BUILDING CONSTRUCTION VIII

ASSIGNMENT 01
SUBMITTED BY:- Ananya Kataria, Harshita, Neetika, Gayatri Ahuja,
Sanyukta Vats, Sejal Singhal, Vidhi Wakodikar
4-A
 Prefabricated structure

Prefabricated buildings, or prefabs, are buildings with components

(walls, roof, and floor) that are manufactured in a factory or
manufacturing plant. These components can be fully or partially
assembled in a factory, then transferred to the site. This method of
building construction is preferred due to its cost efficiency, fast
turnaround, and reusability. Common applications of prefabricated
buildings are temporary construction facilities, office spaces, medical
camps, evacuation centers, schools, apartment blocks, and
single-detached houses.
 Manufacturing process

System production
The term systems production describes a series of operations directly
involved in the manufacturing process or more application of
prefabricated molding units.
The components are manufactured for a large scale project under
standardized measurements but can be customised too according to the
requirements of the project.However, customisation might appear on the
more expensive side.
However, the techniques can be grouped into three basic production
methods.
These are,
● Support system- In the support system, the prefabricated nature is
at the point where they were molded.They are the bed in which
they are prefabricated.
● Conveyer belt- The production system of the conveyor belt
divides the entire production process into a series of operations
carried out at a successive and permanent separate point for heat,
it can be by means of conveyor belts and crane, etc.
 ● Aggregate system- The word aggregates describe a large and complex set of permanently installed machines and A
mechanical application that can carry out most of the separate operations involved in the smelting of concrete
components.
PRODUCTION
● The location of prefabricated yards consists of storage facilities suitable for transportation and assembly equipment and
the availability of raw materials are the critical factors that should be carefully planned and provided for the effective and
economical use of precast concrete components in a building.
● The manufacturing of the components can be done in a factory located centrally in a site where prefabricated yards are
installed at or near the job site.

FOLLOWING ARE THE TWO METHODS OF PRODUCTION:-

FACTORY PREFABRICATION

The prefabrication of the factory is restored in a central plant for the manufacture of standardized products.
● It is a capital intensive production where the work is carried out throughout the year, preferably under a covered shed to
avoid the effects of seasonal variations, the high level of mechanization can always be introduced in this system where
work can be organized similarly to a factory with help from the constant team of workers.
 ● The basic disadvantage in the prefabricated factory is the additional cost in the transportation of elements from
the plant to the workplace, sometimes the shape and size of the prefabricated must be limited due to lack of
adequate transport equipment road controls, etc.

PREFABRICATION ON THE SITE

● In this scheme, the components are manufactured at the site near the worksite as possible.
● It is usually adopted for a specific work order for a short period. The work is usually done in open space with a
valuable local workforce. The equipment, machinery, and molds are mobility.
● Therefore, there is a defined economy with respect to the cost of transportation. This system suffers from the
basic inconvenience of its failure to adapt to any high degree of mechanization. It has no elaborate Quality
control arrangements.
Advantages of prefabricated structure Disadvantages of prefabricated structure
Some major advantages of Prefab structures are: The disadvantages of these structures are:

○ Faster construction ○ Limited customisation

○ Cost-effective ○ Transportation costs
○ Reduced on-site waste ○ Initial design complexity
○ Quality control ○ Site preparation challenges
○ Environmental benefits ○ Dependency on manufacturing facilities
○ Energy efficiency ○ Resistance to change in the construction industry
○ Minimal site disruption ○ Potential for higher upfront costs
○ Easy relocation. ○ Only for large-scale production
Applications of Prefabricated Construction

1. Residential Construction: Prefabricated construction is becoming

increasingly popular in the residential construction industry. Modular
homes, which are built using prefabricated components, offer several
benefits over traditional stick-built homes, including cost savings and
faster completion times.
2. Commercial Construction: Prefabricated construction is also being used
more frequently in the commercial construction industry. Modular office
buildings, schools, and healthcare facilities are all examples of
commercial buildings that can be constructed using prefabricated
components.
3. Infrastructure Construction: Prefabricated construction is also being
used more frequently in infrastructure construction projects. Bridges,
tunnels, and even entire highways can be constructed using
prefabricated components.
HOMB | Taft House / Skylab Architecture
Architects: Skylab Architecture

Area: 3930 ft²

Year: 2013

Location: Portland,USA

Skylab Architecture and Method Homes partnered on developing

a modular and prefab building system named HOMB. The system
uses 100 square foot triangle modules designed to be site
adaptable which fasten together to create endless form
possibilities. Modules are stacked and assembled to meet the
height and square footage requirements for each unique project.

