PREFABRICATED

STRUCTURES
11C026

Objective Oriented Learning Process Format

RBT (OLF)
Branch: IV B.E.
Semester: S7
Subject code & Title: 11C026 Prefabricated
Structures
T-L tools: PPT Presentation

Alpha Breathing
Three steps for alpha breathing
Breath in deeply
Breath out slowly
Hold for a while

(Repeat the three steps for 8 times)

UNIT 1
GENERAL PRINCIPLES OF
PREFABRICATION
Comparison with monolithic construction Types of
prefabrication site and plant prefabrication - Economy
of prefabrication Modular coordination
Standardization Planning for Components of
prefabricated structures Disuniting of structures
Design of simple rectangular beams and I beams
Handling and erection stresses Elimination of erection
stresses Beams, columns Symmetrical frames

Prerequisite Knowledge
Prefabrication
Types of prefabrication
Economy

1A-5

Modular coordination Standardization Planning

for Components of prefabricated structures

1. Topic for Learning through

Evocation
Modular coordination, Standardization, planning for components of
prefabricated structures

2. Topic Introduction
2.1

General Objective

2.2

Specific Objective

2.3

Key words

2.4

Key Diagrams (if any)

1A-8

2.1 General Objective

Students will be able to understand the concepts of
modular coordination and standardization for
prefabricated structures.

1A-9

2.2 Specific Objectives

Students will be able to
1) Define Modular coordination (E)
2) Differentiate the 3 types of modular coordination
(E)
3) Explain the concept of standardization (E)
3) Recall the components of prefabricated structures
(E)
4) Sketch a mind map showing the prefabrication
concepts (E,T)

Taxonomy of Objectives
Knowledge Dimension

The Cognitive Process Dimension

Remember

A. Factual Knowledge

Understand

Apply

Analyse

Evaluate

Create

1,4

B. Conceptual Knowledge
C. Procedural Knowledge
D. Meta Cognitive
Knowledge

Explanatory Notes: (This is not the notes for the topic. It is an explanatory notes to remember the reason for doing a
particular mapping in the table above)
1. Remember (R) the definition of Modular coordination (facts).
2. Analyse (An) the 3 types of modular coordination (concept)
3. Apply (Ap) concept of standardization (concept)
4. Remember (R) the components of prefabricated structures (concept)
5. Applying own strategy to sketch a mind map.

1A-11

Modular coordination

Modular coordination is a concept of

coordination of dimension and space in which
buildings and components are dimensioned and
positioned in terms of basic unit or module.
The basic module is known as 1M which is
equivalent to 100mm.
It is internationally accepted by the
International Standard Organisation and many
other countries including Malaysia.

 Modular Coordination is essentially based on the use

of modules (basic module and multi-modules) and a
reference system to define coordinating spaces and
zones for building elements and for the components
which form them.
There are standard rules to abide by
- Rules for locating building elements within the
reference system;
- Rules for sizing building components in order to
determine their work sizes;
- Rules for defining preferred sizes for building
components and coordinating dimensions for buildings.

 The application of Modular Coordination may be

applied to the design, manufacture and assembly of
buildings, their components and installations
For each participant in the building team, it can
allow a relative independence in decision making
with the common dimensional language. Therefore,
where ever it is necessary to position and size the
components and to ensure their fit with minimum
on-site modification and materials wastage,
modular co-ordination is found to be essential.
IS:7922-1987: Recommendations for Modular
coordination in Building Industry

Purpose of Modular Coordination:

To reduce the component size produced;
To allow the building designer of greater
flexibility in the arrangement of components
Module

Basic modules Multi modules Sub-modular module

Module- It is a standard unit of size to coordinate the

dimensions of buildings and components.
a.) Basic module- It is the fundamental unit of size n
modular coordination. The basic module is represented by
letter M while its international standard value is:
1M=100mm
b.) Multi-module- They are standardized by selected whole
multiples of the basic module. The international standard
values of multi-modules for horizontal coordinating
dimensions are:
3M,6M,12M,30M and 60M
multi-module of 15M is used for special applications.

