REPORT 3
PRECAST TECHNOLOGIES:
There are several drawbacks of RCC such as weakness
of Concrete in Tension which means Concrete in
Tension Zone Cracks Therefore, to limit crack width in
concrete in Tension in steel stress in steel is kept low.
Strain in steel = stress in steel / Es
( Es = Young’s modulus of Elasticity in steel )
CONCRETE IN TENSION ZONE CRACKS
Cracking of concrete in Tension zone may cause
corrosion of steel of reinforcement. Cracking in
concrete makes concrete in tension zone ineffective to
take stresses. Hence Section in an RCC beam is not
fully utilized
IN A PRESTRESSED CONCRETE BEAM
 Hollow Tube is replaced by concrete beam.
 Steel rod is replaced by steel wires or steel
cables.
 Nuts are replaced by steel wedges and end
anchorages. y Steel Tendons.
Pre-stressing is the Technique of introducing in a
concrete member compressive force of permanent
nature, so that it causes compressive stresses in that
zone of member, where Tensile stresses will be caused
by external loads. “
“Concrete in which there have been introduced internal
stresses of such magnitude and distribution that the
stresses resulting from given external loading are
counteracted to a desired degree”. Pre-stressing
(Eccentric P.S ) will induce compressive stresses in
those zones where Tension is induced by External
loading and Tensile stresses in those zones where
compressive stresses are induced by External loading.
PRINCIPLE OF PRESTRESSING:
Principle of applying a compressive force of permanent
nature to a pre-stressed concrete member may be
explained by analogy of applying compressive force to
a hollow steel tube by end steel plates by tensioning a
threaded a steel rod.
ECCENTRIC PRESTRESSING:
Pre-stressing force applied eccentrically below the
Neutral Axis will induce compressive stresses below the
N.A. and tensile stresses above the N.A. This Technique
is called ECCENTRIC Pre-stressing. Stresses induced by
the eccentric pre-stressing will be of nature opposite to
those induced by the external loading.
MATERIALS USED:  Pre tensioning generally used for small pre
cast factory produced elements.
CONCRETE:

Min Grade:
APPLICATION:
Pre Tensioned PSC: M 30
For precast small factory produced building elements
Post Tensioned PSC: M 35
like precast beam elements, precast slab or wall

Concrete strength grades elements.

Commonly used in PSC: M 35 to M 60 Precast Railway sleepers.

Precast electric poles.

2. STEEL: Other similar factory produced precast concrete

elements which may also be pre-tensioned to reduce
High strength steel with yield strength of 1200 to 1800 dead weight.
N/mm in the shape of
2

(i) Wires 4 to 8 mm dia

(ii). Strands in the shape of a rope with 8 to 12 wires.

(iii). Cables with 8 to 20 strands.

s
TWO METHODS OF PRE-STRESSING:

1. Pre- tensioning.
LONG LINE METHOD:
2. Post Tensioning.
“A method used for manufacture of pre tensioned pre-
PRE TENSIONING: Cast identical elements (such as wall panels, slab,
panels, Electric poles or railway sleepers), in which a
“A method of Pre-stressing concrete in which tendons
long permanent bed with strong abutments at each
(Pre-stressing steel wires or rods) are tensioned
end is used for casting a number of elements
(stressed) before concreting”. Pre-stressing steel wires
simultaneously”.
are tensioned before casting concrete in molds.
STEAM CURING:
PRE TENSIONING:
“A process of accelerated curing normally adopted for
 Pre-stressing wires temporarily anchored
factory produced pre tensioned pre-cast concrete
against strong abutments.
elements by long line method, in which the pre-cast
 Transfer of pre-stress to concrete is by bond. elements are cured by passing saturated steam
(circulating saturated steam around the pre-cast
 Transfer of pre-stress after concrete has set. elements). Heat and humidity provided by the
saturated steam accelerates curing. 24 hours steam
 Axial pre-stressing generally adopted.
curing is considered adequate for removing pre cast
 Bending of wires difficult and hence generally elements from casting beds. Steam curing enables
not adopted. curing beds be used quickly.

 Small sized pre-stressing wires (4 mm to 8

mm) generally used.
POST TENSIONING: 3. Sheathing to house cables.

A method of Pre-stressing concrete in which Pre- 4. End Anchorages.

stressing steel is tensioned against hardened concrete”.
(i) Steel bearing plates with holes for cables.
Pre-stressing steel tensioned against hardened
concrete. (ii) Steel wedges (to anchor cables to plates)

ADVANTAGES OF POST TENSIONING: (iii) Special reinforcement to prevent splitting of

concrete due to concrete due to heavy
As post tensioning is normally adopted for In situ
concentrated stresses.
casting, longer spans feasible.