Composed of 28 triangle modules for the Taft House was erected

and assembled in one day. While the subgrade basement was built
on site, the modules were being built offsite. The two modular
levels were delivered in 6 units and consists of 4 bedrooms, 3.5
bathrooms and an accessory dwelling unit for a total of 3,930
square feet.
 Prefabricated structures in India

PATNA,BIHAR PATNA,BIHAR(CM HOUSE) JODA ODISHA

COMPOSITE STRUCTURE
● The term 'composite structures' refer to structures in
which different materials such as timber, steel,
concrete, and masonry are used together for
construction.
● The most common type of composite construction-
steel and concrete (to form steel-concrete composite
structures).
● It is the combination of load bearing and framed
structured
● In this type, external walls are load bearing type and
internal supports are in the form of a column.
● Roofs and floors are supported by load-bearing walls
and internal columns. The design and constructed of
this type of structure may become difficult and
complicated.
● The composite structure is generally adopted for
industrial sheds or warehouse where spans are very
large.
CONCEPT
1. The concept of composite materials is ancient, An example is adding straw to mud for
building stronger mud walls. Most commonly, composite materials have a bulk phase,
which is continuous, called the matrix; and a dispersed, non-continuous, phase called the
reinforcement.
2. The significance here lies in that there are numerous matrix materials and as many fiber
types, which can be combined in countless ways to produce just the desired properties.
WHY COMPOSITE CONSTRUCTION IS MORE OFTEN
The reason why composite construction is often so efficient can be expressed in one simple way -
As concrete is good in compression and steel is good in tension.

Structurally, when these two materials work together then their strengths can be exploited to result in a
highly efficient and lightweight design.
COMPOSITE CONSTRUCTION

ADVANTAGES DISADVANTAGES

1. Typically the strength of the material is 1.Recycling is necessary due to too high lifetime .
increased. 2. Some raw materials and manufacturing methods
2. Lightweight constructions are expensive.
80% lighter than steel 3. Some manufacturing methods suffer from poor
60 lighter than aluminium energy efficiency
3.Production cost is reduced. 4. Strength analysis are usually challenging due to
4.corrosion resistance anisotropic structure of many composites.
5.Thermal properties and electrical
properties
6.Rigidity
7. Design flexibility
8.
APPLICATIONS
Aerospace- wings, fuselages, bulkheads, and other
applications in commercial, civilian and military
aerospace applications.
Appliance/Business- frames, equipment panels,
handles and trims in appliances
Thermoset composites-used in washers, dryers,
refrigerators, freezers, ranges, ovens, dishwashers for
components that include control panels, handles,
knobs, vent trims, side trims, motor housings, kick
plates and many others.
Automotive/Transportation/Farm/Construction-use
d in vehicle and equipment applications, including,
panels, frames, interior components and other parts.
Civil Infrastructure
Some composite infrastructure applications include
buildings, roads, bridges and pilings.
Construction
Thermoset composites are replacing many traditional materials for home and offices architectural
components including fixtures, doors, wall panels, roofing, window frames, moulding, vanity sinks,
shower stalls and even swimming pools.
Corrosive Environments
Composites are ideal for applications in corrosive environments, such as chemical processing plants,
pulp and paper converting, oil and gas refineries and water treatment facilities. Common applications
include fans, grating, tanks, ducts, hoods, pumps and cabinets.
Electrical
With strong dielectric properties including arc and track resistance, Thermoset components include
substation equipment, microwave antennas, standoffs and pole line hardware and printed wiring
boards. Applications and components include switchgear, motor controls, standoff insulators, control
system components, circuit breakers, arc chutes, arc shields, terminal blocks, terminal boards,
metering devices, bus supports and lighting components.
Electric Vehicle Chargers
The properties of thermoset composites such as durability, flame resistance and dielectric properties
make them ideal for multiple applications within the Electric Vehicle industry.
 Pre Engineered Structures

