frame is typically consisting of a vertical column and horizontal

beams which are riveted, bolted or welded together in a rectilinear grid.
Steel beams are horizontal structural members that resist loads applied
laterally to their axis. Columns are vertical structural members that
transfer compressive loads. It can be used to form the skeleton of a
building. Structural steel framing is typically designed, fabricated and
erected in accordance with applicable standards
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Materials Used for Pre Fabricated Construction

Types of Steel Framing
Conventional Steel Fabrication
Conventional steel fabrication involves cutting steel members to the
correct length and welding them to build the final structure. This
construction process may be executed on site entirely which require
massive manpower.
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Materials Used for Pre Fabricated Construction

Bolted Steel Connection

In this technique, all structural steel members are fabricated and painted off-
site, then delivered to the construction site, and finally bolted in place.
It is considered to be the most preferred construction approach because the
most of the fabrication can be done in workshops, with the right machinery,
lighting, and work conditions
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Materials Used for Pre Fabricated Construction

Light Gauge Steel construction
Light gauge steel is a thin sheet (commonly range between 1-3mm) of
steel which has been bent into shape to form C-sections. It is broadly
common and used for the construction of residential and small buildings.
Benefits that light gauge steel construction provide include design
flexibility, high construction speed, strong, lightweight, easy to remodel,
Recyclable, good Quality (durable and low in maintenance).
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Prefabricated Systems
Small Prefabrication:
The first three types are mainly classified according to their degree of
precast elements used in the construction.
For example, brick is small unit of precasted material and used in
buildings. This is called as small prefabrication and the degree of
precast element is very low.

Medium prefabrication:
Suppose the roofing systems and horizontal members are provided
with precasted elements. These constructions are known as medium
prefabricated construction. Here the degree of precast elements is
moderate.
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Prefabricated Systems

The system of prefabricated construction depends on the extent of the use

of prefabricated components, their materials, sizes, and the technique
adopted for their manufacture and use in the building.

The various prefabrication systems are give on the Next Slide

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Prefabricated Systems
Small Prefabrication:
The first three types are mainly classified according to their degree of
precast elements used in the construction.
For example, brick is small unit of precasted material and used in
buildings. This is called as small prefabrication and the degree of
precast element is very low.

Medium prefabrication:
Suppose the roofing systems and horizontal members are provided
with precasted elements. These constructions are known as medium
prefabricated construction. Here the degree of precast elements is
moderate.
Prefabricated Systems
Large prefabrication System

In large prefabrication most of the members like wall panels, roofing /

flooring systems, beams and columns are prefabricated. Here the
degree of precast elements is high.

OFF SITE PREFABRICATION

One of the main factors which affect the factory prefabrication is
transport. The width of the road, mode of transport vehicles are the
factors which determines the prefabrication which is to be done on site
or in factory. Suppose the factory is situated far away from the
construction site and the vehicle needs to cross congested traffic areas
with heavy weighing elements the cast in-site prefabrication is
preferred. Even though the same condition as the cast in site
prefabrication is preferred only when numbers of houses are more for
small elements the conveyance is easier with normal type of lorry and
tractors. We can adopt factory or off-site prefabrication for this type of
construction.
Prefabricated Systems
OPEN PREFABRICATED SYSTEM

This system is based on the use of the basic structural elements to form
whole or part of a building. The standard prefabricated concrete components
which can be used are,
1) Reinforced concrete channel units
2) Hollow core slabs
3) Hollow blocks and battens
4) Precast plank and battens
5) Precast joists and tiles
6) Cellular concrete slabs
7) Prestressed / reinforced concrete slabs
8) Reinforced / prestressed concrete columns
9) Precast lintels and sunshades
10) Reinforced concrete waffle slabs/shells.
11) Room size reinforced / prestressed concrete panels
12) Reinforced / prestressed concrete trusses
Prefabricated Systems
Prefabricated Systems
Large panel Prefabricated System
• This system is based on the use of large Pre fab components. The
components used are precast concrete large panels for walls, floors,
roofs, balconies, staircases etc.The casting of the components
should be at the site or off the site.
• Multistorey buildings are composed of large wall and floor concrete
panels connected in vertical and horizontal directions.
• Panels form a box like structure. Both vertical and horizontal panels
are load bearing and resist gravity load.
• Horizontal floor and roof panels span either on way or two way,
when joined together.
Prefabricated Systems
Wall System
Structural scheme with precast large panel walls can be classified as
1) Cross wall system
2) Longitudinal wall system