5. Electric or Hydraulic jacks for tensioning cables.

Cables can be bent, hence more efficient.

6. Grouting Equipment.
Less loss of pre-stress compared to pre tensioning.

(i) Grouting Tank

DEMERITS OF POST TENSIONING:

(ii) Grouting Pump

Post Tensioning needs sheathing, end anchorages,
bearing plates etc. and is therefore costlier and more (iii) Grouting material
tedious than Pre-tensioning.
(a) Special Grade high strength cement.

(b) Water
STEPS for Post Tensioning:
(c) Super plasticizers.
1. To place pre-stressing tendons, a duct is
formed in the concrete member at the time of
casting.
APPLICATIONS OF POST TENSIONING:
2. The concrete member is cast and allowed to
1. For large span and heavily loaded beams for
harden to
structures like bridges, flyovers, and similar
3. Achieve adequate strength. structures.

4. Steel tendons are inserted and placed loose in 2. For Ground Anchorages.
the ducts at after the concrete member has
GROUND ANCHORAGE:
hardened with end steel plates and end
anchorages devices like steel wedges. • The Technique of Post Tensioning is used to
provide anchorage and support for deep
5. The tendons are stretched and anchored at
retaining walls, basement floors and floors of
each end
large underground water tanks with high water
6. By means of steel wedges. table.

7. Tendons are anchored at each end. Pre-stressing

is transferred to concrete through bearing plates
placed at each end.

EQUIPMENTS NEEDED FOR POST-TENSIONING:

1. Concrete Beam (to be post-tensioned)

2. High strength steel cables.

LARGE-PANEL STRUCTURES
Prefabricated elements of buildings and structures
made from large factory-produced slab elements
(panels) that are assembled on-site. Large-panel
structures are one of the most progressive industrial
types of structural elements. In modern construction
they are used in building apartment houses, public and
industrial buildings, roads, air-fields, dams, and canals.
They have become most widespread in large-scale
housing and civil construction, where the erection of
buildings from large panels manufactured at housing
construction combines and plants makes possible a
reduction in construction time by a factor of 1.5–2.0 in
comparison with erection of the buildings from brick or
other traditional materials, as well as a decrease of 30–
40 percent in labor expenditures at the construction
site. The estimated cost of a square meter of housing
space is 12–15 percent lower than in brick buildings.
All the main parts of a building, including exterior and
interior walls, floor slabs, roofs, and staircases, may be
made up from large-panel structures. Large-panel
structures are used in two main design schemes,
frame-panel and panel (frameless) buildings. In frame-
panel buildings, all the base loads are borne by the
building’s frame, and the panels are usually used to fill
the frame and as enclosure elements. Frameless
buildings are assembled from panels that perform the
load-bearing and enclosing functions simultaneously.
Large-panel structures for exterior walls consist of
panels one or two stories in height and one or two
rooms in width. The panels may be blind (without
openings) or with window or door openings. In terms
of design, the wall panels may be single-layer (solid)
and multilayer (sandwich). Solid panels are
manufactured from materials that have insulating
properties and at the same time can perform
supporting functions—for example, light-weight
concrete, cellular concretes, and hollow ceramic stone.
Sandwich wall panels are made with two or three
layers; their thickness depends on the climatic
conditions of the region and the physic technical
properties of the materials used for the insulating layer
and for the exterior (supporting) layers. The exterior
layers of the panels are usually made from heavy, light-
weight, or solid silicate concrete or from brickwork or
sheeting (asbestos cement, steel, or aluminum).
Polystyrene foam, rigid and semi rigid rock wool
panels, or cellular concretes may be used for the
insulating layer. Wall panels are produced in
completely finished form, with ready-to-paint surfaces
and with windows and doors; the piping for heating
and other systems and for wiring may also be installed
in the panels. The surface of exterior wall panels is
covered with decorative mortar or is faced with
ceramic or other finishing tiles. After assembly, the
joints between panels are filled with mortar or with
lightweight or ordinary concrete and then sealed with
elastic packing and special mastics.
The large-panel structures of interior walls may be
non-load-bearing or load-bearing. In the first case,
they are made from gypsum-slag concrete or from
other materials that act as enclosures. In the case of
load-bearing structures, the wall panels, which
combine enclosing and load-bearing functions, are
made from heavy or lightweight, silicate or cellular
concrete, or vibration-set brick or ceramic work. The
dimensions of the panels are determined by the
dimensions of the rooms (in apartment houses), their
height is equal to the height of a story, the width is
equal to the depth or width of a room, and the
thickness of the walls between rooms is usually 10–14
cm (between apartments, 14—18 cm).
The large-panel structures of floor slabs are usually
made from reinforced concrete. The area of the floor
slabs in apartment buildings usually equals the area of
one room and may be as great as 30 sq. m. flagging
panels have an area of 5–8 sq. m. The large-panel floor
slabs of housing, public, and administrative buildings
are of both the solid and sandwich types; in the latter,
provision is made for a sound-insulation layer to
reduce air and impact noise. Composite floor panels,
consisting of a load-bearing reinforced-concrete panel
combined with a floor or ceiling panel and
soundproofing, insulating, and other layers, are often
used in housing construction.
The large-panel roof elements are used in housing and
public buildings mainly in the form of combined attic
less roofs, and in industrial buildings the roof panels
have a span of up to 12 m.
The weight of large-panel structures depends on the
method of dividing the building into prefabricated
elements; it is
usually 1.5–
7.5 tons.
 Building applications:

