Professional Documents
Culture Documents
INTRODUCTION:
Prefabrication is the production of housing or housing components , using factory
mechanization.
It enhances the affordability through a combination of quantity , purchasing of material ,
mass-production , assembly techniques ant the use of less skilled labour.
Prefabrication may take three forms- prefabricated components , modular housing ,
manufactured housing.
The technique permits the speedy erection of very large structures. It has been
applied to urban housing for more than a century.
Demountable structures
bolted connections can be easily dismantled and re- erected in other places.
2. 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.
Long experience has shown that a good estimate can be made from the following:
Joint width (in mm) = total length of the adjacent panels (in m)
Thus for a joint between two panels of length 7m and 8m, the total is 15m, giving a joint
width of 15mm.
'joggle' joint :In practice it
should be avoided as :
The simplest profile is a straight
square joint. This has several It is more difficult to cast; it
advantages: does not provide enough
space for a double seal; it
it is easier to cast; it gives full
prohibits inspection;; it
space for the sealants; it allows
could collect moisture and
inspection of the inner seal; it does
cause problems with
not interfere with other aspects.
freezing.
APPLICATIONS:
In India, Pre-engineered building systems find application primary in the
construction of rural as well as urban, individual & mass housing projects,
farmhouses, slum reorganization projects and rehabilitation projects, amenity
structures like health centres, kiosks, primary schools, panchayat ghars, etc.
The recent focus has also shifted to cover composite construction for R&D
facilities, the pharmacy industry and exhibition centres, and functional
requirements like offices, seminar halls, call centres supermarkets, showrooms,
etc.
Purlin Ridgc
Bridging Clip
: Endwall Column.
PREFABRICATED PANELS
used for exterior walls
framed with wood or light weight steel framing clad in exterior or interior finishes.
contains insulation , wiring, or pre-cut opening for windows and doors
construction of panelized homes includes whole walls with windows , doors, wires or outside
siding prepared in factory and erected on site.
Precast concrete cladding
Precast concrete panels are reinforced concrete units available in a wide range of mixes, colours
and finishes.
Finishes can include acid-etched, smooth or coarse ground, grit or sand-blasted, rubbed or
polished. Mixes designed to resemble natural stone can also be produced .
Highly articulated designs can be accommodated by the mouldable concrete mix.
Pouring of
concrete
PREFAB CONCRETE PANEL SYSTEM
There are areas where good quality bricks are not available for roofing.
The prefab concrete panel system provides the advantage of prefabrication for increasing
speed in construction and in situ concrete to develop monolithically structure.
In this concrete 3.5cm thk and partially precast concrete joists of length are prefabricated
on the ground with proper reinforcement. the concrete panels are supported on the joist and
3cm thk cement concrete is laid over the roof.
The roof is economical and within the capabilities of the local skilled and unskilled labour.
Process:
Precast concrete panels are cast face-downwards in purpose-built moulds, usually made of
either timber or fibre glass.
A steel reinforcement cage is placed in the mould prior to the concrete being poured.
Timber moulds can be easily adjusted so that maximum use can be made of each basic
mould, further contributing to cost efficiencies.
By inserting mats or rods in the base of the mould different designs and effects can be
created - from false joints to intricate leaf patterns.
Increasingly, maximum use of off-site fabrication is being made by fixing other elements,
from insulation to entire windows, during manufacture of precast panels.
Once de-moulded, the exposed surface of the unit can be treated in a variety of ways -
acid-etched, smooth or coarse ground, grit or sand-blasted, rubbed or polished.
Moulds
Detail at A
Column section
Cast in s/s
Detail at B socket
Detail at B
Cast in s/s
socket
S/s restraint
angle
Brick-faced precast cladding
Description
Brick-faced precast concrete panels are concrete units faced with traditional brickwork.
Brick-facing works equally well on structural elements, such as spandrels and columns, as
on flat cladding panels.
Benefits:Brick-faced precast
-Combines a traditional, unpanelised appearance with the durability and other benefits of
precast concrete panels.
-Speeds up construction time - not affected by weather or labour shortages.
-Improves buildability - no need for scaffolding.
-Alleviates challenges of bricklaying in hazardous places - reduces potential for accidents.
-Produces a high standard of workmanship in factory conditions.
Brick-faced precast
Brick Selection
1. Colour
It's important to choose a brick with good uniformity of colour.
