CONSTRUCTION

SYSTEM

CHITRAKSHII

160BARCHI171

4TH YEAR

7TH SEMESTER

BUILDING CONSTRUCTION

SUSHANT SCHOOL OF ART AND

ARCHITECTURE
INDEX
 PRE CAST
 PRE STRESSED
 PRE ENGINEERED BUILDINGS
 PREFABRICATED CONSTRUCTION
 LIGHT GAUGE STEEL
CONSTRUCTION
 WAFFLE CRETE
 SITE VISIT
  Precast concrete is very durable.
PRE CAST
 There are fewer local environmental
Precast concrete is a form of concrete that is impacts such as dust and noise pollution.
prepared, cast and cured off-site, usually in a
controlled factory environment, using
ELEMENTS
reusable moulds. Precast concrete elements
Precast concrete members are manufactured
can be joined to other elements to form a in factory under controlled conditions to keep
complete structure. It is typically used for
standard dimensions and tolerances.
structural components such as; wall panels, Structural elements used in the construction
beams, columns, floors, staircases, pipes,
of precast concrete buildings include:
tunnels, and so on.
 Precast concrete wall (Panels)
Structural steel frames can provide an
alternative for pre-fabricated structural
components, but precast concrete can be
more economical and sometimes more
practical. Many buildings now include a
mixture of both construction techniques,
sometimes incorporating structural steelwork,
in-situ concrete and precast concrete
elements.

 Precast Slabs

ADVANTAGES
 It is manufactured in a controlled
environment where greater accuracy and
better quality control are possible.
 Reusable factory moulds mean it is
economical to produce repetitive units.
 There is generally less waste.
 On-site assembly can be very fast and is
generally weather independent, reducing
site delays and ensuring the construction
programme can be maintained.  Precast Beam and Girders

 Precast Columns
 Precast Stairs
TYPES OF 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:
 Large Panel System
 Frame System
 Slab-Column System with Shear Wall
 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.
 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. However
linear elements are generally preferred
because of the difficulties associated with
forming, handling and erecting spatial
elements.
• 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 CONCRETE
CONSTRUCTION CONSIDERATIONS
 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.
 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.
 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.
 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 due to all operations
involved in the handling and erection of the
precast units. Headroom availability and
manoeuvrability during erection may also
have an impact on the type of rigging system
selected.
 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.
 Levelling shims
Levelling shims should be formed from a
suitably durable material and should have
adequate strength to carry the full imposed
loads. Levelling 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.
 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.

PRECAST CONCRETE
CONSTRUCTION PROCEDURE
1. After the completion of construction
preparations, the layout of the structure is
set.

2. Then, the foundations of the columns are

constructed (Fig. 10)

4. Beams for precast frames and

precast floors in the case of large
3. After that, the columns are placed using panel systems and column-slab
suitable machines and continuously checked systems are placed.
by surveyor for alignment. In the case of
Frame system and slab-column system with
shear wall. Alternatively, precast panels are
installed in the case of large panel system

Precast Beam Erection

Placement of Hollow Core Precast Concrete

Slab on Walls
5. For precast frames, after the installation of
precast concrete beams, precast concrete
floors are erected.

Beam to Column Seated Connection

 Column to floor connection

Precast Concrete Slab Placement

6. The above steps are followed until the

construction is finalized. For each system of
precast concrete construction, certain type of
connections are used which are discussed
below.

