ME - STRUCTURAL. ENGINEERING, Sy Telb— PREPARRICATEP ereucwor Ed: Tt erm Volune ~ rMae Struct year ST 7016 PREFABRICATED STRUCTURES LTPC 4 3003 OBJECTIVES: (0 To Studythe design principles, analysis and design of elements. “UNIT I DESIGN PRINCIPLES 9 General Civil Engineering requirements, specific requirements for planning and layout of prefabrication plant. IS Code specifications. Modular co-ordination, standardization, Disuniting of Prefabricates, production, transportation, erection, s1aGes of loading and code provisions, safety factors, material properties, Deflection control, Lateral load resistance, Location and types of shearwalls. UNIT I REINFORCED CONCRETE 9 Prefabricated structures - Long wall and cross-wall large pane! buildings, one way and two way prefabricated slabs, Framed buildings with partial and curtain walls, -Connections — Beam to column and column to column, UNIT III FLOORS, STAIRS AND ROOFS 9 Types of floor slabs, analysis and design example of cored and panel types and two-way systems.stairease slab design, types of roof slabs and insulation requirements. Description of joints. their behaviour and reinforcement requirements, Deflection control for short term and long term loads, Ultimate strength calculations in shear and Alexure UNIT IV WALLS 9 ‘Types of wall panels, Blocks and large panels, Curtain, Partition and load bearing walls, load transfer from floor to wall patels, vertical loads, Eccentricity and stability of wall panels, Design Curves, types of wall joints, their behaviour and design, Leak prevention, joint sealants, sandwict wail panels, approximate design of shear walls UNIT V INDUSTRIAL BUILDINGS AND SHELL ROOFS 9 Components of single-storey industrial sheds with crane gantry systems, R.C. Roof Trusses, Roof Panels, corbels and columns, wind bracing design. Cylindrical, Folded plate and hyper prefabricated shells, Erection and jointing, joint design, hand book based design. TOTAL: 45 PERIODS OUTCOMES: 1D At the end of this course student will have good knowledge about the prefabricated elements and the technologies used in fabrication and erection, U1 They will be in a position to design floors, stairs, roofs, walls and industrial buildings, and various joints for the connections. REFERENCES: 1. Konez.T., Manual of Precast Concrete Construction, Vol.I II and III & IV Bauverlag, GMBH, 1971 2. Laiszlo Mok; Prefabricated Concrete for Industrial and Public Structures, Akademiai Kiado, Budapest, 2007. 3. Lewicki.B, Building with Large Prefabricates, Elsevier Publishing Company, Amsterdam’ [ondon/New York, 1998. 4. Structural Design ‘Manual, Precast Concrete Connection Details, Society for the Studies in the use of Precase Concrete, Netherland Betor Verlag, 2009. 5. Warszawski, A., Industrialization and Robotics in Building - A managerial approach, Harper and Row, 1990.UNITI DESIGN PRINCIPLES PREFABRICATED STRUCTURE: Prefabricated structures are structure in which the parts are fabricated and assembled in a central assembly point. Prefabrication is the practice of assembling coinponents 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, EED FOR PREFABRICATION: > Economy in cost To improve the quality To speed up construction To use locally available materials with required characteristics To use the material which possess their characteristics like light weight, easy availability, “thermal insulation, non- combustible. VANTAGES: 1. Self-suppotting ready-made components are used, so the need for formwork, shuttering and scaffolding is greatly reduced. 2. Construction time is reduced and buildings are completed sooner, allowin; _>retum of the capital invested. 3. On-site construction and congestion is minimized. ‘4. Quality control can be easier in a factory assembly line setting thayt'a coil setting. 5. Prefabrication can be located where skilled labour is more readily aailabld and costs of labour, power, materials, space and overheads are lower 6. Time spent in bad weather or hazardous environments ts gbghe Cope prion site is minimized. Bee: 7. Less waste may occur 8. Advanced materials such as sandwich-structured compbijain be easily used, improving thermal and sound insulation{ang airtightnessNTAGES: 1. Careful handling of prefabricated compéhents such as concrete panels or steel and glass panels is required. 5 ~ 2. Attention has to be paid to'tlie strength and corrosion-resistance of the joining of prefabricated sections to avoid failure of the joint. 3. Similarly, leaks can form at joints in prefabricated components. 4, Transportation costs may bé higher for voluminous prefabricated sections than for the materials of which they are made, which can often be packed more efficiently, 5. Large prefabricated sections require heavy-duty cranes and precision measurement and handling to place in position, 6. Larger groups of buildings from the same type of prefabricated elements tend to look drab and monotonous 7. 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. STAGES INVOLVED IN PREFABRICATIO! 1. ‘Lhe structure divided into number of units. t in permanent facto- (site prefabrica- 2. The different units are prec: ries (plant fabrication) or temporary plants tion). 3. Transported tw the site. 4. Hoisted set into their final places, and assembled to form @ complete structure PREFABRICATED SYSTEMS: ‘The system of prefabricated construction depends on > The extent of the use of prefabricated components > The materials > Sizes ‘YPES OF PREFABRI > Reinforced/Pre-stressed concrete channel unit > Reinforced/Pre-stressed concrete slab unit > Reinforced/Pre-stressed concrete beamsReinforced/Pre-stressed concrete columns Reinforced/Pre-stressed concrete hollow core slab Reinforced/Pre-stressed concrete wall elements Reinforced concrete wafile slab/shell Hollow/solid blocks and battens Precast planks and joists for flooring and roofing Precast joints and trussed girder Light weight/cellular concrete slabs Precast lintel and chajjas Reinforced/Pre-stressed concrete trusses Reinforced/Pre-stressed roof purlins Precast concrete L-panel unit Prefabricated brick panel unit Prefabricated sandwich concrete panel vVY¥YVYVV