 Dehumidifier Kilns
 Swimming Pool Buildings
 Refrigerated/Cold Storage
 Commercial
WAFFLE CRETE SYSTEM:  Schools
 Offices
"Waffle-Crete" has evolved into a
state-of-the-art structural precast
Panel Sizes
concrete building system. Years of
The standard "Waffle-Crete" panel is 8'-0" [2,438mm]
working with the product has enabled Advance Precast
wide and can be cast in any length up to a maximum
Ltd to develop the construction system far beyond the
of 40'-0" [12,192mm]. From single story to multistory
original curtain-wall concept. Utilization of modular
buildings, the applications are virtually endless.
design can give a functional and efficient wall
Connections
competitively priced far below other conventional
precast systems.
 PANEL TO PANEL:
Each panel to panel connection is fully-detailed on
"Waffle-Crete" is manufactured by Advance Precast
CAD Drawings. Typical panels are welded together at
Ltd. at our CSA Certified Plant to C.S.A. specifications
the top and mid-height of the panels, as well as grout
A23.4-09.
tubes to connect to the foundation. Corners are
welded.
Versatility
The versatility of the product seems to increase with  WOOD TRUSS TO PANEL:
each new project. By using an "adjustable-pan" steel A top plate is bolted to the top of the panel, typically
forming system for the precasting, the panels can be on 4' [1,219mm] centers using cast-in 3/4" [19mm]
made to dimensions that will be the most cost- diameter bolt holes.
effective for each project. With proper planning, future
 STEEL JOIST TO PANEL
expansion can be accommodated. By considering the
location of panel joints and panel sizes, in conjunction A "truss pocket" can be cast into panel to allow the
with detachable connections, entire walls can be truss to sit on a steel bearing plate. Depending on the
relocated as a building is expanded over the years. project, a parapet (change in height) may be used.

 BEAM TO PANEL
Key Benefits
A "beam seat" can be cast into the panel to allow the
beam to sit on a steel bearing plate. In most cases, the
 Custom-made with window rough
precast panel can be changed in order to support the
openings and cast-in door frames;
structural requirements of the beam (deleting the need
 Delivered direct to job site;
for a structural steel beam). For small beams, a face
 Installed by our qualified inside crew;
weld plate with anchor studs allows for flush mounting
 In most situations, panel extends to footing
of beams.
(below grade);
 Can have conduit cast-in for electrical and  LINTEL CONNECTIONS
plumbing; Lintels are welded to adjacent panels.
 Fully engineered C.S.A. approved panels
 Reduced construction time
 Energy efficient
 Durability
Installation 3D VOLUMETRIC CONSTRUCTION:

Panels are set on shims and grouted under bearing 3D Volumetric construction (also known as modular
surfaces. All panels manufactured by Advance Precast construction) involves the production of three-
Ltd. are installed by our installation crew unless noted dimensional units in controlled factory conditions prior
otherwise on CAD drawings. to transportation to site. Modules can be brought to
site in a variety of forms, ranging from a basic structure
Grouting to one with all internal and external finishes and
services installed, all ready for assembly. The casting of
All load bearing surfaces under wall panels are to be modules uses the benefits of factory conditions to
grouted to distribute loads. A sand/cement mix is create service-intensive units where a high degree of
acceptable as long as good penetration is achieved. repetition and a need for rapid assembly on-site make
Any locations requiring a pre-packaged grout will be its use highly desirable. This modern method of
noted on the plans. construction offers the inherent benefits of concrete,
such as thermal mass, sound and fire resistance, as well
as offering factory quality and accuracy, together with
Transportation speed of erection on-site.