c.) Sub-module increment - Sub-modular

increment is an increment of size, the value of
which is a selected fraction of the basic module.
The international standardized value of the submodular increment is M/2 = 50mm.
It is to be used where there is a need for an
increment smaller than the basic module.
Determining the displacements of different
modular grids
Modular coordination is the basis for a
Standardization of a mass production of
component

 A basic module can be represented as module M and

for larger project modules are represented a Mp.
These rules are adaptable for,
-The planning grid in both directions of the horizontal
plan shall be
1)
3M for residential and institutional
buildings,
2) For industrial buildings,
15M for spans up to 12m
30M for spans between 12m and 18m
60M for spans over 18m

Dimensions of prefab components

Flooring and Roofing
Length- multiple of 3M
Width multiple of 1 M
Thickness multiple of M/4

BEAMS
Length multiple of 3M
Width multiple of M/4
Depth multiple of M/4

Column
Height multiple of 1M for ht up to 2.8m and ht above
2.8m is multiple of 2M
Lateral dimension- multiple of M/4

 Wall
Thickness multiple of M/4
Staircase
Width multiple of 1M

Lintels
Length multiple of 1M
Width multiple of M/4
Depth multiple of M/4

Sunshade
Length multiple of 1M
Projection- multiple of 1M

STANDARDIZATION:
Standardization refers to the creation and use of
guidelines for the production of uniform,
interchangeable components, especially for use in
mass production.
Standardization will facilitate quicker construction
of similar elements, avoid duplication of effort.
ADVANTAGES OF STANDARDIZATION:
Easier design
Manufacture is easy
Easy erection and completion

Components of Prefabrication
"Prefabricated
Components"
means
any
structural sub-assembly or component such as wall,
floor or roof panels; plumbing or electrical service
walls; bath, kitchen or utility service modules;
service core modular units; refrigeration panels,
provided they are built at an off-site location using
closed construction.
It does not include roof trusses, open wall panels
and similar sub-assemblies which are built at an offsite
location
using
open
construction.

Types of system:
Long wall system
Homogeneous system
Non-homogeneous system
Cross wall system
Long wall system
The main beams are load bearing walls are placed parallel to the long
axis of building. The longitudinal external walls which carry the floor
loads must posses not only thermal properties but also sufficient load
carrying capacity.

Cross wall system

The cross walls are load bearing walls whereas the facade wall
(generally one exterior side of a building) are non-loading bearing,
this system is suitable for high rise building.

Disuniting of structures Design of simple rectangular beams

and I beams Handling and erection stresses Elimination of
erection stresses

Disuniting of Structures

2.1 General Objective

Students will be able to understand the disuniting of
structures

1A-26

Disuniting of Structures
The solution for the problems connected with the
transportation and placing of structures demands the
disuniting the larger member in to smaller member.
One bay frames, not exceeding 40tons in weight, may
represent an exception, because the problem of their
hoisting and placing can be solved with the aid of modern
available hoisting machine and equipment.
Disuniting of these frames can be done at corners or
points of minimum moments, to make the hoisting of
these smaller members possible using simpler equipments.

Disuniting of Structures- Advantages:

Easy to transport the members from casting yard
Ease in placing in required position.

Disadvantages:
The identifying joint location is a problem in
disuniting of structures.

 The hoisting of one larger member is, as a rule less

expensive than that of two smaller members having
the same combined weight.
Hoisting of a large member requires a hoisting
machine and lifting tackle with a far greater bearing
capacity.
It is a direct consequences of the following
circumstances:
The assemblage of lifting tackle
The transfer of hoisting machine
Hoisting, placing and plumbing must be done for
each member separately, independent of its weight

 The disuniting into larger members means

lower costs of hoisting and placing, as well as
saving in the jointing costs. This is due to the
smaller number of joint.
The hire of the equipment may be higher, but
the work itself much less for disuniting into
larger members.

