PREFABRICATION

And its techniques

SUBMITTED TO: AR.NIPPY GARG SUBMITTED BY: NARENDER KONDLAS SYED SUHAIB KHAMANSHU BANSAL SATINDER KAUR SILVEY DEAN SANDRA BERNARD

INTRODUCTION
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. It is frequently used when 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. An example from house-building illustrates the process of prefabrication. The conventional method of building a house is to transport bricks, timber, cement, sand, steel and construction aggregate, etc. to the site, and to construct the house on site from these materials. In prefabricated construction, only the foundations are constructed in this way, while sections of walls, floors and roof are prefabricated (assembled) in a factory (possibly with window and door frames included), transported to the site, lifted into place by a crane and bolted together.

THE PROCESS & THEORY OF PREFABRICATION

The theory behind the method is that time and cost is saved if similar construction tasks can be grouped, and assembly line techniques can be employed in prefabrication at a location where skilled labour is available, while congestion at the assembly site, which wastes time, can be reduced. The method finds application particularly where the structure is composed of repeating

units or forms, or where multiple copies of the same basic structure are being constructed.
Prefabrication avoids the need to transport so many skilled workers to the construction site, and other restricting conditions such as a lack of power, lack of water, exposure to harsh weather or a hazardous environment are avoided. Against these advantages must be weighed the cost of transporting prefabricated sections and lifting them into position as they will usually be larger, more fragile and more difficult to handle than the materials and components of which they are made.

Current uses:
The most widely-used form of prefabrication in building and civil engineering is the use of
prefabricated concrete and prefabricated steel sections in structures where a particular part or form is repeated many times. It can be difficult to construct the formwork required to mould concrete components on site, and delivering wet concrete to the site before it starts to set requires precise time management. Pouring concrete sections in a factory brings the advantages of being able to re-use moulds and the concrete can be mixed on the spot without having to be transported to and pumped wet on a congested construction site. Prefabricating steel sections reduces on-site cutting and welding costs as well as the associated hazards.

Prefabrication techniques are used in the construction of apartment blocks, and housing
developments with repeated housing units. The quality of prefabricated housing units had increased to the point that they may not be distinguishable from traditionally-built units to those that live in them.

 The technique is also used in office blocks, warehouses and factory buildings.
Prefabricated steel and glass sections are widely used for the exterior of large buildings. Detached houses, cottages, log cabin, saunas, etc. are also sold with prefabricated elements. Prefabrication of modular wall elements allows building of complex thermal insulation, window frame components, etc. on an assembly line, which tends to improve quality over on-site construction of each individual wall or frame.

However, tradition often favors building by hand in many countries, and the image of
prefab as a "cheap" method only slows its adoption.

Advantages of prefabrication
Self-supporting ready-made components are used, so the need for formwork, shuttering and scaffolding is greatly reduced.

Construction time is reduced and buildings are completed sooner, allowing an earlier return of the capital invested.
On-site construction and congestion is minimized. Quality control can be easier in a factory assembly line setting than a construction site setting. Prefabrication can be located where skilled labour is more readily available and costs of labour, power, materials, space and overheads are lower. Time spent in bad weather or hazardous environments at the construction site is minimized.

Less waste may occur

Advanced materials such as sandwich-structured composite can be easily used, improving thermal and sound insulation and airtightness

DISADVANTAGES
Leaks can form at joints in prefabricated components.

Transportation costs may be higher for voluminous prefabricated sections than for the materials of which they are made, which can often be packed more efficiently.
Large prefabricated sections require heavy-duty cranes and precision measurement and handling to place in position. Larger groups of buildings from the same type of prefabricated elements tend to look drab and monotonous. Local jobs may be lost, if the work done to fabricate the components being located in a place far away from the place of construction. This means that there are less locals working on any construction project at any time, because fabrication is outsourced.