Standard panels weigh an average of 45 lbs per square
foot (220 kg. per square meter) and are shipped flat on
standard trailers. For jobs outside the Kelowna area,
Super-B train (98,000 lb or 44,492 kg) or B-train
(80,000 lb or 36,320 kg) truck transport is the most
cost-effective choice.
PanelFinishes
Four finishes are available:
3D Modular Volumetric Precast (Onsite / Offsite)
construction offers an alternative to this current
construction status-quo by promising transformative
improvements in Time, Cost, Quality and Health and
Safety. But most importantly, it offers predictability.
The 3D Monolithic, Volumetric Precast eliminates the
problems inherent to 2D Panel based construction and
employs the least possible number of qualified
engineers, trained technicians without leaving the
construction to the availability of unskilled labour.

1. Smooth (Hand trowelled);

3D Monolithic Volumetric construction (also known as
2. Broomed;
modular construction) involves the production of
o Fine
three-dimensional modular units in controlled factory
o Coarse; and
conditions prior to transportation to site. Modules can
o Striated
be brought to site either as a basic structure or with all
3. Sand float (sold on the basis that it will be
internal and external finishes and services installed, all
painted after installation as the finishing
ready for assembly.
method used to obtain the surface texture
This Unique method of construction offers the inherent
creates a variation in hydration colours); and
benefits of concrete such as thermal mass, sound and
fire resistance, as well as offering factory quality and
Exposed Aggregate (has a light sandy brown tome and
accuracy, together with speed of erection on-site.
we recommend spraying these panels with a methyl
The 3D Volumetric Construction offers Schedule
methacrylate sealer. The sealer gives a high gloss to
benefits as most of the activities are undertaken away
the exposed rock and seals against moisture and
from the building site with minimal work at the
stains)
building site. This enables taking some activities off
the critical path and brings in path and brings in
certainty in the delivery of the project. The diagram
below shows the Schedule benefits of 3D Volumetric
PRE-ENGINEERED BUILDING TECHNOLOGY:
Pre-engineered buildings are factory-built buildings of
steel that are shipped to site and bolted together.
What distinguishes them from other buildings is that
the contractor also designs the building - a practice
called design & build. This style of construction is
ideally suited to industrial buildings and warehouses; it
is cheap, very fast to erect, and can also be dismantled
and moved to another site - more on that later. These
structures are sometimes called 'metal boxes' or 'tin
sheds' by laymen - they are essentially rectangular
boxes enclosed in a skin of corrugated metal sheeting.
Great speed is achieved because while the foundations
and floor slab are being constructed, the beams and
columns - the structural system - are being fabricated
in the factory. Once the foundations and floor are
done, the columns are shipped to the site, lifted into
place by cranes, and bolted together.
STRUCTURAL SYSTEMS
The structural system of pre-engineered steel buildings
gives it its speed and flexibility. This system consists of
factory-fabricated and factory-painted steel column
and beam segments that are simply bolted together at
site. The columns and beams are custom-fabricated I-
section members that have an end plate with holes for
bolting at both ends. These are made by cutting steel
plates of the desired thickness, and welding them
together to make I sections. The cutting and welding is
done by industrial robots for speed and accuracy;
operators will simply feed a CAD drawing of the beams
into the machines, and they do the rest. This
production line style of work makes for great speed
and consistency in fabrication. The shape of the beams
can be tailored to optimum structural efficiency: they
are deeper where the forces are greater and shallow
where they are not. This is one form of construction in
which the structures are designed to carry exactly the
loads envisioned, and no more.
ERECTION
Each piece of the system is very much alike - an I
section with end plates for bolting. The painted steel
sections are lifted into place by crane, and then bolted
together by construction workers who have climbed to
the appropriate position. In large buildings,
construction can start with two cranes working inwards
from both ends; as they come together, one crane is
removed and the other finishes the job. Usually, each
connection calls for six to twenty bolts to be installed.
Bolts are to be tightened to exactly the right amount of
torque using a torque wrench.
FOUNDATIONS AND FLOOR SLAB
The foundations for pre-engineered metal buildings
are made with conventional concrete systems, usually
open foundations. Since these structures are usually
quite large, they attract a fair amount of wind forces.
Wind can cause a net upwards force on a building,
called uplift. Since these structures are very light (they
can weigh as little as 50 kg per square meter, excluding
the foundations and floor slab), the foundations are
designed to firmly anchor the structures to the ground,
preventing them from being blown away by the wind.
The floor system for industrial and storage buildings is
usually a thick (about 8" to 12" / 200 to 300mm)
concrete grade slab that rests directly on the prepared
earth beneath it. The concrete can be topped with a
thin, abrasion resistant smooth coating called an epoxy
floor or polyurethane floor if desired.
CLADDING AND ROOFING - THE BUILDING
ENVELOPE
The most economical cladding for these structures is
light corrugated metal sheeting, on both the roof and
the external walls. These steel sheets, barely 0.5mm
thick, are coated with an aluminium-zinc alloy for
corrosion protection on both sides, and come with an
attractive, durable paint finish on the outside. These
sheets are installed over a grid of purlins, a steel
member that rests on the main structural frame and
supports the roofing material. In pre-engineered
buildings, cold formed Z sections are the member of
choice for purlins.
Before installing the sheets, contractors will install
layers of insulation and vapour barriers. Rolls of glass
wool or mineral wool are the most common type of
insulation for such buildings. Since there is no inner
wall over which to fix these layers, a layer of galvanized
chicken wire mesh is first laid over the purlins. Over
this, the insulation and vapour barriers are laid, and
then the corrugated sheets are laid. The sheets are
fixed with self-tapping screws that run through the
sheets and layers of insulation directly into the purlins.
The purlins, chicken mesh and insulation are thus
visible from below, and can be left as such or covered
with a false ceiling. Polycarbonate skylights can be
installed in the roof sheeting to create natural lighting.