TYPES OF CONNECTIONS
 Beam to Column Connections Seated Connection

 Panel to Panel Connections

Expensive but Safe Cleated Connector

PRE STRESSED
It is a form of RCC that builds in compressive
stresses during construction to oppose those
found when in use is termed as Prestressed
concrete. Prestressed concrete is a
combination of concrete and steel that takes
advantages of the strength of each material.
Sliding Plate Connections
Prestressing has a simple theory and has been
used for many years in different types of
structures. Prestressing is used to counteract
the tension stresses in the concrete beam are
caused by the weight of members and
imposed loads and these loads cause a
positive bending moment in a beam, so
Prestressing is used to introduce a negative
bending moment that should counteract the
all of the positive bending moment.
APPLICATION OF PRESTRESSED
CONCRETE:
 With the use of PSC reduction in
structural members like slab and beam
element.
 Prestressed concrete also reduces the
overall weight of the structure.
 Prestressed concrete is used in bridges to
increase the possible span of the bridge
and to make the structure more durable
under moving traffic condition.
 Prestressed concrete is widely used for
residential and commercial products on
the interior and exterior of building
construction.
 This concrete is used in large span
distances between which are not possible
through the normal RCC construction.
PRINCIPLE
 High yield strength steel alloys are used to
producing permanent pre-compression in
areas subjected to tension.
 The area of tensile stresses forces is
counteracting by reducing the cross-
sectional area of the steel rebar.
FORMS OF THE PRESTRESSED STEEL
 Wires: It is a single unit made of steel.
 Tendons: Tendons are wires and a group
of strands is wound to form a Prestressing
strand.
 Strands: Strands are two, three or seven
wires that are wound to form a
Prestressing strand.
 Cables are the series or group of tendons.
 Bars: The tendons are simply made up of
a single steel bar and diameters of this
steel bar Is larger than that of wire.
METHODS OF PRESTRESSING:
Two methods of Prestressing are as follows:
 Pre-tensioning,
 Post-tensioning.
1: PRE-TENSIONING:
Placement of concrete around the steel
tendons which have been stressed to the
desired degree. Pre-tensioning is a type of
prestressed concrete in which the tendons or
wires are stretched before the pouring of
concrete. After the concrete hardens, the
tendons were cut and the prestressed
concrete force was transmitted to the
concrete by the bond. In pre-tensioning, the
tension is applied to the tendons before the
pouring of concrete. The placement of
concrete around the tendons that have been
stressed to the desired degree. Pre-tensioning
concrete gives a good bond between the
tendons and concrete. Mostly the pre-
tensioning concrete elements are precast in a
factory and must be transported to the
construction site. Prestressed concrete the sides and grouts filled with as per mix
produces a good bond combination between design.
the concrete and tendons. Pretensioning is  Post-tensioning requires specialized
very difficult to perform at the site; its knowledge, experienced engineers and
structure is only done in precast yards. skilled labour.
Tendons used in pre-tensioning should only  Post-tensioning is used in structural
be straight and circular. member like a beam, in bridge decks, roof
slab, etc.
ADVANTAGES OF PRE-TENSIONING
ADVANTAGES OF POST-
 Suitable for precast members that are to
be produced in bulk.
TENSIONING:
 Absence of large anchorage device.  Concrete is good in resisting compression
but weak in tension.
 This fact will cause the bottom section of
POST-TENSIONING: the beam to elongate and causes
cracking.
 Pre-tensioned tendons are considered as
active reinforcement.
 On the other hand, rebar is considered as
passive reinforcement.
 It can be designed to minimize deflection
and cracking.