Prefabrication in India
Prefabrication in India began with the emergence of the Hindustan Housing Factory. The company was developed by the first Prime Minister of India, Pandit Jawaharlal Nehru, as asolution to the housing crisis that resulted from the influx of refugees from West Pakistan in the

1950s. The Hindustan Housing Factory pioneered the production of pre-stressed concrete railway
sleepers to replace dilapidated wooden sleepers on Indian Railways. The company changed its name shortly there after to reflect the diversity of its operations. It is now known as the Hindustan Prefab Limited or HPL.

Located in Delhi, today the government run company prefabricates primarily precast concrete for
architectural and civil projects throughout greater India. When HPL began it was intended to produce low-income housing solutions for the deficit in India. Precast wall panels and frame members such as beams and columns provided a much needed set of

tools to erect quick structures for mass housing.

The most difficult technology transfer obstacle for the HPL has been the cost of machinery and materials for production. Since the government could not recoup the return on investment for the factory through housing production, prefabrication from HPL.

COMPONENTS AND JOINTING

Components are manufactured units, made to pre-determined sizes, to be used in building. Dimensional co-ordination governs their design and use and forms the necessary discipline for industrialized, "system" or "component" building. For example a prefabricated standard staircase component to rise 2660 mm will govern the floor to floor height of the building in which it is to be fixed.

Pqefabqicave d uvaiqcaue

uvaiqcaue

Prefabricated wall cladding panels will closely govern the storey heights and the length of the building, or part of a building where they are used.

 The structural frame is usually erected by site work methods, e.g. insitu reinforced concrete, and the prefabricated units, whether mass produced to standard sizes or specially made for the particular building project, are fitted to it.
An accurate tie-up between the respective dimensions of structure and cladding units is essential, and only a certain degree of tolerance my subsequently be allowed for either.

Standardized components are joined together to form building elements. The dimensional co-ordination between all the components concerned is essential, and for this method of building it is necessary that this co-ordination shall be based upon a suitable module. That is a certain unit length which shall form the increment of change of size, and so the overall dimensions of the building will be a multiple of these modules or units of length

Acvtal mantfacvtqed componenvu sill vaqy ulighvly shen made fqom vhe upecified dimenuionu and may be utbjecv vo ftqvheq movemenv Bovh vaqiavion in uize allosed sivhin accepvable limiv limiv and uhape limivu. aqe vo

be

Componenv Max.uize Min. uize

The diffeqence bevseen vheue vso qepqeuenvu vhe voleqance allosed.

limivu

-The vaqiavionu in uize and uhape, and upace neceuuaqy vo move vhe componenv invo pouivion and fix iv, aqe allosed foq in vhe sidvh of vhe joinv bevseen componenvu. -The joinv sidvh sill vaqy sivh vhe soqk uize (uize upecified foq ivu mantfacvtqe) + deviavion (vaqiavion in uize and uhape) foq each componenv. THE JOINT:-The gqeaveq vhe acctqacy of vhe componenvu vo be joined, vhe leuu sidvh

In oqdeq vo qemain avvached vo vhe vso faceu of a joinv, vhe uealanv hau vo be able vo accommodave movemenv dte vo vheqmal oq ovheq facvoqu.

"movemenv accommodavion facvoq" (MAF) (vaqieu bevseen diffeqenv uealanv maveqialu. )

Long expeqience hau uhosn vhav a good euvimave can be made fqom vhe follosing:
Joinv sidvh (in mm) = voval lengvh of vhe adjacenv panelu (in m)

'joggle' joinv The uimpleuv Thtu foq iu a ajoinv bevseen vso panelu of lengvh :In pqacvice pqofile uhotldabe 7m and 8m, vhe voval iu 15m, iv giving joinv uvqaighv urtaqe avoided au : sidvh ofThiu 15mm. joinv. hau ueveqal Iv iu moqe advanvageu: diffictlv vo cauv; iv doeu iv iu eauieq vo nov pqovide cauv; iv giveu enotgh upace ftll upace foq foq a dotble vhe uealanvu; ueal; iv iv allosu

PREFABRICATED PANELS
tued foq exveqioq sallu fqamed sivh sood oq lighv seighv uveel fqaming clad in exveqioq oq inveqioq finiuheu.

convainu inutlavion , siqing, oq pqe-ctv opening foq sindosu and dooqu

conuvqtcvion of panelized homeu incltdeu shole sallu sivh sindosu , dooqu, siqeu oq otvuide uiding pqepaqed in facvoqy and eqecved on uive. Pqecauv concqeve cladding

Pqecauv concqeve panelu aqe qeinfoqced concqeve tnivu available in a side qange of mixeu, colotqu and finiuheu.