It is common for industrial buildings to have a masonry
wall up to a height of 10 or 15 feet (3 to 5m). This
allows doors and windows to be easily fitted, and
provides security. This wall can be built behind the
metal sheeting, making it invisible from the outside.
There are many advantages of pre-engineered building
systems, but all advantages lead to reduced
construction time. Following are advantages of Pre-
Engineered Building Systems:
Reduced Construction Time:
Due to the systems approach, the use of high strength
steel, use of tapered built-up sections which are
optimized by the computerized design program and
the use of continuous light gage secondary steel
section, there is an overall reduction in steel weight,
cost and time relative to conventional steel
construction.
Pre-engineered buildings are a predetermined
inventory of raw materials that has proven over time to
satisfy a wide range of structural and aesthetic
requirements. The components are engineered
beforehand and standardized. Use of these standard
components reduces the engineering, production and
erection time. Use of customized software for design &
drafting increases the speed of the project.
The production line is highly sophisticated, having
Auto welders, multi-cutting torches, shear cutting
machines etc., which greatly reduce the time of
fabrication of built-up components. Roll forming
machines for producing Z & C members and sheeting,
having standard dimension, increases the production
capacity of secondary members. Use of standard
accessories greatly increases the speed of production
& erection.
Buildings are typically delivered in just a few weeks
after approval of drawings. Foundation and Anchor
Bolts are cast in parallel with manufacture of the
building. Site assembly is fast, as all building
components are delivered finished, ready for site
bolting. It can reduce total construction time on a
project by at least 50%. This will allow faster occupancy
and earlier realization of revenue.
Design:
Since PEB’s are mainly formed of standard sections and
connections, the design time is significantly reduced.
Specialized computer analysis and design programs
optimize material require. Drafting also computerized
using standard details that minimizes project custom
details. The low-weight flexible frames offer higher
resistance to seismic forces.
Lower Cost:
Due to the systems approach, there is a significant
saving in design, manufacturing and site erection cost.
The structural elements are shaped to follow the stress
diagram of the member, thus reducing weight, cost
and load to foundations. The secondary members and
cladding nest together reducing transportation cost.
The overall price per square meter may be reduced as
much as 30% lower than conventional steel.
Foundations:
Pre-engineered Buildings are about 30% lighter than
the conventional steel structures. Hence, the
foundations are of simple design, easy to construct
and lighter weights.
Erection:
Since all the connections of the different components
are standard, the erection time is faster.
Flexibility of Expansion:
Buildings can be easily expanded in length by adding
additional bays. Also, expansion in width and height is
possible by pre-designing for future expansion.
Large Clear Spans:
Buildings can be supplied to around 90M clear spans.
Quality Control: As buildings are manufactured
completely in the factory under controlled conditions,
the quality is assured.
Low Maintenance: members is first constructed, and then clad with dry
sheeting on both sides to form a load bearing wall.
Buildings are supplied with high quality paint systems Construction with steel follows the platform frame
for cladding and steel to suit ambient conditions at system of house building. Connections between
site, which results in long durability and low members are made with self-tapping self-
maintenance costs. drilling screws.