A pre-engineered building is a building that is made up of components that are manufactured at a factory and
assembled together at a particular site.It includes a plethora of varied materials like precast concrete, wood, masonry
block, steel sheets, glass curtain wall, and so on. Pre-Engineered Building is a new manufacturing concept replacing
traditional manufacturing.
The components are fabricated at the factory to exact size, they are transported to the site and assembled at the site.
These are built up with bolted connections. These are mainly used to build-up
● The structural steel framing system
● Metal roofing system
● Wall panels of varying materials

The prefabricated structural members are usually “I” sections. The foundations of these buildings are the
conventional concrete foundations to support the lighter super-structure and to carry heavy loads. The floor of such
buildings is also built of conventional concrete in certain cases.
Components of Pre Engineered Buildings:

Primary Member:
Primary framing of a PEB is an arrangement of built-up I-shaped steel members & framing consisting of trusses or
castellated beams etc. all structural elements that pass the load to the base and consist of End wall frames. End walls
are either designed with economical bearing frames or with rigid frames. Such frames are reinforced with wind
bracing, connecting bolts, if necessary anchor bolts. Instead of individual parts, a combination of these three
components and weather covering sheeting results in robust steel constructions.

Secondary Member:
The secondary structure consists of roof purlins, wall girts, struts, and clips, etc. which help and support the
primary framing of roof and wall panelling. The secondary framing method consists mainly of Z and C purlin
types of various sizes. The first method contains rafters and columns, while C and Z Purlin have been involved in the
preservation of the structure. In contrast with traditional beams, channels and angles the application of purlins help to
reduce costs. For the overall stability of the building structure, Purlin / Girts transfers force and instants from one
frame to another and functions as a framing device for weather covering sheeting needs. Purlins are available in
various lengths and thicknesses, ensuring no cost of production and wastage. Purlins can be easily mounted, resistant
to corrosion, lightweight and robust.
Roof and Wall Panels:
With this group typically comes tin shades & curtain wall crafted from glass & rolled steel sheets. For the transfer of
wind force and other acting loads, the frame to the foundation is used to convert the trajectory of forces in order to
reduce the effect of the forces.
There are also other options, such as special roofing sheets, that will help minimize energy usage, in particular in
colder regions. It is no surprise that PEBs are the future of construction and manufacturing worldwide with benefits
like less construction time, lower the cost of materials and function, increased energy quality and sustainability
through modular design.

Accessories:
PEBs once done with primary and secondary members and enclosed with Roof and wall panels need some
accessories to make it waterproof, weatherproof, and have a good working environment inside the building.
Self-Driven Roof Top Ventilator, Skylight Sheets, Flashings, Insulations, Cage ladder, Mezzanine Floor, Cranes,
Cable Trays, Ducts, Hooks to hang Lights and many more can be added to PEBs as per requirement.
 Applications of pre-engineered structures

This type of pre-engineered building is

preferred for:-
● Low rise industrial buildings
● Ware houses
● Power plants
● Laboratories
● Airport hangers
● Parking lots
● Factories etc.
Where it is necessary to have a large floor
space area that is intermediate columns are to
be avoided. In these cases conventional
concrete proves useless because over such
long spans, the load due to its own self
weight increases, thus making the structure
critical.
 Steps involved in Construction of PEB Structure

Step-1: Design of PEB Structure

The steel frames to be used in a particular structure is extensively designed and fabricated in a company. This
design involves the use of meticulous design software giving no room for any error or change in the structural
frames. Thus design forms a key aspect in the construction of a PEB

Step-2: Construction of Foundation

This step involves the conventional construction practise of site clearance and building of concrete foundations.
Usually shallow isolated foundations are preferred for a PEB since the self-weight of the super structure is very
less.