PRE ENGINEERED
BUILDINGS:
 In the post-tensioning method, the
tension is applied to the tendons after the
hardening of the concrete.
 The conduits, sleeves and the metal tubes
with unstressed tendons inside located in
the form and the tendons are stretched.
 The pre compression is transmitted from
the steel to concrete by using the
anchorage device.
 Post-tensioning is an easier process than Pre Engineered Buildings (PEB) is the buildings
pre-tensioning because it can be done at which are engineered at a factory and
the site. assembled at site. Usually PEBs are steel
 Post tensioning requires specialized structures. Built-up sections are fabricated at
knowledge and person to fabricated, the factory to exact size, transported to site
assemble and install. and assembled at site with bolted
 After the proper curing of concrete, connections. This type of Structural Concept is
tendons are stretched by using jacks on
generally used to build Industrial Buildings,
Metro Stations, and Warehouses etc.
COMPONENTS OF PEB:
Pre Engineered Buildings consist different
steel structural member which are as follows,
 Primary Frame: Primary framing of a PEB
is an assembly of built-up I-Shaped steel
members & that framing consist trusses
or castellated beams etc.
 Secondary Structural Elements: It is
actually Cold Formed Members, which can
be in diff. shapes like “Z”, “C” etc. In
general known as “Purlins”.
 Roof & Wall Panels : Tin shades & Curtain
Wall made of Glass & Roll-formed steel
sheets usually comes in this category , S
 Sandwich Panels: Sandwich Panel is made
of three layers, in which a non-Aluminium
Core is inserted b/w two aluminium
sheet.
 Other Accessories: Mezzanine floors,
Bolts, Insulation, etc.
ADVANTAGES OF PEB:
There are many advantages of Pre Engineered
Buildings, which are as follows,
 Quality control is the main advantage as
all the structural member are engineered
beforehand, standards of different codes
also taken into consideration & these
components are made in factory under
the supervision of Quality Control
Engineer.
 Lower cost due to the saving in design,
manufacturing and on site erection cost.
 Minimizing time of construction due to
the use of software for design of the
structural components.
 Low Maintenance due to use of standard
quality of paints over steel members ,
which increases the ability to withstand &
finally the maintenance cost will be low as
compare to conventional steel building.
 Quick Erection, as all the members are Pre
Manufactured & skilled labor is used for
connections of different components.
 Warranty on PEB, mostly warranty period
of 20 years given by manufactures for
PEB.
DISADVANTAGES OF PEB:
Although PEB have many advantages in the
field of Industrial structure but still there are
some demerits of Pre Engineered Buildings,
which are as follows,
 Rusting / Corrosion Sensitive, as if the
quality of steel used or paint used for
coating of steel members is not of good
quality , than it can damage the structure
and thus reduces the life of structure.
 Insulation Cost, as insulating the building
to an agreeable benchmark will
furthermore add to your construction
costs.
 Appearance, Steel Sections can be
unattractive when left exposed.
PREFABRICATED
CONSTRUCTION
Prefab or prefabrication is the practice of
bringing together components of a structure
in a factory or other manufacturing site and
then transporting the complete assembles to
the construction site where the structure is
planned to be located. This technique controls
construction costs by economizing time,
wages, and materials. Prefabricated units may
include doors, wall panels, floor panels, stairs,
window, walls, roof trusses, room-sized
components, and sometimes even entire
buildings.
This building method has been gaining a lot of
popularity and builders across the world are
using factory precision and efficiencies to
construct quality structures.
PREFAB CONCEPT
Prefabricated construction is a combination of
great design with up-to-date high-
performance mechanisms and quality-
controlled manufacturing procedures. The
work is carried out in mainly two stages, first
is the manufacturing of the components
which takes place in the factories or a location
that is other than its final location and the
second stage is the erection of the structure
in the final position.
The different prefabricated sections are
produced in huge quantities and then shipped
to various construction sites. The precast
concrete units are hardened and cast before it
is used in the construction. However,
sometimes, builders cast components at the
construction site and hoist them into the
actual location after they harden.
With prefab techniques, bad weather
conditions no more hinder the construction
process, in fact, it helps in reducing waste in
time and materials at the site. This technique
also ensures speedy erection of the
structures.
APPLICATION
Prefabrication is just not used in the
construction of huge buildings, but it has
several other uses too:
 The most commonly used form of
prefabrication building is the use of
prefab concrete and steel sections in
structures where one particular building
element is repeated a number of times.
 Prefabrication eliminates the need to
transport concrete to the construction
site and the need to mix and pump wet on
a congested construction site. Also
pouring concrete sections in factories
ensure the moulds can be reused time
and again.
 Prefabricating steel sections cut cost on
on-site cutting/welding and also lessens
the linked hazards.
 These techniques are also being used in
the construction of apartment blocks,
housing developments which have
repeated housing units, office blocks,
warehouses and factory buildings.
 Prefab glass and steel section are being
widely used in the exteriors of large
buildings.