Energy Efficient Roof and Wall Systems: Contractors will usually order pre-punched sections -
sections with factory-made holes in them - so that
Buildings can be supplied with polyurethane insulated
wires and plumbing can be easily passed through the
panels or fibreglass blanket insulation to achieve
walls. The gaps between members are filled with
required ‘U’ values.
insulation.
This form of construction can also be used for non-
Architectural Versatility: structural framing, such as interior partitions or
external cladding. In fact, this form of construction was
Buildings can be supplied with various types of fascia,
originally developed for interior partitions in offices.
canopies, and curved eaves and designed to receive
pre-cast concrete wall panels, curtain walls, block walls
and other wall systems.

LIGHT GAUGE STEEL CONSTRUCTION

TECHNOLOGY:

Light gauge steel construction is very similar to wood

framed construction in principle - the wooden framing
members are replaced with thin steel sections. The
steel sections used here are called cold formed
ADVANTAGES OF LIGHT GAUGE STEEL
sections, meaning that the sections are formed, or
CONSTRUCTION
given shape at room temperature. This is in contrast to
thicker hot rolled sections that are shaped while the
steel is molten hot. Cold formed steel is shaped by Light gauge steel structures have many of the
guiding thin sheets of steel through a series of rollers, advantages of light wood framed structures:
each roller changing the shape very slightly, with the
 They are light, and allow quick building without heavy
net result of converting a flat sheet of steel into a C or
tools or equipment. Every component can easily be
S-shaped section.
carried by hand - a house is like a carpentry job on a
larger scale. The main tool is a light, handheld screw
The steel used here is coated with zinc (called
gun. Since steel is strong, LGS structures are lighter
galvanized) or a mixture of zinc and aluminium to
than wood framed structures of equivalent strength.
protect it from corrosion. The thickness of this coating
 Their higher strength allows greater spacing between
can be varied to suit a range of environments.
members when compared to wood frame construction:
Typically, marine environments require the most
about 24" (600mm) for LGS vs. about 16" or 20" (400 or
protection and dry, arid regions the least.
500mm) for wood. Fewer members translates to
quicker construction times.
The thicknesses of steel used here range from about 1
 It is able to shape itself to any form, and can be clad
to 3mm for structural sections, and 1 to 2mm for non-
and insulated with a wide range of materials.
structural sections. The members are sized to roughly
 It is easy to change or modify this construction at any
correspond to wood members: 2"x4" and 2"x6" are
point in its lifespan.
common sizes.
 There are a great range of systems
and products catering to this type of construction.
Like in wooden framed construction, a frame of steel

In addition,
 Light gauge steel structures are non-combustible,
which is a code requirement for some types of
structures. Since steel loses its strength in fire quite
easily, it must be protected from fire with fire rated
sheeting.
 Light gauge steel structures do not rot, shrink, warp, or
decompose like wood structures, and can be used in
areas where there is a probability of termite attack.
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.
EPS TECHNOLOGY:
Expanded Polystyrene (EPS) core Panel system is a
modern, efficient, safe and economic construction
system for the construction of buildings. These panels
can be used both as load bearing as well as non-load
bearing elements. EPS core panel is a 3D panel
consisting of 3-dimensional welded wire space frame
provided with the polystyrene insulation core. Panel is
placed in position and shot Crete on both the sides.
The EPS panels consist of a 3-dimensional welded wire
space frame utilizing a truss concept for stress transfer
and stiffness. EPS panel includes welded reinforcing
meshes of high-strength wire, diagonal wire and self-
extinguishing expanded polystyrene uncoated
concrete, manufactured in the factory and shot Crete is
applied to the panel assembled at the construction
site, which gives the bearing capacity of the structure.
EPS panel after shot Crete has the following five
components (as Fig. 1.1):
i. The outer layer of shot Crete.
ii. Welded reinforcing mesh of high wire.
iii. The core of expanded polystyrene sheet.
iv. Diagonal wire (stainless or galvanized wire).
v. The inner layer of shot Crete.
The welded mesh fabric connected piercing
polystyrene with truss of steel wire, welded to the
welded fabric at an angle. It gives a rigidity spatial
structure, and simultaneously prevents polystyrene
core shifting.
EPS is used widely in the building and construction
industry. EPS is an inert material that does not rot
and provides no nutritional benefits to vermin
therefore does not attract pests such as rats or
termites. Its strength, durability and lightweight
nature makes it a versatile and popular building
product. Applications include insulated panel
systems for walls, roofs and floors as well as facades
for both domestic and commercial buildings. It is
also used as a void-forming fill material (pods) in
domestic housing slabs, civil engineering projects
(block) as a lightweight fill in road and railway
construction, and as floatation material in the
construction of pontoons and marinas.
Individually welded internal strut wires or diagonals
extend through the panel core between each
surface. These galvanized strut wires are welded
continuously in the required spacing so they form,
with the welded wire fabric, into a triangulated truss
system which greatly increases the panel strength.
EPS panel is a versatile structural element designed
for floors, walls, partitions, roof and stairs.
The typical EPS panel is generally manufactured with
dimensions of 1200 m width, 3000 mm length and
over all thickness range of 80-230 mm.
The panels are finished at the site using minimum 30
mm thick shot Creting of cement & coarse sand in
the ratio of 1:4 applied under pressure. The shot
Creting coat encases the EPS Core with centrally
placed steel welded wire mesh.
EPS is widely used in many everyday building and
construction situations where its light weight,
strength and thermal insulation characteristics
provide cost effective high performance solutions.
Major applications of EPS include insulated panel  Columns
systems for use in floors, walls and roofs of domestic  Light coves
as well as commercial buildings.  Bas Relief
 Domes
EPS is also well proven in civil engineering  Capitals
applications where its inherent strength means it can  Fireplace Surrounds
support structures such as roadways and railways  Medallions
with complete  Custom shapes

