CONSTRUCTION OF PREFABRICATED BUILDING

COMPONENTS USING FLY ASH

TEJASWI.CH * KRISHNA TULASI.G*
*3/4 B.Tech Students
KONERU LAKSHMAIAH COLLEGE OF ENGG, VADDESWARAM.
E-mail: [email protected]
[email protected]
ABSTRACT:
In todays world, where speed and convenience play a big part in
influencing the use of any product, the age of prefabricated housing products
seems to have finally arrived. The usefulness of these products help significantly in
speeding up construction by offering ready-to-install building elements such as
blocks, joist beams, roof blocks and panels is being widely recognised in the
industry. Pre-fabricated components are becoming immensely popular due to the
several attractive advantages that they offer, such as off-site fabrication, which
allows reduction in construction time and this function helps greatly in managing
the schedule of the construction project. Due to their low density, the prefabricated
components impose a relatively lighter load on the structure and
superior quality can also be achieved as these components are manufactured
under a strictly controlled environment. In recent times few innovations in the
field of materials are expected to make these products even more popular, user
friendly and eco friendly. The present paper discusses on the manufacturing of
prefabricated building components using fly ash, and explains regarding
fabrication, centring, placing, applications and the advantages over the monolithic
construction.
This paper aims to popularize the promotion of prefabrication building
methodologies for low cost housing by highlighting the different prefabrication
components and techniques, and the economical advantages achieved by its adoption.
1. INTRODUCTION:
1.1 Prefabrication:
Prefabrication is the manufacture of an entire building or components cast in a
factory or on site before being placed in position, assembling the structural units so that
they can be easily and rapidly erected. Prefabricated buildings are pre-cut, pre-drilled,
and pre-engineered before the actual building is constructed. Prefabricated Structures
(PFS) are useful for sites, which are not suitable for normal construction methods such
as hilly regions, and also when normal construction materials are not easily available.
Structures which are used repeatedly and can be standardized such as mass housing,
storage sheds, godowns, shelters, bus stands, security cabins, site offices, foot over
bridges, road bridges, concrete building blocks etc., are prefabricated structures. This
paper discussing about the mix proportions f the materials to manufacture the prefab
components and the construction procedure for an ordinary single story residential
building.
1.2 Criteria for selection of prefab in India:
In India, the technology adopted for housing components should be of the order
that, the production and erection technology be adjusted to suit the level of skills and
handling Facilities available under metropolitan, urban and rural conditions. In other

words, the structural systems and components selected should ensure minimum material
Utilization with maximum structural advantage. However, the component and systems
so designed are to be manufactured and erected by manual means in villages, semi
mechanical techniques in towns and more or less fully mechanical operations in the
metropolitan cities. In urban areas, the concentration of construction activity does not
justify prefabrication. A wide variety of roofing methods to suit these requirements
have been developed and used on mass scale in many housing projects such as funicular
shell, cored slabs, RCC channel units, precast cellular units, precast RC planks and
joists, prefab brick panels and joists, RCC joists and hollow concrete blocks.
1.3 Material used for Prefabrication:
Prefabricated components can be manufactured using many materials, depends
up on the type of structure. Generally materials used are Wood, Steel, concrete, plastic
and composite materials .If the structure is wooden house then prefabricated wooden
panels, columns, posts are used. If the structure is prefabricated steel truss bridge then
steel members like angles, I, L-sections and rives, bolts are used. If the structure is
houses in developed countries then the prefabricated plastic internal partition walls,
doors, panels and toilets are used. The man made rock concrete is also widely used for
the manufacturing of the prefabricated members. Instead of using complete cement
concrete we are replacing the some quantity of cement with an industrial waste product
like flyash. Because of adding the flyash we can get many benefits for the environment
as well as prefabricated structure. Before going for the advantages of it, first know the
properties of the flyash.
1.4 Fly Ash:
Fly Ash is a by-product of a thermal power station, after combustion of coal and
production of power. Fly Ash is generated from coal fired generation units. Coal has a
dominating role for the power generation in India. Presently there are 70 coal based
thermal power plants operating in India. Most of the thermal power plants in India use
inferior quality coal, having low calorific value which after combustion, leaves behinds
a larger per cent of ash. As the power required in industrial and agricultural sectors
increase, production of ash increases. Fly ash contains many toxic elements. Abundant
quantities of fly ash are being produced by thermal power plants situated all over the
world. At present 100 MT of coal ash is produced annually in India.
Fly ash is a complex material and its characterization is quite difficult. It is
observed that the overall chemical composition varies from particle to particle and from
one sample another. Even initial pulverization of the coal and efficiency of firing have
significant influence on the grading of the fly ash produced. It appears that difference
in particle size distribution; morphology and surface characteristics of fly ash would
influence water demand and reactivity. The principal constituents of fly ash are silica
(SiO2), Alumina (Al2O3), Iron oxide (Fe2O3), Calcium oxide (CaO), small amounts of
magnesium, sulphur, and unburned carbon. Let us know the properties of the Fly Ash.
1.4.1 Physical Properties:
Fly ash particles are typically spherical ranging in diameter from 1 to 150
microns. The type of dust collection equipment used largely determines the range of
particle size in any given fly ash. The fly ash from boilers where mechanical collectors
are used is coarser than fly ash from electrostatic precipitators.
Fly ash consists of the large part of solid or hollow spherical particles of