 Prefab bridge systems and elements offer
noteworthy benefits in terms of cost,
construction time and safety
environmental impact constructability for
bridge designers and contractors.
 Mobile phone radio towers and other
services very often comprise of numerous
prefabricated sections.
 This technology is also being widely used
in the assembly of space crafts and
aircraft. Components like fuselage
sections and wings are often
manufactured in different countries or
states and then finally assembled in the
actual site.
ADVANTAGES OF PREFABRICATED
CONSTRUCTION
Prefabricated Construction, Prefab, Prefab
technology, off-site construction
Prefabricated construction is fetching more
popularity, improving in quality and is now
available in a variety of different budgets. Lets
now take a look at the advantages of
prefabricated construction for both
businesses and customers:
 Speed – The off-site fabrication process
takes place in the factory; hence the site
preparation activities can go on in
parallel. This can significantly help in
reducing the overall constriction time of a
project.
 Sustainability – Least site disturbance,
closely managed material flow and
construction waste, and pre-planned
assembly/disassembly can help in cutting
down the environmental impact of
construction. Pre-fab structures are very
sustainable because they reduce the
amount of waste produced.
 Safety – In factory settings, controlling
health and safety is much easier.
 Quality – Factory controlled processes
ensure the products are of a
predetermined quality. Also, the indoor
environment protects the buildings and
the components from climate extremes
and destruction.
 Clean – Minimisation or total elimination
of on-site wet trades as elements are pre-
formed and pre-applied in the factory
setting.
 Technology – The edge between
fabrication technologies and emerging
computer-aided designs is set to
revolutionize construction.
 Value – Faster time to completion of
projects can generate income for the
clients earlier and also lead to lower site
outlays due to less time on site.
DISADVANTAGES OF
PREFABRICATED CONSTRUCTION
Prefabricated Construction, Prefab, Prefab
technology, off-site construction
Irrespective of the array of benefits,
prefabrication has its disadvantages too
 Increased Risks
First, there can a lot of risks associated with
this technique in comparison to the
traditional construction methods. This is
because the majority of the large building
elements are constructed off-site, a huge
amount of trust is given to the manufacturer
to produce exactly what is needed. Hence,
even the tiniest of errors can put the entire
structure in danger.
 Rapid Completion Times = Errors
Once the pieces arrive on the site, they have
to be attached and bolted together. Workers
working on the site are under intense time
limits to complete their jobs quickly, this can
lead to higher potentials for mistakes.
 The Disconnect
Every site is different and unique; hence it has
its own individual characteristics and
challenges. Prefabricated buildings that are
designed for efficiency might look ideal in
theory, but they lack detail and
personalization. By creating the bits and
pieces off-site, a huge disconnect between
the architect and land itself exists.
 Other
Quite obvious disadvantages of prefab
technology are high transportation cost, high
risk of breakages, need for erection
equipment, skilled labour, and extra
supervision.
LIGHT GAUGE STEEL
CONSTRUCTION
Light Gauge Framed Steel Structure (LGFSS) is
based on factory made galvanized light gauge
steel components produced by the cold
forming method assembled as panels at site
forming structural steel framework of a
building and varying wall and floor
construction as detailed in this Certificate. The
panels are assembled on site with screws and
bolts to form the internal and separating walls
and inner leaf of the external walls of a
building and floors & ceiling. The building is
completed by the installation of an external
layer of insulation material and outer leaf of
CP Board or dry mix shot Crete. The system
can incorporate all types of architectural
features like coving, boxes, cantilevers,
projections, infill walls, mezzanine floors etc.
This system can also incorporate all types of
services viz. electrical, gas and plumbing etc.
The design and engineering of the structures
is executed by following the norms &
guidelines stipulated in relevant Indian
Standards.
ADVANTAGES OF LIGHT GAUGE
STEEL CONSTRUCTION
Light gauge steel structures have many of the
advantages of light wood framed structures:
 They are light, and allow quick building
without heavy tools or equipment. Every
component can easily be carried by hand -
a house is like a carpentry job on a larger
scale. The main tool is a light, handheld
screw gun. Since steel is strong, LGS
structures are lighter than wood framed
structures of equivalent strength.
 Their higher strength allows greater
spacing between members when
compared to wood frame construction:
about 24" (600mm) for LGS vs. about 16"
or 20" (400 or 500mm) for wood. Fewer
members translates to quicker
construction times.
 It is able to shape itself to any form, and
can be clad and insulated with a wide
range of materials.
 It is easy to change or modify this
construction at any point in its lifespan.
 There are a great range of systems and
products catering to this type of
construction.
DISADVANTAGES OF LIGHT GAUGE
STEEL CONSTRUCTION
 Light framed structures allow the passage
of sound more readily than the more solid
masonry construction.
 Light gauge steel will lose strength in the
advent of fire. Adequate fire protection
must be used. The easiest form of fire
protection is to clad the steel with fire
rated sheeting or drywall.
LIGHT GAUGE STEEL FRAMING
MEMBERS
 Steel components are cold-rolled from
steel sheet.
