REPORT ON PRE-FABRICATION

BUILDING CONSTRUCTION
8TH SEM

SUBMITTED BY

LAKSHAY BANSWAL

SUBMITTED TO AYUSHI GOSWAMI

AR. PUNEET NARANG SHIVANI RANA

AR. REKHA BHASKARAN SOUMYA SINGH

PRE-FABRICATE
To fabricate something is the same as to ‘construct or manufacture’ something. Once you add ‘pre’ to
the word it means to construct or manufacture something ahead of time, and this is the main principle
behind the idea of prefabrication.

Prefabrication, also known as factory-build structures, system-built structures or pre-fab structures, is

the process of fabricating or preassembling the finished or semi-finished structural components, such
as and wall panels, doors, windows, roof trusses, cabinets, staircases and even entire building parts
from production site or factory to building terminus for joining and designing of structural
components.

The basic purpose of the prefabrication process is to create a route for better-designed, high-
performance structures that require less labour, resources, time, and money. This procedure can result
in structural components with standard size units (for instance, stiff steel frameworks with lengths up
to 120 feet (37 m) and wall frames with conventional dimensions of 8 feet in height by 4, 8, 16 or 24
feet, among others). Prefabrication is mostly favoured for light-weight constructions, and its
components are often built of steel and wood. However, in some specific circumstances, concrete,
reinforced concrete, aluminium composites, and plastics are also utilised.

Prefabricated Structure
https://www.researchgate.net/publication/353701764_Chapter7_Prefabricated_Structutres_and_its_Components -
_Advances_in_Civil_Engg_Book
NEED OF PREFABRICATION
1. To decrease the labour requirement of construction.
2. To improve the quality of construction with low cost.
3. To increase the productivity of construction and to attain sustainability of the structure.
4. To enhance speedy construction because there is no need of curing period.
5. To improve the performance of the structure with less requirement of maintenance.
6. To develop country’s economy and civilization.
7. To decrease the consumption of money, time, wages and material.
8. To enhance the proper usage of space. To increase the strength and stability of structures.
9. To provide better aesthetic or attractive finish of the building structures.

https://www.researchgate.net/figure/Different-types-of-prefabrication-Source-Moradibistouni-and-Gjerde-2017_fig1_330970824

USES OF PREFABRICATION
1. The use of prefabricated concrete and steel pieces in projects where one specific building
feature is repeated several times is the most popular type of prefabrication building.
2. Prefabrication removes the requirement for wet mixing and wet pumping on a crowded
building site, as well as the necessity to transport concrete to the construction site.
Additionally, the firms that pour concrete pieces ensure that the moulds may be used
repeatedly.
3. Prefabricating steel pieces reduces the risks associated with on-site cutting and welding while
also lowering costs.
4. These methods are also utilised to build office buildings, warehouses, manufacturing
structures, apartment complexes and housing projects with multiple dwelling units.
5. Large structures' exteriors frequently incorporate prefabricated glass and steel sections.
6. For bridge designers and constructors, prefab bridge systems and components provide notable
advantages in terms of cost, construction time, safety, and environmental effect.
7. Numerous prefabricated parts are frequently used to construct mobile phone radio towers and
other services.
8. In addition, this technique is frequently employed in the construction of aeroplanes and
spacecraft. Fuselage parts and wings, for example, are frequently produced in other nations or
states before being combined on the construction site.
https://gosmartbricks.com/prefabricated-construction/
https://netpositivestudio.org/construction/

METHODS OF PREFABRICATION
There are two primary categories of prefabrication techniques

1. Factory or plant prefabrication (for the manufacturing of large quantities of components)

2. Site prefabrication (for the creation of large-scale prefabricated components).
https://www.researchgate.net/publication/353701764_Chapter7_Prefabricated_Structutres_and_its_Components-
_Advances_in_Civil_Engg_Book