Finiuheu can incltde acid-evched, umoovh oq coaque gqotnd, gqiv oq uand-blauved, qtbbed oq poliuhed. Mixeu deuigned vo qeuemble navtqal uvone can aluo be pqodtced .
Highly aqvictlaved deuignu can be accommodaved by vhe moldable concqeve mix.

PREFAB CONCRETE PANEL SYSTEM

Theqe aqe aqeau sheqe good rtalivy bqicku aqe nov available foq qoofing. The pqefab concqeve panel uyuvem pqovideu vhe advanvage of pqefabqicavion foq incqeauing upeed in conuvqtcvion and in uivt concqeve vo develop monolivhically uvqtcvtqe.

In vhiu concqeve 3.5cm vhk and paqvially pqecauv concqeve joiuvu of lengvh aqe pqefabqicaved on vhe gqotnd sivh pqopeq qeinfoqcemenv. vhe concqeve panelu aqe utppoqved Pqoceuu on vhe joiuv and 3cm vhk cemenv concqeve iu laid oveq vhe qoof. Pqecauv concqeve panelu aqe cauv facedosnsaqdu in economical ptqpoue-btilv tutally made The qoof iu andmotldu, sivhin vhe of eivheq vimbeq oqlocal fibqeukilled glauu. and tnukilled capabilivieu of vhe labotq. A uveel qeinfoqcemenv cage iu placed in vhe motld pqioq vo vhe concqeve being potqed. Timbeq motldu can be eauily adjtuved uo vhav maximtm tue can be made of each bauic motld, ftqvheq convqibtving vo couv efficiencieu. By inueqving mavu oq qodu in vhe baue of vhe motld diffeqenv deuignu and effecvu can be

TECHNIQUES
PRECAST RC PLANK SYSTEM PRECAST BRICK PANEL ROOFING PRECAST RC CHANNEL PRECAST CONCRETE PANELS ROOFING THIN PRECAST RC LINTEL

PRECAST RC PLANK ROOFING SYSTEM This system consist of precast RC planks supported over partially precast joist. The completely finished slab can be used as intermediate floor for living also. The total thickness of slab is 6 cm . The planks are made in module width of 30 cm with maximum length of 150 cm and the maximum weight of the dry panel is 50 kg . The scheme is ideally suited for spans up to 4.2 m , but can be used for large spans, by providing secondary beams.

PRECAST BRICK PANEL ROOFING

This system comprises of prefab brick based component and partially precast Rc joists panels are laid over partially precast joist the typical size of panel is 1040mm X 640mm in which 16 bricks 2 bars of 6mm dia. And m-15 conc. are used .

PRECAST RC CHANNEL ROOFING

Precast channels are trough shaped with the outer sides corrugated and grooved at the ends to provide shear key action and to transfer moments between adjacent units. Nominal width of units are 300 mm or 600 mm with overall depths of 130 mm to 200 mm . The lengths of the units are adjusted to suit the span.

PRECAST CONCRETE PANELS ROOFING

The system comprise of precast panels 600 mm 600 mm and only 30 mm thick . The reinforcement consists of 2 mm dia MS wire or equivalent welded mesh. The panels are placed over fully precast RCC beams of 75 mm width and 125mm to 150 mm depth depending on the span. The ends of panels are tapered so as to form a V-groove when placed over beams. This groove is filled with cement mortar. The beams are designed as simple supported.

THIN PRECAST RC LINTEL

LINTEL WITH CHAJJA Lintels can be as well designed as composite member consisting of 75mm Thick rc lintel with the masonry on top the precast lintel 75mm X230mm with (3)numbers of MS dia bars.