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This paper aims to popularise the promotion of prefabrication building methodologies for low cost housing by
highlighting the different prefabrication techniques, and the economical advantages achieved by its adoption.
4 IE (I) JournalAR
laying slab, the finishes and services can be done combining standardised mass-manufactured roofing and other
below the slab immediately. While in the components (at site) with in-situ brick walls or other
conventional in-situ RCC slabs, due to props and masonary structures. A wide variety of roofing methods to
shuttering, the work cannot be done, till they are suit these requirements have been developed and used on mass
removed. Saving of time means saving of money. scale in many housing projects such as funicular shell, cored
slabs, RCC channel units, precast cellular units, precast RC
(4) In prefabricated construction, there is better quality
planks and joists, prefab brick panels and joists, RCC joists
control, shape and size of precast elements.
and hollow concrete blocks, precast RCC Kular slab.
Therefore, in structural design, full advantage of
properties of cement and steel can be exploited. There TECHNIQUES
is disciplined use of scarce materials like cement, steel
and timber. Precast RC Plank Roofing System
This system consist of precast RC planks supported over
(5) In precast construction, similar type of components
partially precast joist. The completely finished slab can be
are produced repeatedly, resulting in increased
used as intermediate floor for living also. The total thickness
productivity and economy in cost too.
of slab is 6 cm. The scheme is ideally suited for spans upto 4.2 m,
(6) In precast construction, the construction is not but can be used for large spans, by providing secondary
affected due to weather, rain, wind etc. beams. RC planks are made with thickness partly varying
(7) In prefabricated construction, the work at site is between 3 cm and 6 cm. There are haunches in the plank
reduced to minimum and therefore, work is which are tapered. When the plank is put in between the
qualitatively better, more reliable and clean. joists, the space above 3 cm thickness is filled with in-situ
concrete to get tee-beam effect of the joists. A 3 cm wide
(8) Because of faster completion and reduction in time tapered concrete filling is also provided for strengthening the
period of construction the houses can be occupied haunch portion during handling and erection. The planks
earlier, which means early return of the investment. have 3 numbers 6 mm dia MS main reinforcement and 6 mm
dia @ 20 cm centre to centre cross bars. Concrete used is of
LIMITATIONS OF PREFABRICATIONS
grade M-15. The planks are made in module width of 30 cm
(1) As the precast elements have to behave monolithic on with maximum length of 150 cm and the maximum weight of
erections, extra reinforcement may be necessary in the dry panel is 50 kg (Figure 1).
some cases.
Precast joist is rectangular in shape, 15 cm wide and the
(2) Extra reinforcement is required to take care of precast portion is 15 cm deep (Figure 2). The above portion is
handling and erection stresses. casted while laying in-situ concrete over planks. The stirrups
(3) Temporary props may be required in some cases, remain projected out of the precast joist. Thus, the total depth
before the in-situ concrete joints achieve strength. of the joist becomes 21 cm. The joist is designed as composite
Tee-beam with 6 cm thick flange comprising of 3 cm
(4) The cracks may develop at the joints between the precast and 3 cm in-situ concrete (Figure 3). This section of the
precast and in-situ concrete due to shrinkage and joist can be adopted upto a span of 400 cm. For longer spans,
temperature stresses. To overcome them, extra steel is the depth of the joist should be more and lifting would require
required across the joint. simple chain pully block.
(5) As there are chances of leakage/seepage through the
joints between the precast components, extra care is
required to make them leak proof.
Figure 2 Partially precast joists sand mortar or M-15 concrete. Panels can be made in any size
but generally width is 53 cm and the length between 90 cm to
120 cm, depending upon the requirement. The gap between
the two panels is about 2 cms and can be increased to 5 cms
depending upon the need. A panel of 90 cm length requires
16 bricks and a panel of 120 cm require 19 bricks (Figure 4).
(b) Partially Precast Joist
It is a rectangular shaped joist 13 cm wide and 10 cm to 12.5 cm
deep with stirrups projecting out so that the overall depth of
joist with in-situ concrete becomes 21 cm to 23.5 cm, it is
designed as composite Tee-beam with 3.5 cm thick flange.