Why GFRG?

Flame Resistant

GFRG is a mineral and will not burn. In

addition, the nature of gypsum acts like a
thermal regulator when exposed to flame.
GFRG not only will not burn, but it also
protects the materials behind it from the heat
of the flame for up to two hours.

Easy Installation

GFRG is relatively light in weight compared to

traditional stone or plaster ornaments. Its
installation is quick and relatively easy.

Finish
GLASS FIBRE REINFORCED GYPSUM PANELS:
GFRG is available in a white colour and is easily
GFRG is primarily composed of two raw materials: high
finished with virtually any paint.
density alpha-based gypsum and glass fibre
reinforcement. The gypsum plaster should be neutral POLYURETHANE FOAM PANELS:
or of low alkalinity to ensure its compatibility with "E"
glass fibres. Additives commonly used within the Polyurethane’s Functional Uses

plaster industry are acceptable provided they are used

in accordance with the gypsum manufacturer's One outstanding use of polyurethane is rigid foam,
recommendations. which has unique insulating properties that make it
ideal for walls and roofs for new homes and when
Applications:
remodelling an existing home. With heating and
GFRG is for use where it is not subject to dampness. cooling costs amounting to 56 percent of the energy
(Do not use where it is openly exposed to rain or for used in the average American home (according to the
fountains, pools or wet locations.).GFRG can be used U.S. Department of Energy), rigid polyurethane foam
wherever a light, strong and fire retardant material is can save money while maintaining uniform
required (casinos, hotels, theatres, residential, etc.) temperature and reducing noise levels.
 Mouldings
 Ceilings
In fact, the insulating quality of rigid polyurethane
foam is high, it enables builders to make walls
thinner—but just as quiet, warm and sturdy—and roof
profiles lower, creating more space for your family.
Rigid foam can also save homeowners money, both in
reduced construction costs and lower utility bills.
Sprayed polyurethane foam provides weather proof
sealants, forms a seamless layer of insulation, fills gaps
and seams during application, and covers irregular,
hard-to-insulate shapes. In fact, closed cell spray
polyurethane foam insulation forms an air barrier and
moisture barrier. Spray foam insulation can also reduce
drafts while creating sturdier, quieter buildings.
Polyurethane insulating products are also often
structurally self-supporting, and can be attached to a
wide range of substrates while requiring no additional
adhesive.
When combined with the proper materials,
polyurethanes perform well as external weather and
moisture barriers. High-performance polyurethane
foam insulation can be spray-applied to various
substrates, or moulded to special shapes in large sizes.
Polyurethanes Increase Creative Options
Polyurethane building materials add design flexibility
to new-home and remodelling projects. Foam-core
panels offer a wide variety of colours and profiles for
walls and roofs, while foam-cored entry doors and
garage doors are available in drent finishes and styles.
Structural insulated panels feature polyurethane foam-
core insulation with both an exterior and interior
facing, and can be made part of the structure of a
building. Facing materials include gypsum, engineered
wood or natural wood products. These structural
insulated panels improve the look and utility of the
home, speed construction, and reduce the amount of
expensive wood necessary for structural framing. The
finished product can save time, energy
construction costs.
AUTOCLAVED AERATED CONCRETE:
Autoclaved aerated concrete (AAC) is a type of precast
concrete composed of natural raw materials. It was first