Factory prefabrication

Factory prefabrication is the process of fabricating structural components under controlled conditions
over an extended period of time in manufacturing or production units. In order to mitigate the effects
of unfavourable environmental conditions, this prefabrication technique is a capital-intensive
production that spreads out the fabrication work over a year under controlled conditions.

https://offsitebuilder.com/so-you-want-to-open-a-modular-factory/
Site prefabrication

For the fabrication of structural components over a shorter period of time, site fabrication is carried
out at a location closer to the building site. This method is used mostly for the particular sort of task
and is executed in an open area with readily available labour. This method of production uses
transportable machinery, equipment, and moulds for convenient transit. It is divided into two
categories.

https://www.researchgate.net/figure/The-onsite-prefabrication-yard-Courtesy-Company-A_fig1_338150034

COMPONENTS OF PREFABRICATION
The important components of prefabrication consist of

• Roofing or flooring
• Slab
• Joist
• Beams
• Wall panels
• Columns

Roofing or flooring

Planks and joists made of reinforced concrete are used in roofing. These structural elements are
manufactured in controlled environments to a specified size and connected with reinforced cement
concrete joists that are offered at regular, scheduled intervals. The reinforced cement joists receive
loads from the floors and roofs, which are subsequently transferred to the main beams. The main
beams are made up of channel sections with regular intervals of spacing and 10 cm projections on
either side. Bolts are used to join the RCC joists to the channel sections. The only piece that is
manufactured on the job site is the foundation.

Slab

Planks make up the flooring or roofing slab, which is supported by joists made of reinforced cement
concrete. The following sections, with or without prestressing, are used to make the planks. The
prefabricated slab can be between 0.5 and 5 metres wide and long (without prestressing). Components
are categorised depending on the size and weight of prefabrication.

• Hollow core sections.

 • Double tee section\Channel sections.
• Light weight concrete roofing slab.
• Solid rectangular planks.

https://pdf4pro.com/view/precast-concrete-structures-paradigm-1ff32d.html

Joist

Joists frequently serve as a beam that carries loads that are applied to the planks and transfers them to
the main beam via channel sections. Joists are made up of stirrups with a triangle form that are
utilised to properly bind the blanks together. To promote consistency, extra bars of planks are linked
to the joist after it has been partially constructed using connecting rods in the manufacturing unit.

https://www.c-joist.com/

Beams

Main and secondary beams are 300mm x 300mm in size, with varied reinforcing provided at certain
conditions in accordance with moments. The translucent space between the columns is created with
beams. For connecting beam or column reinforcement by welding and securely pouring concrete at
the junction, a square hole 10 cm x 10 cm x 10 cm in size is supplied on either side of the beam. It is
required to provide site concreting at beam and column joints. The top corner of the beam is
appropriately directed for the use of site concrete and to produce optimum compaction as a result.

https://pdf4pro.com/view/precast-concrete-structures-paradigm-1ff32d.html
Wall Panels

All essential temporary fixtures, including doors, windows, frames, ventilators, and so on, are
included in the manufacture of wall panels. The structural component is made of sandwich-style
cellular concrete blocks with a thickness of about 75 mm and is covered with reinforced cement
concrete of grade M25 with a thickness of about 37.5 mm on each side, which has less requirement
for reinforcement. Wall panels are typically non-load bearing members, so solid rectangular cross
sections are ignored. The main benefits of wall panels are their capacity to offer great resistance to
stress brought on during construction and their simple raw material availability.

https://pdf4pro.com/view/precast-concrete-structures-paradigm-1ff32d.html

Columns

In order to attain the desired strength and stability of the building or to place the structure securely,
columns are constructed with the requisite grooves given on each side. Additionally, grooves serve as
a portion or component of the column. If the column's area rose as a result of the nibs, the grooves
would provide more moment as well as load bearing capability. Additionally, it gives the structure a
soft aesthetic impression.

https://pdf4pro.com/view/precast-concrete-structures-paradigm-1ff32d.html

IMPLEMENTION OF PREFABRICATION TECHNIQUES

For smooth operation and successful integration of prefabricated components, various procedures
must be taken when implementing prefabrication techniques on a building site. An overall summary
of the implementation procedure is provided below:
1. Design and Planning:
• Collaborate with architects, engineers, and contractors to develop a comprehensive design
that incorporates prefabrication.
• Identify areas in the project where prefabricated components can be utilized effectively.
• Determine the scope of prefabrication, including the type of elements to be prefabricated
(e.g., walls, floors, roof trusses) and their dimensions.