In severe exposure areas like coastal zones pile foundations are laid but the depth of the pile is less when compared
to the conventional concrete structures. They often prefer to lay a flat slab base of PCC below the pedestal (isolated
footing of shallow depths) to prevent its direct contact with the soil. The columns of the super structure are bolted
to the pedestal.
Step-3. Erection of Steel Frames

The grade of steel used varies based on the structural

requirement, for instance if it is a one storey building then the
thickness of the steel provided can be less (.9mm to 1.2 mm)
but for a warehouse (large structure) thickness to be provided
increases (4mm to 50mm).

The steel columns and beams are bolted together. Steel is also
used in roofing of a one storey building and for both floors
and roofs in two or more storey buildings.

Step-4. Construction of Walls on all Sides

The final step in construction of a PEB is building the walls.

Usually for a PEB the walls are built with different range of
materials like granite, fibre cement insulated panels, insulated
steel or aluminium panels, conventional brick work, stone
cladding etc., the choice depends upon the user. But generally
insulated steel panels are preferred because of their structural
stability.
 Advantages of Pre-Engineered Building

Reduced Construction time: When the foundation is being built in site, the structural members are simultaneously
fabricated in industries. Since the erection time is also less it results in the early completion of the structure

Less Manpower at Site: Most of the work in a PEB construction is done in the industries thus the requirement of
manpower at the site is very less comparatively

Reduction in Cost: Since both materials and manpower is minimized the overall cost of construction is reduced

Flexibility in Design: The steel structural members are designed in software and is fabricated with machines, thus desired
shape can be achieved without any compromise. Hence the PEB can be architecturally versatile

Scope for Future Expansion: Since bolted connections are only used, the length wise expansion in a PEB becomes more
evident

Low Maintenance: Modern metal finishes and coatings will help the steel panels to resist corrosion, chemical attack etc.,
and also the steel surfaces can be easily repaired if damaged.

Seismic Resistance: The super structure made of steel is light in weight and flexible enough to offer greater resistance to
seismic waves when compared to conventional concrete structures.
 Disadvantages of a PEB structure

Susceptible to Corrosion: If not properly maintained the steel frames are susceptible to corrosion, thus special
coatings becomes necessary to resist the corrosion of steel

Low Thermal Resistivity: Steel being a metal is good at conducting heat, thus it reduces the thermal comfort in the
building.

Low Fire Resistance: During fire, this type of building becomes more susceptible to damage due its conductivity.
Framed Structure
A framed structure is a structure having the combination of beam, column and
slab to resist the gravity and other lateral loads.
These structures are generally used to overcome the large forces, moments
developing due to the applied loading.

Component of Framed Structure and Their Role

○ Frames are generally used in building and are composed of beams and
columns that are either pinned or fixed connected, like trusses.

○ Frames extend in two or three dimensions. Frames can be of any

materials i.e. RCC, steel, wood etc.

○ In case of framed structure, the loads of floors, roofs and panel walls
are supported by the beams which ultimately transmit these loads to
the columns.

○ In framed structure, load transfer path is from slab/floor to beam, beam

to column and column to footing, i.e. to ground.
Advantages of Framed Structures Disadvantages of Framed Structures

● Strength and Stability ● Limited Span Lengths

● Versatility ● Cost of construction can be high
● Large Clear Spans ● High maintenance
● Speed of Construction ● Limited flexibility of the floor plan
● Lightweight
● Resistance to Environmental Factors
● Sustainable Design
Types of Framed Structures

● Based on the connection between the elements of a frame structure

Rigid Frame Structure

A rigid frame does not bend under the weight of its beams and columns, making it
resistant to vertical and lateral stresses.

Beams and columns with rigid connections give the rigid frame its stiffness. The
joints need to be sufficiently strong and rigid with little distortion.

A rigid frame structure can be divided into two categories:

I. Fix-Ended Rigid Frame Structure Pin-Ended Rigid Frame Structure
The conditions at the ends are usually set in this rigid frame This rigid frame is held together by pins and is no longer a
system. rigid frame if the pins are removed.
Braced Frame Structure:

Bracing is typically installed between beams and columns in this frame

system to strengthen the system’s resistance to lateral forces and sideways
forces.