2. Type
Bricks have to be anchored securely into the panel. When '3 hole' type bricks are
cut the resulting shape provides an excellent anchor.Frogged bricks should be
avoided.
A three hole brick.
Panel Design
3. Panel size
Panels can be sized in normal brick modules as with any wall. There is no limit to
the size of panel other than practicality of transport - for instance at The Trafford
Centre some panels were over 12.5m long.
100mm 60mm
concrete bricks
Minimum thickness of
panels
5. Brick layout
joint
10mm joint may be positioned at works or recessed for pointing on the side
Any normal brick bond pattern can be provided .Try to avoid excessive use of headers, and
ensure that no unfinished faces are visible on the edges of panels, particularly at returns and
reveals.
6. Finishing
They are usually finished with a
gunned-in sealant to provide a fully
weathertight envelope.
Natural stone-faced precast cladding
Description
Natural stone-faced precast concrete panels are concrete units faced with any type of
natural stonework. Stone-facing works equally well on structural elements, such as
spandrels and columns, as on flat cladding panels.
Benefits :-Natural stone-faced precast
Combines a traditional natural stone appearance with the durability and other benefits of
precast concrete panels.
Alleviates challenges of in-situ stonework in hazardous places - produces a high standard
of workmanship in factory conditions, reduces potential for accidents, addresses on-site
skill shortage.
Enables faster programme times - not affected by weather or labour shortages.
Improves buildability - early enclosure of dry envelope enables follow-on trades to start
sooner.
Has a high quality finish that can be left exposed - concrete's thermal properties can be
exploited in low-energy buildings.
Process
-Natural stone-faced units are produced by laying the natural stone face-down in the
bottom of the mould prior to casting the concrete backing mix around the stone.
-Hard stone, such as granite, should be a minimum of 30mm thick whereas other stones,
such as Portland and Bath, should be a minimum of 50mm thick.
-A debonding agent is applied to the back of the stone, and stainless steel pins are arranged
at the ratio of 11 per square metre, so that the stone can move relative to the backing panel
to accommodate thermal movement.
GLASS REINFORCED CEMENT CLADDING
Description
-Glass Reinforced Cement (GRC) is formulated with a cement and fine aggregate mix
containing 5% of 25mm-long glass fibre strands.
-The glass fibre has a tensile strength three to four times greater than the equivalent steel
fibre, making GRC a material with high impact resistance.
-Typically manufactured to a thickness of 10mm, GRC cladding panels are much lighter
weight than their precast equivalents.
a series of
distinctive
bathroom units for
a new luxury hotel
Benefits:
-Provides the same durability and quality of finish as reconstructed stone
-Is ideal where limited access means small, lightweight panels are required
-Improves buildability - no need for scaffolding or heavy crane capacity
-Speeds up construction time - not affected by weather or labour shortages
Process
-GRC is cast in timber moulds which are very similar to, though can be lighter than,
those used for precast concrete.
-The GRC is sprayed into the mould in layers, the first layer being a pure
cement/aggregate mix to form the seen surfaces and subsequent layers containing the
chopped glass fibres.
-The spray gun contains both the grout nozzle and a glass chopping gun, so both grout
and glass fibres are sprayed simultaneously.
-Each layer is compacted with rollers before the next is sprayed, to a total thickness of
10mm.
-The production cycle is 24 hours with the GRC unit being de-moulded around 16-18
hours after casting.
STRUCTURAL INSULATED PANELS
Most common form of prefab building envelope systems.
Composed of 2 exterior skins such as orients strand board , wafer board , plywood,
gypsum board, adhered to rigid casting insulating foam core usually polystyrene .
Available in variety of thicknesses , depending upon application requirements and
sizes.
primary application is for exterior walls , roofs with conventional wood or steel stud
framing for interior partitions.
THE JUMP FORM SYSTEM
A frame is constructed from structural steel members over the central core.
Steel formwork panels are hung from this frame, some supported on rollers.
After the concrete walls are poured, the formwork is released and rolled back
from the concrete face.
Jacks then lift or climb the whole frame up one
level. All the formwork panels are attached to the
frame.
This process takes approximately one and
a half hours.
Once the climbing formwork is in position,
the formwork panels are closed and
the next concrete wall is poured.
The cycle continues, which is normally four days.
Faster times have been achieved.