STRUCTURAL DESIGN
The prefab brick panel for roof as well as for floor of residential
buildings has two numbers 6 mm dia MS bars as
reinforcement upto a span of 120 cms.
The partially precast RC joist, is designed as simply supported
Tee-beam with 3.5 cm thick flange. The reinforcement in joist
is provided as per design requirements depending upon the
spacing and span of the joist.
An overall economy of 25% has been achieved in actual
practice compared to cast-in-situ RCC slab.
Figure 3 RC planks laid over partially precast joists
In residential buildings, balcony projections can be provided Precast Curved Brick Arch Panel Roofing
along the partially precast joists, designed with an overhang This roofing is same as RB panel roofing except that the panels
carrying super imposed loads for balcony as specified in do not have any reinforcement. A panel while casting is given
IS : 875-1964, in addition to the self load and the load due to a rise in the centre and thus an arching action is created.
balcony railings. The main reinforcement of the overhang An overall economy of 30% has been achieved in single
provided at the top in the in-situ concrete attains sufficient storeyed building and 20% in two or three storeyed buildings
strength. The savings achieved in practical implementations (Figures 5 and 6).
compared with conventional RCC slab is about 25%.
Precast RC Channel Roofing
Prefabricated Brick Panel Roofing System Precast channels are trough shaped with the outer sides
The prefabricated brick panel roofing system consists of: corrugated and grooved at the ends to provide shear key
action and to transfer moments between adjacent units.
(a) Prefab Brick Panel Nominal width of units are 300 mm or 600 mm with overall
Brick panel is made of first class bricks reinforced with two depths of 130 mm to 200 mm (Figure 7). The lengths of the
MS bars of 6 mm dia and joints filled with either 1:3 cement units are adjusted to suit the span. The flange thickness is
6 IE (I) JournalAR
The width of a panel is 300 mm and depth may vary from 100 mm
to 150 mm as per the span, the length of the panel being
adjusted to suit the span. The outer sides are corrugated to
provide transfer of shear between adjacent units. The kulars
are placed inverted so as to create a hollow during precasting
(Figure 8). Extra reinforcement is provided at top also to take
care of handling stresses during lifting and placement. There is
saving of about 30% in cost of concrete and an overall saving
of about 23%.
Precast Concrete Panels Roofing
The system comprise of precast panels 600 mm × 600 mm and
only 30 mm thick (Figure 9). The reinforcement consists of
2 mm dia MS wire or equivalent welded mesh. The panels are
Figure 5 Curved brick arch panels
8 IE (I) JournalAR
CONCLUSION REFERENCES
Mass housing targets can be achieved by replacing the 1. Study on Low Cost Incremental Housing Scheme for UP State. BMPTC,
conventional methods of planning and executing building Adlakha and Associates.
operation based on special and individual needs and accepting
2. Standards and Specifications for Cost Effective Innovative Building
common denominator based on surveys, population needs
Materials and Techniques. BMPTC.
and rational use of materials and resources.
No single approach and solution is available which can satisfy 3. IS 4326: Earthquake Resistant Design and Construction of Materials, 1993.
the community at large. However, what is ideal and desirable
is to have a system which can provide choice for people and 4. Workshop on Capacity Building for Project Managers of Building Centres.
also appropriate techniques to meet the situation. The essence organised by HSMI, April 20-May 2, 1988.
lies in the system approach in building methodology and not
5. P K Adlakha. Cost Reduction in Roofing through Small Panel
necessarily particular construction type or design. Adoption Prefabrication. National Seminar on New Building Materials and Technology,
of any alternative technology on large scale needs a guaranteed Delhi, May 19-21, 1989.
market to function and this cannot be established unless the
product is effective and economical. Partial prefabrication is 6. P K Adlakha. New Economical Construction Techniques for Walls and
an approach towards the above operation under controlled Roofing. Seminar on Intraction on New Materials and Technologies in Built
conditions. Environment, Delhi, October 14-17, 1993.
The methodology for low cost housing has to be of 7. P K Adlakha. Innovative Small Panel prefabricated Roofing using Earthen
intermediate type less sophisticated involving less capital Clay Pots. Third National Convention of Architectural Engineers, Bombay,
investment. May 14-15, 1988.