Placing the diagonal elements between the beams and columns is a common
bracing method. This skeleton design is more able to withstand earthquake
and wind pressures. Compared to rigid frame systems, this one is superior.
A braced frame structure can be divided into two categories:

Portal Frames Gabled Frames

Most portal frames are designed to resemble doors. In the Most of the time, the peak is at the top. This type of frame is
commercial and industrial sectors, this frame system is used where it might rain or snow a lot.
widely used.
PRE-ENGINEERED PRE-FABRICATED COMPOSITE FRAMED PRE-STRESSED

Manufactured at factory, Manufactured at factory, Manufactured in factory or Manufacturing in factory

assembled on site fully or partially assembled on site-depending upon the and on site
in factory material

Commonly steel, but also Concrete, timber, steel, Combination of different Steel, RCC, Wood concrete
Pre-cast concrete, wood, fiber-glass. wood materials together-Timber,
masonry blocks, glass etc. steel, masonry

Fast Construction Fast Construction Normal Fast Construction

High Initial Cost High Initial Cost Low Initial Cost High Initial Cost

Low maintainence Low Maintainence High Maintainence High maintainence cost Low Maintainence

man power required on site Less man power required More man powered More man power required Depends on tensioning
on site required on site on site method: less in pre and
more in post

More Design Flexibility No Design Flexibility More design flexibility Limited Design Flexibility

Scope for future Scope for future expansion No scope for future No scope for future Scope for future expansion
expansions expansion expansion

Low maintainence Low Maintainence High Maintainence High maintainence cost Low Maintainence

man power required on site Less man power required More man powered More man power required less in pre and more in post
on site required on site on site
Prestressed concrete
● Prestressed concrete is a system into which internal
stresses are deliberately induced without any form of
external loads to improve its performance.
● Prestressed concrete is a marriage between two
high-strength materials: concrete and high strength steel
reinforcement called prestressing steel.
● Concrete is great in compression (pushing it together)
and not great in tension (pulling it apart).
● The picture below shows how a beam behaves both
without reinforcement, with standard reinforcement and
with high strength prestressing steel as a truck travels
across it.
● The prestressing steel helps the concrete gain strength
in tension by adding additional “pushing” force on the
concrete after it has hardened.
Advantages
● Longer span length
● As the span length is larger, fewer joints are needed
than in traditional RC structures.
● Low maintenance is required.
● Long term durability
● Resists stresses that are higher than normal RCC
structures and is free from cracks.
● Rapid construction with better quality control is
possible.
Disadvantages
● Requires high-strength concrete and
high-tensile-strength steel wires.
● Construction requires additional special equipment
like jacks, anchorage, etc.
● Needs highly skilled workers under skilled
supervision.
● Construction cost is a little higher than RCC
structures.
Methods of Prestressing
The prestressing can be performed by two methods :

1. Pre Tensioning
2. Post Tensioning

Pre Tensioning

Pretensioned concrete is when the high strength steel tendons are

stressed (pulled or stretched) before the concrete is cast.

A. Part (a) in the diagram below shows an initial casting bed

setup. It has two end abutments that anchor the
prestressing steel cable that is pulled the entire length of
the bed.

B. Part (b) shows the casting bed after the concrete has been
cast into the form, covering the prestressing steel cables.

C. Part (c) shows the transfer of force from the tensioned steel
cable to the hardened concrete. This is what gives a
prestressed concrete beam its strength.
Post Tensioning

Post-tensioned concrete is when the concrete is cast and hardens, and then the high strength steel cables are
stressed.
Hollow tubes called ducts are used to reserve space for the high strength steel cables after the concrete has been
cast.

A. Part (a) in the diagram below shows a

concrete beam having been cast on a
casting bed. The duct can be seen running
the full length of the beam.
B. Part (b) shows the prestressing steel cables
being pulled in the beam.
a. Rather than anchoring the strands to
casting bed abutments, they are
anchored to the hardened beam
itself.
b. A hydraulic jack is used to give the
cables their strength.
C. Part (c) shows the transfer of force from the
hydraulic jack to the hardened concrete,
with both ends of the prestressing steel
cables now anchored to the beam.
Column to Column
Column to beam
Column to beam
Column to beam
Column to wall
Column to foundation