The use of climbing formwork (jump form)
to construct the cores.
i. the use of a climbing formwork system
(sometimes referred to as self-climbing or self-
lifting) to construct the central core walls,
ii. precast facades and steel panel formwork (or
alternatively climbing formwork) to construct
the residential wings, The use of climbing formwork (jump
form) to construct the cores. Precast
iii. aluminium system soffit formwork to construct facades and steel panel formwork are
the floor slabs. used in the construction of residential
wings.
What is Modular?
-It is just a different method of building offices, health care centers, schools and almost any
other type of building you can imagine.
-Modular construction employs factory techniques to improve quality, shorten
manufacturing time, and reduce cost.
-While it is not quite an assembly line approach to manufacturing buildings, the economies
of scale, increased worker efficiencies, and reduction of delays from weather or vandalism
add up to greater speed at less cost.
-A modular building is constructed to be quickly assembled and easily disassembled. That
is unlikely with a standard brick and mortar facility.
-In fact, with modular, you can disassemble and move the entire building to another
location and be back in business within a relatively short period of time.
Interior Details
The interior of a modular building gives style and personality to an organization. Modular
buildings offer the widest array of colors, carpets, wall coverings and trim details to set
your building apart and to achieve the mood you have in mind for your environment.
Denim charcoal mushroom
Tile
Floors
Taupe Blue Cloud
Description: This is
a 42'x70' building
(2,940 s/ft).It has
large wide open
space that can be
used for work areas,
copiers, etc..
Modular office
Isometric view
Composite Steel and Concrete Structures
Description
Composite structures involve the combined use of precast concrete and structural steel
sections. This is particularly relevant for structurally complex projects, such as
Paddington Station, where the resulting structure was very slender in relation to its
purpose.
Benefits
Can produce very elegant solutions to complex structural engineering challenges.
Enable faster programme times - not affected by weather or labour shortages.
Improve buildability - early enclosure of dry envelope enables follow-on trades to
start sooner.
Produce a high standard of workmanship in factory conditions - reduces potential for
accidents, addresses on-site skill shortage.
Have a high quality finish that can be left exposed - concrete's thermal properties can
be exploited in low-energy buildings.
Process
Steel sections are pre-encased into the concrete, and though the steel may only be
required at the ends to form joints, it is better to have the steel running full length rather
than in two isolated pieces. The benefits of this are: end-to-end tolerances can be
determined before the concrete is cast, the section has full strength almost immediately
allowing early handling and transport and no intermediate reinforcement is needed to
connect the two ends together.
Hardwall Structures
Description
Hardwall structures involve an insulated sandwich panel system that uses composite
fibre rods to tie the two leaves of the wall together. These rods are stronger, less
thermally conductive, less corrosive and more elastic than the traditional steel
connectors.The panels are turned vertically, so that the inner wall is used as a structural
load-bearing member to support the roof in a column-free solution. In addition, hardwall
cladding can serve a structural purpose, such as bracing a frame or combining with a
roof structure as a diaphragm to transfer wind forces.
Benefits
Enable life-time energy costs to be reduced.
Provide high levels of fire and impact residence - safer and more durable.
Keep inner and outer faces clean as there is no requirement for columns, sheeting rails
or sag rods.
High-quality finish can be left untreated, further contributing to energy efficiency and
requiring low maintenance.
Speeds up construction time - not affected by weather or labour shortages; large panels
result in quick build time.
Improves buildability - no need for scaffolding.
Process
The outer wall is cast first at the bottom of the mould around the necessary
reinforcement. The styrofoam insulation layer is then compacted on top of this, and the
rods are inserted into the polystyrene before the reinforcement for the inner wall is
placed above. The inner wall is then cast, forming the last layer of the sandwich.
Hybrid Concrete Structures
Description
Hybrid concrete construction is the combined use of precast and in-situ concrete.
Recent research, undertaken for the Reinforced Concrete Council, showed the benefits
of hybrid construction in several key performance areas: aesthetics, function, speed,
safety and buildability.
Benefits
Achieve a more pleasing aesthetic appearance - in-situ elements, which are important
structurally but cannot achieve the same quality of finish as precast.
Save time by work taking place in parallel on site and in the precast factory.
Enable faster programme times - not affected by weather or labour shortages.
Improve buildability - early enclosure of dry envelope enables follow-on trades to start
sooner.
Produce a high standard of workmanship in factory conditions - reduces potential for
accidents, addresses on-site skill shortage.
Have a high quality finish that can be left exposed - concrete's thermal properties can
be exploited in low-energy buildings.