* In the longitudinal wall system, the walls resisting the gravity and lateral loads are
placed in longitudinal direction
Prefabricated Systems

Cross wall construction is a building construction technique in which the

precast load-bearing walls are placed perpendicular to the lateral axis
of the building. In this type of construction, the floors, roofs and the
beams are supported by the load-bearing walls. The structures
developed with the cross wall technique are structurally efficient and
economical.
Prefabricated Systems
Floor System
Depending upon the composition of units, precast flooring units could
be homogeneous or non-homogeneous.

1) Homogeneous floors could be solid slabs, ribbed or waffle slabs.

2) Non-homogeneous floors could be multilayered ones with combination

of light weight concrete or reinforced / pre stressed concrete with filled
blocks.

Depending upon the way, the loads are transferred the precast floors
could be classified as one way or two way systems.
Prefabricated Systems
Floor System
Prefabricated Systems
Floor System
Prefabricated Systems
Staircase System
Prefabricated Systems
Box Type System
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Prefabricated Systems
Partial Prefabrication
In this method of construction, the building elements required are precast and
then erected. Since the casting of horizontal elements (roof / floor) often take
more time due to erction of frame work, the completion of the building is
delayed and hence this method is restored. In most of the building sites, this
method is popular, so in industrial buildings where the elements have longer
spans.
Use of double tees, channel units, cored stabs, slabs, hyperboloid shells, etc, are
some of the horizontal elements used. This method is efficient when the
elements are readily available and the building has reached the roof level. The
delay caused due to erection of framework, delay due to removal of
framework is eliminated completely in this method of construction suitable for
any type of building provided lifting and erection
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Prefabricated Systems
Total Prefabrication
Very high speeds 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 is done on-site or off-site. The choice of the 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 we should have a very good

transportation facility for the products to be transported to the site of
construction.
• If the elements are cast near the building site and erected, the
transportation of elements can be eliminated, but we have to consider the
space availability for establishing such facilities though it is temporary .
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Materials Characteristics for Prefabrication

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Transportation of Prefabricated members

Transport of prefabrication elements must be carried out with extreme

care to avoid any flock and distress in elements and handled as far as
possible to be placed in the final portion.

Transport of prefab elements inside the factory depends on the method of

production selected for the manufacture.
Transport of prefab elements from the factory to the site of action should
be planned in conformity with the trafficable rules and regulations as
stipulated by the authouritic the size of the elements is often restricted by the
availability of suitable transport equipment, such as tractor-tailor, to suits
the load and dimension of the member in addition to the load carrying
capacity of the bridges on the way.
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Transportation of Prefabricated members

While transporting the prefab elements in various systems, such as wages,

trucks, bullock cards etc. care should be taken to avoid excessive
cantilever actions and desired supports are maintained.
Special care should be taken in negotiating sharp beds uneven of
slushy roads to avoid undesirable stresses in elements and in transport
vehicles. Before loading the elements in the transporting media, care
should be taken to ensure the base packing for supporting the elements
are located at specified portion only.
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Transportation of Prefabricated members

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Precautions for Transportation

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Erection of Prefabricated members

• Slinging of Prefab elements

• Tying up of erection slopes and connecting to erection hooks
• Cleaning the elements and site of erection
• Cleaning the steel inserts and setting the elements to correct position
• Adjustment to get the stipulated level line and plumb
• Welding of deats
• Putting up and removing the necessary supports

The erection work in various construction jobs by using prefab elements

differ with the risk condition, hence skilled foremen and worker are
employed on the Job.
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Production Techniques for Prefabricated

members

There are many techniques for producing prefabricated

components and can be grouped in three main techniques

a. The Stand system

b. The conveyor belt system/Production line system

c. The Aggregate system

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Production Techniques for Prefabricated

members
a. The Stand system

In stand system the prefabricates mature at a point where they are

moulded, while the production team moves to successive stands
on the beds on which prefabricates lie.
The bed on which these prefabricates are cast may be fixed or
movable.
Tilting forms are often used and in this system steam curing is
generally done.
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Production Techniques for Prefabricated

b. The conveyor belt system
members
• The whole production system is split up in a series of operations carried
out at separate successive and permanent points served by specialized
teams. The movement of the mould or the prefabricate from one point to
the other is done by conveyor belts.