VY YY VV Precast foundation TYPES OF PREFABRIC. ‘D SYSTEMS: > Partial Prefabricated System > Full Prefabricated Systems > Large Panel Prefabricated Systems > Box type construction PARTIAL PREFABRICATION SYSTEM: > It should be in the form of in-situ’ frame work or load bearing walls > {tshould be used in the roofing and flooring components | FULL PREFABRICATION: > In this system all structural components are prefabricated > It should be used for brick masonry or brick workLARGE PANEL PREFABRICATION: > This system is based on the use of large prefabricated components. - > The components used are precast concrete large panels for walls, balconies, roofs, stairs etc.. MODULAR CO-ORDINATIO} The principle object of this is to assist the building design. OBJECTIVE : > Facilitates co-operation b/w building designers, manufactures, distributors, contractors and authorities. > — Optimizes the number of standards sizes of buildings components. > Simplifies site operations > Ensures dimensional co-ordination b/w installation as well as with the rest of the building PURPOSE OF MODULAR CO-ORDINATION: > To reduce the variety of component sizes produced > To allow the building designers greater flexibility in the arrangement of the components BASES OF MODULAR CO-ORDINATION: MODULES (M): > Itis a standard unit of size > Used to co-ordinate the dimension of the buildings and components > IM= 100mm MULTI MODULE: > It’s size is a selected multiple of the basin module > The International standardizes values of the dimensions are 3M , 6M , 12M, 30M , 60M SUB MODULE: It is the fraction of the basic module. BM=IM=10cm S.M = M4 = 10/4 = 2.5 emMODULAR GRID: A rectangular co- ordinate reference system in which the distance b/w consecutive lines is the basic module or multi module. a STANDARDIS: IN: Standardisation refers to the creation and use of guidelines for the production of uniform. imerchangeable components especially for using mass production. ADVANTAGES OF STANDARIZATION: > Easier in design ~ Elimination of unnecessary choices. > Easier in manufacture ~ Limited number of variants > Easier in erection and completion ~ Repeated use of specialized equipment. DISADVANTAGES OF STANDARIZATION: [Bice the joints are, at comers that are at places where the moments reach their maximum values, the forming of joints is dificult. ‘The forming of in-situ joints is very difficult; hence the Joints must be over dimensioned. ‘No of joints are reduced and if larger precast members are needed. FACTORS INFLUENCING STANDARIZATIO! > To limit the number of types of elements and to use the large quantities. > To limit the size and a number of prefabricate by the weight. > — Touse the largest sites to the extent possible, this resulting the less number of joints. > To select the most rational type of member for each element from the point of production, ~ assembly, serviceability and economy.DISUNITY OF PREFABRICATD STRUCTURE: In prefabrication many elements of prefabricated are assembled or united or joined to form a single structure. ‘The problem in prefabrication is the transportation. To avcid in this probiem transportation the stmicture is disunited or separates into smaller elements so that the transportation becomes very easy and in the site they may be united are assembly. ‘This method of Separating into smaller member or element is called disunity-structure in prefabrication. - ¢ gl “Instead of using the larger member as beam or-gifder, two or three * gmaller Sectiohs may be used and united together < ‘as a single member | but the load carzying capacity. of a singie large member should be equal to Sum ofload carrying capacity two or three sinaller members. ~ Nonmally in factoriés in production is done ini a faster rate for many small prefabrication elements. This leads to disunity of the structures into .-members. suitable for plant prefabrication, and for shipping, There are 4 " thethods of disunity structures. ADVANTAGES: « The number ofj joints is reduced. » Failure at joints is imihimuh: © This disuniting rmethiod js Suitable for site pre! Transportation cost for imany elements to the fabrication. site is reduced.DISADVANTAGES: © ‘The lifting or Hoisting ofthe entire frame is more difficult. > Transportation of the frame from the plant is difficult ». Transport cost is high forthe transport of entire frame. «,.The stress distribution during lifting is a problem. Kolin consisting of near members disuhited at joints: He “3 pos Disunity at joints gives linear members this means a great advantage at facilities in manufacturing and.assembling. : MET! Advantages: @ | Scaffoldings or auxiliary scaffoldingsyare not necessary. * Hoisting or lifting method is very sifple. : 3 me Disadvantages: : a : i ‘The main disadvantages the joints ‘at the corners that is places were the moments are maximum. So the formation of joint is very difficult. * ‘he quality of concreting should be very high in these precast members. * The joints must be over dimensioned. * This makes additional materials to be used for precast members. ‘This disadvantage is overcome are rectified by the new trend or method of replacing moment resistance joints by hinge like structures etc... In this method more material is required for beams the complicated construction of rigid corners can be omitted.given for the prefabrication of disuniting into entire frames: In this method the.pntire frames thé total structure are disunited or separated. parated, fo advantages: -« iy . Jrot a + The members of joints are Rduced— qt » Failures pf joints are minimum. «This disunity method is suitable for site prefabrication. * ‘Transpoftation cost for many- Check that material and plant is moved or operated outside the “No Go Zone” of 3000 mm i from an overhead electrical cable on a pole or 8000 mm if the electricity cable is on a tower line (If erecting scaffolding, the “No Go Zone” during this process is 4.6m distant and 5m below from the nearest power line) > Ifwork or plant is able to encroach on this clearance, the erector must obtain permission from the electricity company or develop a SWMS and work in accordance with it.