Disuniting of member
a.) System consisting of linear member disunited
b.) System for prefabricates of entire rigid frame
c.) System consisting of I, T, U of straight
members disunited at points of minimum
moment.
d.)Two hinged and three hinged arches

a) Systems consisting of linear members disunited at

joints:
Advantage of Systems consisting of linear members
disunited at joints:
Disuniting at joints gives linear members. This means a
great advantage and facility from the view point of both
manufacture and assembly
Disadvantage of Systems consisting of linear members
disunited at joints:
The disadvantage of the system is that the joints are at the
corners, ie at places where the moments usually reach their
maximal values, so the forming of the joints is difficult.
Joints must be over dimensioned to cope with in-situ
concreting.
And one alternate solution to replace moment resistant joints
by hinged connection.

b.) System for prefabricates of entire rigid

frames
In this system, the trend to lessen the number
of joints and to precast larger members in one
leads to the prefabrication of entire frame.
Production of the frames does not cause any
particular trouble but the hoisting is more
difficult and requires careful preparation.
The stress distribution of straight members
during hoisting is in general statistically
determinate.

Advantage:
1. It is ideal for site prefabrication.
2. Small number of joints so rapid prefabrication work is
possible.
3. Suitable for long walls consisting of great number of uniform
frames.

c.) System consisting of I, T, U of straight

members disunited at points of minimum
moment.

 Another method of disuniting of structures is by division

into different membranes at points, where the moments
are thin or smallest. This method is called as lambda
method.
Using this method hinge joints are made.
Advantage:
Functions are made at points of minimum moments or at
points of contra flexure.
Disadvantage:
Hosting and temporary bracing of L joined asymmetric
frame members is particularly complicated.

d.) Two hinged and three hinged

arches
Arched structures are normally
two hinged and three hinged
arches.
Arched structures are normally
used for bridging span more
than 20- 25m. Their production
and placing is more difficult
than straight members.
Arch can be two hinged and
three hinged but they can also
be fixed at footings and can be
constructed with or without tie.

 Arched structures are generally precast and assembled in

statistically determined three hinged variance and middle
hinge is only eliminated after placing is finished.
Thus the structure is transformed into hinged arch,
increasing thereby its rigidity as well as reducing its
motion under wind load.
The shuttering made of timber or concrete is required
having the same curvature as the arch itself.
The prefabrication of larger arches in the horizontal
position is found to be more economical.
The construction of arch trusses can be properly carried
out in the horizontal position only.

DESIGN OF SIMPLE RECTANGULAR

BEAMS AND I-BEAMS

The c/s of a precast reinforced concrete structures can be T,U,I and V

shaped. They may be solid and their profile can be hollow or divided.
Design of c/s based on efficiency of materials,
1. Homogeneous prefabricates
i. Solid
ii. Hollow
iii. Ribbed
2. Composite prefabricates
iv. Solid c/s
v. Hollow c/s
vi. Ribbed c/s
Based on the c/s, the members are classified as,
a. Rectangular section
b. Tee section
c. I- section
d. U or V section

1. Rectangular section:
. The most simple c/s of precast structure is the rectangular.
Nowadays, this is only used for lighter members to be produced in
smaller numbers. Their prefabrication is simple but they are not
economical.
. The disadvantage is rectangular section are not economical.
. The other sections I,T,U,V shaped are frequently used in
prefabrication.
. The advantages of these sections are,
.30-50% savings in concrete
.5-10% savings in steel
.Savings in cost in hoisting work (lifting work)
.Less concrete mix a proportionate savings in weight.
. The most important advantage of precast reinforced concrete
structures over monolithic or cast in-situ structures lies in the
possibility of forming c/s which from the view point of the theory of
strength of materials, are more advantageous.