• The rigid steel forms are assembled at station 1 where they are mould
oil to reduce the adhesion of concrete. Then the conveyor belt moves
from station 1to station 2 where the prestressing wires are fixed and in
the next station anchoring wires are carried out.

• The prepared mould is then taken to the casting station, after casting it is
shifted to vibration table and then finally stacked at next station for
setting.

• The production system of the conveyor belt divides the entire

production process into a series of operations carried out at a successive
and permanent separate point by means of conveyor belts and crane, etc.
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Production Techniques for Prefabricated

b. The conveyor belt system
members
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Production Techniques for Prefabricated

C . The Aggregate System
members

The word aggregates describe a large and complex set of permanently

installed machines and A mechanical application that can carry out most of
the separate operations involved in casting concrete system.

At the production point, the reinforcement is fixed in the form and remote
controlled aggregate (machine) inserts the duct formers, cast and vibrates
the concrete and floats (finishing) the top of the floor.

The prepared fabricate then move to the autoclave chember in which the
hardening of the concrete is accelerated.

In many factories, combined technology are employed when complex

prefabricate is required.
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Production Techniques for Prefabricated

members

Aggregate System
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Classification of Prefabrication based on

manufacturing Location
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Classification of Prefabrication based on

manufacturing Location
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Process involved in Manufacture of Prefabricated

structures

There are many process involved in the manufacture of Precast

elements and they are classified as
Main Process:
• Providing and assembling the moulds, placing reinforcement cage in

position for reinforced concrete work, and

• Fixing of inserts and tubes where necessary.

• Depositing the concrete in to the moulds.

• Vibrating the deposited concrete into the moulds.

• Demoulding the forms.

• Curing (steam curing if necessary)

• Stacking the precast products

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Process involved in Manufacture of Prefabricated

structures
Secondary (Auxiliary process)

This process is necessary for the successful completion of the process

covered by the main process.
• Mixing or manufacture of fresh concrete (done in a mixing station or by
a Batching plant)
• Prefabrication of reinforcement cage (done in a steel yard of workshop)
• Manufacture of inserts and other finishing items to be incorporated in
the main precast
• products.
• Finishing the precast products.
• Testing the precast products
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Stages for Pre fabricated Concrete product

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Basic definitions/ terminology

Standardization

Standardization is to the creation and use of guidelines for the

production of uniform interchangeable components especially for use in
mass production. It also refers to the establishment and adoption of
guidelines for conduct to global marketing the term is used in describes
the simplification of the procurement and production to achieve
economy

Tolerance

It is the sum of acceptable positive and negative discrepancies of the

actual dimensions from the theoretical one. The limits of the tolerance
is based on the manufacture and erection requirements.
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Factors influencing Standardization

• To select the most rational type of member for each element form
point of production , assembly, serviceability and economy.

• To limit the no. of types of elements.

• To use large size of elements so as to reduce no. of joints.

• To limit size so as to manage overall weight to handle the

component during its stacking transportation and erection.
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Limitations/ Drawbacks of Prefabrication

• Extra reinforcement is required to take care of handling and

Erection Stresses.
• Cracks may appear at the joints between the precast in site
concrete due to shrinkage and temperature stresses.To overcome
extra steel is required across joint.
• Temporary Properties may be required in some cases before the
un site concrete joints achieve strength.
• Careful handling of prefabricated components such as concrete
panels of steel and glass panels is reduced.
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Factor of Safety in Designing

Prefabricated System
• In prefabricated structures, the prefabricated components shall
be designed with proper structural integrity to avoid situations
where damage to small areas of a structure or failure of a
single element may lead to the collapse of major parts of the
structure.

• All buildings shall be capable of safely resisting the minimum

horizontal load of 1.5% of the characteristic dead load applied
at each floor level