siliceous and aluminous gas with small proportions of thin walled, multifaceted
polyhedrousiron
content and are irregularly shaped, relatively porous carbon or carbon
coated particles. The fineness of fly ash in many a case is to the same extent as that of
Portland cement. The color varies from light to dark grey depending upon its carbon
contents. The quality of fly ash varies from source to source and is seldom uniform
even for the same source because of the important factors like the nature and size of
coal, the type of combustion equipment, control of combustion process, mode of fly ash
collection etc. the product from a modern power plant when working on base-load is
normally quite consistent.
Table-1: PHYSICAL PROPERTIES OF FLYASH

1.4.2 Chemical Properties:

In Indian fly ashes, contents of SiO2, Al2O3 are relatively higher than Fe2O3,
SO3. The crystalline phases were identified as mullite, magnetite, hematite and quartz.
The chemical composition of fly ash and its particle size differ widely for different
power plants. This is due to different types of coal used, their various treatment and
different types adopted for combustion. Generally, fly ash is differentiated on the basis
of degree of fineness and their carbon contents.
Table-2: CHEMICAL COMPOSITION OF INDIAN FLY ASH

1.4.3 Advantages and applications of Fly ash:

Fly Ash is having so many advantages due to their unique properties like,
Strength is more and reduces the permeability.

 Corrosive resistances, specific gravity, lime reactivity.

Workability: Several reports suggest that fly ash decreases bleeding and
segregation, improves plasticity and cohesiveness and permits easier placing and
finishing of concrete having no air-entraining agent. Some fly ash reduce the
water requirements of test mortars, others (generally of high carbon content)
showed increase water requirement above that of control mortars.
It is cheaply available and fulfills all the requirements.
Fly Ash can be used for land fillings, soil stabilization.
Can be used as a partial replacement of cement, as fine aggregate and as coarse
aggregates.
Improves the 20% to 40% of production in agriculture.
In the manufacturing of Special concretes.
Finally in the manufacturing of prefabricated components like bricks, blocks,
inter locking members, flooring and wall tiles.
2. PREFABRICATED COMPONENTS USED IN CONSTRUCTION:
In a building the foundation, walls, doors and windows, floor and roof are the
most important components. These components can be analyzed individually based on
the needs. This will improve the speed of construction and reduce the construction cost.
2.1 Foundations:
Various type of foundations normally adopted are Open foundations, Rib
foundations, Columns and footings and RCC raft foundation. Conventional methods
using in-situ techniques are found to be economical and more practical for low cost
housing of slums, which generally consists of low rise structures. In seismic regions,
special attention is required to make the foundations continuous using horizontal
reinforcement. Prefabrication is not recommended for foundations in normal situations.
2.2 Walls:
In the construction of walls, rammed earth, normal bricks, soil cement blocks,
hollow clay blocks, dense concrete blocks, small, medium and room size panels etc of
different sizes are used. However, bricks continue to be the backbone of the building
industry. In actual construction, the number of the bricks or blocks that are broken into
different sizes to fit into position at site is very large. As a result of this, there is wastage
of material and the quality of construction also suffers. Increasing the size of wall
blocks will prove economical due to greater speed and less mortar consumption, which
can be achieved by producing low-density bigger size wall blocks and advantages of
industrial wastes like blast furnace slag and fly ash, can be made. Several prefabrication
techniques have been developed and executed for walls but these medium and large
panel techniques have not proved economical for low-rise buildings as compared to
traditional brickwork.
2.3 Floor and Roof:
Structural floors/roofs account for substantial cost of a building in normal
situation. Therefore, any savings achieved in floor/ roofs considerably reduce the cost
of buildings. Traditional cast-in-situ concrete roof involve the use of temporary
shuttering, which adds to the cost of construction and time.
Use of standardized and optimized roofing components where shuttering is
avoided prove to be economical, fast and better in quality. Some of the prefabricated
roofing/flooring components found suitable in many low-cost housing projects are