developed in Sweden in the 1920s, where an architect
combined the conventional concrete mixture of
cement, lime, water, and sand with a small amount of
aluminium powder. AAC concrete typically is made into
blocks, or masonry units, and is used to build mortared
walls similar to standard concrete block construction.
How Aerated Concrete Is Manufactured
Autoclaved aerated concrete contains air bubbles
throughout the material that generate a low-density
lightweight material when it is fired in an autoclave
oven. It is highly workable and can be cut and drilled
with conventional woodworking tools, such as band
saws and ordinary power drills. Because it is
lightweight and relatively low-density, the concrete
must be tested for compressive strengths, moisture
content, bulk density, and shrinkage. The concrete can
be used on walls, floor, roof panels, blocks, and lintels.
Properties of Aerated Concrete
AAC blocks are solid blocks that are stacked and
bonded with mortar and can be reinforced with steel
or other structural members for additional strength.
AAC offers only moderate insulation values of about R-
10 for an 8-inch-thick wall and R-12.5 for a 10-inch-
thick wall. However, AAC structures can be very airtight
to reduce energy losses due to air leaks.
The thermal mass of AAC slows temperature swings to
reduce the need for heating and cooling as outdoor
temperatures change. AAC also creates an excellent
soundproofing barrier. AAC structures can be finished
with paint, stucco, and most standard siding materials.
Interior surfaces can be finished with drywall, plaster,
tile, or paint, or can be left exposed.
Aerated Concrete Benefits and Applications
Some of the benefits of using autoclaved aerated
and concrete include:
 Thermal protection of approximately 1.25 per inch.
 Excellent soundproofing material and acoustic
insulation.
 Highly fire- and termite-resistant.
 Manufactured in a variety of forms and sizes. PRE CAST TECHNOLOGY:

 Offers thermal mass that stores and releases energy

over time.

 Recyclable material.

 Chases and holes for electrical and plumbing lines are

easy to cut.

 Shipping and handling more economical than poured

concrete or concrete block.

 Panels are available in thicknesses of between 8 inches

to 12 inches and 24 inches in width, and lengths up to
20 feet.

 Blocks come in lengths of 24, 32, and 48 inches, and POLYURETHANE

thicknesses of 4 to 16 inches thick; height is 8 inches. FOAM PANELS:

Aerated Concrete Drawbacks

Like all building materials, AAC has some

disadvantages:

 Some inconsistency in quality and color.

 Unfinished exterior walls require exterior cladding to

protect them from weather.

 If installed in high humidity environments, interior

finishes with low vapor permeability and exterior
finishes with a high permeability are recommended.

 Low R-value compared to energy-efficient insulated

wall construction.

 Cost is higher than a conventional concrete block and

wood-frame construction.

LIGHT GAUGE STEEL CONSTRUCTION

TECHNOLOGY:
IMAGES FROM SITE VISIT:
 LARGE PANEL STRUCTURES:

GLASS FIBRE REINFORCED GYPSUM PANELS

EPS TECHNOLOGY:

WAFFLE CRETE SYSTEM

BUILDING
CONSTRUCTION

JAANISSAR GERA 3B
160BARCHI039
 INDEX

 PRECAST TECHNOLOGIES
 PRINCIPLE OF PRESTRESSING
 ECCENTRIC PRESTRESSING
 MATERIALS USED
 PRE TENSIONING
 LONG LINE METHOD
 STEAM CURING
 POST TENSIONING
 APPLICATIONS OF POST TENSIONING
 LARGE-PANEL STRUCTURES
 WAFFLE CRETE SYSTEM
 3D VOLUMETRIC CONSTRUCTION
 PRE-ENGINEERED BUILDING TECHNOLOGY
 LIGHT GAUGE STEEL CONSTRUCTION
TECHNOLOGY
 EPS TECHNOLOGY
 GLASS FIBRE REINFORCED GYPSUM PANELS
 POLYURETHANE FOAM PANELS
 AUTOCLAVED AERATED CONCRETE
 PRE CAST TECHNOLOGY
 IMAGES FROM SITE VISIT