 Cold-forming increases metal strength.
 Members are essentially non-combustible
equivalents of wood light frame
construction.
THE PROCESS
The machinery features a twin track system
that can simultaneously produce a range of C
and U shaped stud and track profiles from
Galvanised steel of 0.75mm to 1.6mm
thickness (22 gauge to16 gauge). Producing
the same variety of profiles would usually
require up to six different machines. All
output lengths are completely finished,
labelled and ready for assembly.
 Architect's Rendition
The process begins with an architect's design
that can then be transferred to our design,
detailing and engineering software.
 Software
The entire frame is then designed and
detailed using the designing software. The
completed file, then ready for manufacturing,
is sent electronically to the steel frame
machine.
 Production
The steel frame machine then creates each
component of the building frame individually,
labelling them according to their location in
the frame for error free construction.
Individual Components
Every component is produced and detailed
with individual characteristics according to its
position in each panel. Cut to length, service
and fastening holes pre- punched, swaged,
notched and ready for assembly.
 Assembly
The assembly process usually takes place at
the manufacturing plant as each finished
component is produced by the steel roll
former. They are assembled and screwed
together to form the panels and trusses.
 Transport
The completed panels and trusses are then
transported to the construction site.
 Construction
Once at the construction site, the panels and
trusses are unloaded and positioned for rapid
and accurate assembly.
WAFFLE CRETE
(Waffle-Crete) Building system shall consist of
large, structural, ribbed panels of reinforced
precast concrete, bolted together and the
joints between the panels shall be caulked to
form the walls, floor and pitched or flat roofs
of buildings. The surface of each panel shall
consist of 51 mm thick slab or skin, stiffened
with the ribs around the perimeter and across
the panel, giving an overall panel thickness of
152 mm or 203 mm. In single storey
buildings, floors are constructed using precast
reinforced concrete floor panels supported on
precast concrete grade beams on well-
compacted earth. The walls are constructed of
152 mm thick wall panels of precast
reinforced dense concrete. For buildings of
more than one storey, the walls shall be
supported on foundations designed by the
engineer.
The Waffle-Crete system consists of the
following core elements:
 Lightweight insulated precast insulated
molds
 Insulated curing covers that shall be used
in conjunction with Waffle-Crete molds
 Specialized equipment shall be designed
for use with Waffle-Crete molds and
covers
 A construction methodology for casting
and erecting Concrete panels with molds
and equipment.
WALL PANELS
TYPE OF WALLS
There are six types of internal and external
walls which shall be used in conjunction with
brick or concrete masonry walls etc. The wall
panels shall be 152 mm or 203mm thick
overall.
i. Type 1 152 mm or 203 mm panels, unlined.
ii. Type 2 Wall panels lined on one side with
12.7 mm thick X-rated gypsum plasterboard
on 38 mm x 38 mm timber studs 7 at 600 mm
centres fixed to the panel ribs with screws
into nailer blocks cast into concrete at 600
mm centres.
iii. Type 3 Wall panels lined on one side with
12.7 mm thick X-rated gypsum plasterboard
of 63.5 mm x 35 mm x 0.71 mm thick on
galvanized steel studs spaced at maximum
450 mm centres fixed to the ribs of the panels
with 18 gauze steel galvanized wire wound
around threaded 6 mm dia. galvanized steel
fasteners hand-driven into a previously drilled
hole in the rib of the floor panel.
iv. Type 4 Wall panels lined on one side with
two layers of 12.7 mm thick X-rated gypsum
plasterboard on galvanized steel studs with
staggered joints similar to those used in Type
3 wall fixed to the panel ribs in the same
manner as wall Type 3.
v. Type 5 Wall panels lined on one side with
12.7 mm thick X-rated gypsum plasterboard
on top hat section galvanized steel channels
fixed to the panel ribs as for wall Type 3 and
insulated with 150 mm thick glass fibre.
ribs of the panels with 18 gauze steel
galvanized wire wound around threaded 6
mm dia. galvanized steel fasteners hand-
driven into a previously drilled hole in the rib
of the floor panel. When ribbed panel require
a 120 minute fire- resistance rating, two
layers of 12.7 mm thick x-rated gypsum
plasterboard are used, fixed as for floors with
a 60 minute fire- resistance rating. A 120
minute fire-resistance rating shall also be
required for wall, floors and ceilings that
enclose emergency routes in buildings. The
joints between the plasterboard shall be
sealed according to the manufacturer’s
recommendations. Floor slabs with a 30
minute fire-resistance rating shall not require
a concrete topping. Thickness of concrete
topping may vary for different requirement of
fire-ratings.
SITE VISIT

vi. Type 6 Wall panels lined on one side with

12.7 mm thick X-rated gypsum plasterboard
on timber studs fixed to the panel in the same
manner as for wall Type 2 and insulated with
50 mm thick glass fibre.

FLOOR SLABS
Thickness of concrete of topping may vary for
different requirement of fire ratings. Floor
slabs with a 60 minute fire-resistance rating
shall require a minimum of 38 mm concrete
topping and floor slabs with a 120 minute fire-
resistance rating shall require a minimum
concrete topping of 75 mm or cladding to the
underside. Where ribbed panel require a 60
minute fire- resistance rating, the cladding to
the underside of the floor shall consist of 12.7
mm thick x-rated gypsum plasterboard of 63.5
mm x 35 mm x 0.71 mm thick on galvanized
steel channels at 600 mm centers fixed to the
GURGAON RAILWAY STATION