Precast RC planks, precast hollow concrete panels, Precast RB panels; Precast RB

curved panels, precast concrete panels, and Precast RC channel units.
2.4 Thin Precast RCC Lintel:
Normally lintels are designed on the assumption that the load from a triangular
portion of the masonry above, acts on the lintel. Bending moment will be WL/8 where
W is the load on the lintel and L is the span assumed for the design purpose. By this
method, a thickness of 15 cm is required. Thin precast RCC lintels are designed taking
into account the composite action of the lintel with the brickwork. The thickness of the
lintel is kept equal to the thickness of brick itself having a bearing of 230 mm on either
supports. Use of precast lintels speeds up the construction of walls besides eliminating
shuttering and centreing. Adoption of thin lintels results in up to 50% saving in
materials and overall cost of lintels.
2.5 Doors and Windows:
Innumerable types and sizes of doors and windows used in single and similar
buildings. This involves the use of additional skilled labour on site and off site and also
wastage of expensive materials like timber, glass etc. Economy can be achieved by:
(i) Standardizing and optimizing dimensions;
(ii) Evolving restricted number of doors and window sizes; and
(iii) Use of precast door and window frames.
PREFABRICATED BUILDING COMPONENTS

CHOWKHATS
BLOCKS
INTERLOCKING

ASH BRICKS ROOF

TILES

BLOCKS

JOIST BEAMS
INTERLOCKING WALL BLOCKS
3. MANUFACTURING PROCEDURE OF THE COMPONENTS:
Generally for the manufacturing of the components these proportions are used,

3.1 Mixing process:

The above materials are mixed in a grinding /mixer as per proportions and some
water (2-3%of total wt) for at least 6 minutes and then the mixer is pumped in to the
Hydraulic brick manufacture unit and then solid bricks can be manufacture. In
smallscale
plants by using Manual Leg-line hydraulic machine is used. But the solid bricks
manufactured using Mechanical unit will give smooth finish and more productivity.
Then hollow bricks, column blocks and beam blocks are manufactured using
moulds (the moulds are made with cast iron) are filled with the fly ash mixer which is
prepared previously and hollow bricks are prepared. The roof blocks and joist beams
are prepared by skilled labour because these are used for the roof covering.

3.2 Roof block:

Roof blocks are the roof coving blocks, which are placed over the joist beams.
These are prepared based upon the dimensions of the rooms and the load coming over
the roof. Based up on loads the thickness is fixed. The shape of the roof blocks is shown
in figure. It consists of central holes, which acts as a ventilator for the room.

3.3 Joist beam:

Joist beam is the prefab component, which is used as a support for the roof
blocks. These joist beams length and width are decided based on the clear span of the
rooms. These joist beams can be laid up to span of 15meters without any supports/
scaffoldings. First these are placed over compound walls then with a spacing of the
width of the roof blocks another joist beam is placed in b/w these beams roof blocks are
placed one beside the another as shown then the entire roof is completed.
These figures show the roof blocks and joist beams

4. ADVANTAGES OF PRECAST/PREFABRICATED CONSTRUCTION:

In prefabricated construction as the components is readymade, selfsupporting,
shuttering and scaffolding is eliminated with a saving in
shuttering cost.
In traditional construction, the repetitive use of shuttering is limited, as it
gets damaged due to frequent cutting, nailing etc. On the other hand, the
mould for the precast components can be used for large number of
repetitions thereby reducing, the cost of the mould per unit.
In prefabricated housing system, there is saving of time as the elements can
be casted before hand during the course of foundations being laid and even
after laying slab, the finishes and services can be done below the slab
immediately. While in the conventional in-situ RCC slabs, due to props and
shuttering, the work cannot be done, till they are removed. Saving of time
means saving of money.
In prefabricated construction, there is better quality control, shape and size
of precast elements. Therefore, in structural design, full advantage of
properties of cement and steel can be exploited. There is disciplined use of
scarce materials like cement, steel and timber.
In precast construction, the construction is not affected due to weather, rain,
wind etc.
We can save Labour cost of mixing, placing of concrete.
As the components are light weight they can be transport easily and place
and construct ever is needed especially during natural calamities like floods,
earth quakes, major accidents are takes place.
Because of easy of placing, these are mainly used for construction of
temporary bridges during wars.
We can construct structures which are located in congested places like
where the lack of place for storage of materials and machinery.
5. WHY SHOULD WE PREFER PREFABRICATION?
In India, adoption of prefabrication building techniques has many merits, like
availability of materials, labour, and technical skills. Advantages of prefabrication are