 The
economy of c/s is measured by a factor denoted by .
The value of is,
=
F= Area of c/s investigated
F= Area of rectangular c/s with the depth h and width b and
modulus of resistance k; b and k are identical for both c/s.
For the rectangular c/s,
F= b.h..(1)
k = = k ..(2)
h = (6k/b) ..(3)
F = b(6k/b)
F= (6kb)
Hence, = =

 For Rect. c/s =1

For other I,U,T,V c/s , <1
For a smaller value of , the c/s is more
economical
The value of form factor for various sections are,
I-profile of = 0.31-0.33
Pre-stressed concrete structures, =0.45-0.50
Precast reinforced concrete structures, =
0.50-0.60

HANDLING AND ERECTION

STRESSES

Erection of Buildings

Prefabricated structures are erected in a convenient

sections which when fixed correctly should be
sufficiently rigid in all directions.
Normal sequence of erection:
a. Structure units- external load bearing walls,
columns, etc
b. Non structure units- internal walls, partition walls,
etc
c. Floor panels, balconies, stair units
d. Specialized prefabricated units- chimney flumes.
Ventilators, sanitary installation.

 The erection which produces some stresses can

be minimized by tolerance factor.
Tolerance is the limiting value of admissible
deviation in the size or shape of the finished
prefabricate from the design requirements.

The hoisting and fixing up of the beams:

 Pick up and hoisting Beams in general are lifted at two

points depending on the weight and dimensions as well
as the load bearing capacity of hoisting machines.
The hoisting girder which is heavy to a great can be
executed with hydraulic jacks.
The jacks are lowered and the beam is placed to the
required position to the column.
Suspension:
For lifting up of truss and large beams of length 25-30m
care is taken to lift the rocker in uniform rate with two
hoisting machines otherwise the beams would be
subjected to distortion during the lifting leading to
cracks.

Hosting of Columns:

 The hoisting machine for small column is less than

five tones.
First of all pick up gear must be assembled on to the
column and the column is then under pinned.
Thereafter the column is lowered temporarily on to a
sheep shoe assembled at the foot and the roller track is
pushed under the shoe.
When column is hoisted the pick up points moves
vertically and bottom resting on the roller tracks shifts
towards the footing.
When the column is lifted to the required height, the
retaining cable is used to decrease and finally stop the
swinging motion of the column.

In the erection of precast elements;

All the following items of work are meant to be included:
(a) Slinging (suspend) of the precast elements;
(b) Tying up of erection ropes connecting to the erection hooks;
(c) Cleaning of the elements and site of erection;
(d) Cleaning of the steel inserts before incorporation in the joints
(e) Adjustment to get the stimulated level, line and plumb;
(f) Welding of cleats,
(g) Putting up and removing of the necessary scaffolding or
support;
(h) Welding of the inserts
(i) Finishing the joints to bring the whole work to a workman like
finished product.

1. Location of lifting inserts

before hoisting
2. Leveling
3. Provide level pads or shim
plates
4. Provide backer rods (A
backer rod is a small foam rod
or cord that is used to fill joints
between the building material.
Builders and contractors often
use this tool initially in grooves
or cracks and then they
apply mortar,
sealant,
or
around it. The rod adds
stability, precision )

5. lifting of precast
element
6. adjusting the panel
position
7. Prepare and apply the
mortar to fill the gap
between the joints.

Equipment
The equipment used in the precast concrete industry
can be classified into the Following categories:
(a) Machinery required for the quarrying of
coarse and fine aggregates.
(b) Conveying equipment, Concrete mixing
machines.
(e) Erection equipment, Transport
machinery, Workshop machinery,
(k) Steam generation plant for accelerated
curing.

2.3 Key words

Prefabrication
Modular coordination
Standardization
Disuniting
Handling stresses
Erection
1A-61

2.4 Key diagrams

1A-62

3. Group Discussion

4.Mind Map

5. Summary

Modular coordination
Standardization
Components of prefabricated structures
Disuniting of structures
Handling and erection stresses

6.
Assessment
through
Stimulating
questions/Analogy/New ideas and Concepts
Why careful attention to be paid on joints ?

1A-66

7. References:
(Books/Periodicals/Journals)
1. T. Koncz, Manual of Precast Concrete
Construction, Vol. I, II, III & IV, Berlin, 1971
2. B.Lewicki, Building with Large Prefabricates,
Elsevier Publishing Company, Amsterdam,
London, New York, 1998
3. Structural Design Manual, Precast Concrete
Connection Details, Society for the Studies in the
use of Precast Concrete, Netherland Betor Verlag,
2009
1A-67