2. Procurement and Fabrication:

• Identify prefabrication suppliers or manufacturers who can deliver the required components
within the project timeline.
• Provide detailed design specifications to the suppliers to ensure accurate fabrication.
• Monitor the fabrication process to maintain quality control and adherence to design
specifications.
• Coordinate delivery schedules to ensure components arrive on-site when needed.

3. Site Preparation:
• Assess the construction site for accessibility, utilities, and other requirements for installing
prefabricated elements.
• Prepare the site by clearing obstructions, setting up necessary equipment, and establishing a
staging area for receiving and storing prefabricated components.
• Coordinate with subcontractors and workers to ensure a smooth transition between site
preparation and prefabrication installation.

4. Installation:
• Develop a detailed installation plan, including sequencing, lifting and rigging procedures, and
safety protocols.
• Provide necessary training to the on-site crew regarding the installation of prefabricated
components.
• Set up temporary supports or bracing as required to ensure stability during installation.
• Use cranes, forklifts, or other appropriate equipment to lift and position prefabricated
elements into place.
• Ensure proper alignment, connection, and integration of prefabricated components with the
existing structure.
• Follow manufacturer guidelines and industry best practices during installation.

5. Quality Control and Inspection:

• Conduct regular inspections during the installation process to ensure compliance with design
specifications and safety standards.
• Perform quality control checks to verify the accuracy, integrity, and functionality of
prefabricated components.
• Rectify any issues or deficiencies identified during inspections promptly.

6. Integration and Finishing:

 • Coordinate with other construction trades to integrate prefabricated components with the rest
of the building system (e.g., electrical, plumbing, HVAC).
• Complete any necessary finishing work, such as sealing joints, applying finishes, or
connecting utilities.
• Ensure that the prefabricated elements are seamlessly integrated with the overall construction
to achieve a cohesive and functional structure.

7. Post-Installation Evaluation:
• Conduct a final inspection to ensure that all prefabricated components are installed correctly
and meet the required standards.
• Evaluate the effectiveness of prefabrication techniques in terms of cost savings, time
efficiency, and quality improvement.
• Document lessons learned for future projects and identify areas for improvement.

Depending on the particular project needs, the complexity of the prefabricated components, and the
degree of integration with the current building process, the implementation method may vary. To
achieve a successful implementation, it is essential to work with seasoned experts that have
prefabrication knowledge, such as architects, engineers, and contractors.

PREFABRICATION TECHNOLOGIES

Prefabrication Technology Types

Formwork Systems 1. Monolithic concrete construction

system
2. Modular tunnel form
3. Kayson's formwork system:
4. Sismo building technology

Precast Sandwich Panel Systems 1. Panel prefab system:

2. Advanced building system
3. Ferrocement sandwich panel
4. Structural insulated panels (SIPs)
5. Glass fibre reinforced gypsum (GFRG)
panel system
6. Prefabricated modular units using
organo-clay/ glass fibre reinforced
polymer composite

Light Gauge Steel Structural Systems 1. Pods- Small rooms of light steel frame
with all fittings and finishing

Precast Concrete Construction Systems 1. Industrialized 3-S System using cellular

light weight concrete slabs & precast
columns:
2. Pre-stressed precast system using
hollow core slab, beams, columns etc:
3. Waffle crete building system

Steel Structural Systems 1. Speed floor system:

 2. Timber-concrete prefabricated
composite wall system:
3. Factory made fast track modular
building system

https://www.nbmcw.com/product-technology/precast/prefabrication-building-construction-an-indian-perspective.html