multiple as the components are readymade and self-supporting, shuttering and

scaffolding is eliminated, with a saving in shuttering cost. In traditional construction,
the repetitive use of shuttering is limited, as it gets damaged due to frequent cutting,
nailing, etc. On the other hand, the mould for the precast components can be used for a
large number of repetitions, thereby reducing the cost of the mould per unit. In the
prefabricated housing system, there is saving of time, as the elements can be cast
beforehand during the course of the foundation being laid. Even after laying slab, the
finishes and services can be done below the slab immediately. In the conventional insitu
RCC slabs, due to props and shuttering, the work cannot be done till these are
removed. Saving of time means saving of money. In prefabricated construction, there is
better quality control, shape and size of precast elements. Therefore, in structural
design, full advantage of the properties of cement and steel can be taken. There is
disciplined use of expensive materials like cement, steel and timber.
6. CONSTRUCTION PROCEDURE USING PRE FAB COMPONETS:
For case study we consider, single storied residential building consists of 4rooms constructed with prefab components and compared with monolithic construction.

Steps for construction using prefabricated components:

1. The foundation is constructed as usual monolithic construction procedure; here
also we can use fly ash blocks for supporting walls.
2. For construction of columns a specially made column blocks are available which
is having central gaps, which are useful for placing of the reinforcement.
3. All the load bearing and internal walls are constructed with solid fly ash bricks
and hollow bricks.
4. The corners joints can be constructed using inter locking wall bricks.
5. After completion of the room height beam blocks are laid over the walls, which
are acted as a beams for the building.
6. Roof is constructed as explained in roof blocks and joist beams.
7. After placing all the roof blocks and joist beams, a 6mm wire mesh is laid over
the entire roof then lean mix of cement mortar is laid over it and the total
thickness of the roof should be restricted to 4 inches only.
8. Being long spans of joist beams are available we can lay the roof for all the
rooms at a time so that economically we can save the manpower.
9. After hardening of 3 days curing is to be done for two days. Then the finishing
of walls and floors are to be done. Since the bricks used are fly ash, the
plastering cement can be minimized.
Then the construction is compared with monolithic construction,
So by using prefab comp., we can save the materials up to 40%.
Come for cost of construction is about 25-30% we can save.
We can get more strength with less weight.
We can control the temperature variations.
We can save 15% of labour cost.
The figure shows the roof block and joist beam lay out

7. LIMITATIONS OF PREFABRICATIONS:
As the coin has both faces prefabricated construction is having some drawbacks,
As the precast elements have to behave monolithic on erections, extra
reinforcement may be necessary in some cases.
Extra reinforcement is required to take care of handling and erection stresses.
Temporary props may be required in some cases, before the in-situ concrete
joints achieve strength.
The cracks may develop at the joints between the precast and in-situ concrete
due to shrinkage and temperature stresses. To overcome them, extra steel is
required across the joint.
As there are chances of leakage/seepage through the joints between the precast
components, extra care is required to make them leak proof.
The greater cost of transporting precasting units as compared with transporting
materials.
The additional technical problems and cost of site connections of precast
elements, precast construction is used in all types of structures: Industrial
buildings, residential and office buildings, hall of sizable span, bridges, stadiums
and prisons.
CONCLUSIONS:
Mass housing targets can be achieved by replacing the conventional methods of
planning and executing building operation based on special and individual needs and
accepting common denominator based on surveys, population needs and rational use of
materials and resources. No single approach and solution is available which can satisfy
the community at large. However, what is ideal and desirable is to have a system, which
can provide choice for people and also appropriate techniques to meet the situation. The
essence lies in the system approach in building methodology and not necessarily
particular construction type or design. Adoption of any alternative technology on large
scale needs a guaranteed market to function and this cannot be established unless the
product is effective and economical. Partial prefabrication is an approach towards the
above operation under controlled conditions.
The methodology for low cost housing has to be of intermediate type less
sophisticated involving less capital investment. The Govt. of India has to popularize
these components and the implement them at least for low cost Govt. houses. People
should be more aware about these products and save the environment by using the

thermal waste in a better manner.

Use the Thermal Waste in proper way and gets the Economical
Construction
REFERENCES
1. Prafabricated structures a case study by charl .h, jevan.p
vol .6, 2001, structural engineering journal.
2. Prefabricated structures by Charan singh.
3. www.prefabricate.com