Process
The precast concrete elements of the structure are produced in the same way as other
precast frames - the combination of structural precast and in-situ concrete will vary from
project to project.
Precast Concrete Frames
Description
Precast concrete frames involve an entire structure being
fabricated off-site. In addition, structural components can be
supplied for incorporation into a structure on-site. Frames can
simultaneously achieve both structural and decorative design
requirements - a wide variety of mixes, colors and finishes can
be accommodated. Architecturally-finished precast structures
can be left exposed to exploit concrete's high thermal capacity
in a building.
Benefits
Enable faster programme times - not affected by weather or labour shortages.
Improve buildability - structure is fabricated off-site for rapid erection on-site
Produce a high standard of workmanship in factory conditions - reduces potential for
accidents, addresses on-site skill shortage.
Have a high quality finish that can be left exposed - concrete's thermal properties can
be exploited in low-energy buildings.
Process
Precast concrete frames are cast in the same way as precast concrete cladding, but as
they are designed as structural elements have heavier reinforcement than is required for
non-structural cladding. Elegant connections are required between columns and beams
to transfer considerable forces without adversely affecting the visual appearance of the
frame.
Street Furniture
D-Form Street Furniture
D-Form offers the landscape architect a unique range of street furniture that is
contemporary, robust and adaptable.
The D-Form range currently includes a bench, planter, bollard and waste bin, and
a range of standard finishes - including sparkling white stone, terracotta and grey -
are held in stock.
Each item is cast in precision fibre-glass moulds and has a light acid-etched finish
to expose the attractive fine aggregates in the mix.
Bench
The D-Form bench is available in two types of solid
natural hardwood - American Light Oak and Teak - from
certified sustainable resources. Treatment of the timber,
and the use of Grade 316 stainless steel for the
supporting chassis, ensure excellent outdoor
performance.
Measurements: Height 825mm, Width 2730mm, Depth 590mm
Waste bin
Bollard
The D-Form Bollard weighs 54kg. Optional versions
incorporate a plinth or plinth and uplighter. The uplighter
produces even more dramatic effects by enhancing the
bollard's sculptural form and highlighting the spectacular
effects of the fine aggregates.
Measurements: Height 820mm, Width 260mm, Depth 155mm
Structural Components
Description
Precast concrete structural components are items which are supplied and incorporated
into the overall structure, rather than forming the complete structure in themselves. Trent
has supplied a wide variety of precast structural components from special,
architecturally-finished floor slabs to columns and cantilevered balconies in precast
concrete, reconstructed stone, natural stone-faced or brick-faced precast.
Benefits
Precast concrete structural elements are used when the
form required would be difficult, costly or too time-
consuming to produce on site. In addition, precasting
the elements overcomes the requirement for scarce,
highly-skilled site labour.
Process
Precast concrete structural components are produced
in a similar way to precast concrete frames.
WHAT ARE PRE-FABRICATED STRUCTURES(PFS)?
Structures which are used repeatedly and can be standardized such as
mass housing, storage sheds, godowns, shelters, bus stands, security
cabins, site offices, foot over bridges, road bridges, tubular structures,
concrete building blocks etc., are prefabricated structures
Prefabricated homes are houses where the components are built and
pre-assembled at a factory, then shipped to the building site by truck,
lowered onto its foundation by crane, and then the structure is finished
by connecting all the wiring and plumbing.
Advantage:
once workers build and create the foundation, the actual house
can be constructed in a matter of days.
Disadvantage:
typically there are limitations to changes in the design of the house.
HPL was the first Construction Company to introduce the use of large panel
technique of construction in 336 Nos. fully prefabricated large panel, 4 storied
middle Income group houses for Delhi Development Authority at Hauz Khas,
New Delhi, way back in 1965.
PREFABRICATED HOUSING UNITS FOR DISASTER MANAGEMENT
Customizable design:
The BiniShelter floor plan is totally flexible.
The empty, but completely finished and waterproofed shelter has been
designed to be easily customized internally in accordance to the needs of
any person(s), family or school requirements in accordance to any local
custom, local regulations and/or special projects
Easy development:
The BiniShelter automatic construction system has been thoroughly
developed to allow for its immediate use under the most adverse conditions
and it has been studied with the aim to use the minimum consumption of
energy and, essentially, employing no building contractors nor skilled labor
Low Cost:
It uses pre-fabricated,
inexpensive, mass produced
structural components made of
locally available material.
These components are easily
assembled around a pre-fabricated
footing.