UNIT 1

INTRODUCTION
Need for prefabrication – Principles – Materials –
Modular coordination – Standardization – Systems –
Production – Transportation – Erection.

1
 INTRODUCTION
 Prefabricated System can be defined as building systems in
which structural components are manufactured in a factory, on
or off site, transported and assembled into a structure with
minimal additional site works.

 PFS is one of the improved building systems that are being

introduced to achieve the target of faster completion with
mass production of the building elements in places out of its
final location in a building.

 It has been proven successful in some countries, namely

Finland, Denmark, Netherlands, Singapore, England and the
United States.
WHY PFS???
 Scenario in construction industry compared to other
sectors is that the construction industry suffers from low
productivity, safety and quality control.

 Due to the traditional labor-intensive practices, the 3- D

Syndrome (Dirty, Difficult & Dangerous) has always
been associated with the construction industry.

 PFS is a good solution for these kind of problems of the

construction industry- messy sites, high wastages, labor
intensive works, low quality work, delays.
CHARACTERSTICS OF PFS
 One of the major characteristics of the PFS is the Industrial
production of components through prefabrication, “OR”
sometimes highly mechanized in-situ processes i.e. permanent
steel formworks, tunnel forms, etc.
 Reduced labor during prefabrication of components and site
works.
 Modern design and manufacturing methods involving
Information Technology like usage of Computer Aided design
(CAD) and Computer Aided Manufacturing (CAM).
 Systematic Quality Control i.e ISO 9000 principles.
 Open Building Concept- permitting hybrid applications, and
adaptable to standardization and MC (Modular Coordination)
ADVANTAGES
 1. Reduction of site labor
 2. Minimal wastage
 3. Less site material
 4. Cleaner environment
 5. Controlled quality
 6. Neater and safer site
 7. Faster Project Completion
 8. Lower total construction cost
 Low site workers requirement due to simplified
construction methods.
 Quality-controlled and highly aesthetic end
products through the processes of controlled pre-
fabrication and simplified installations.
 Reduction of construction materials at sites
through usage of pre-fabricated components.
 Reduction or elimination of conventional timber
formworks and props which are replaced by pre-
fabricated components and alternative moulds
with multiple-usage capability.
 Reduction of construction waste with the usage
of the standardized components and less in-site
works.
 Cleaner sites due to lesser construction waste.

 Safer construction sites due to the reduction of

site workers, materials and construction waste.
 Faster completion of construction projects due
to the usage of standardized pre-fabricated
components and simplified installation
processes.
 Cheaper total construction costs.
 CLASSIFICATION OF PFS
 Thereare various Industrialized Building
Systems (IBS) used throughout the world, and
they can be classified into three major
categories.

 These categories are:-

 1. Frame or Post & Beam System.

 2. Panel System.

 3. Box system.
 General System Production
System Material
1 Frame Light weight frame Wood, light gauge
In the evaluation of System metals
the systems various Medium light weight Metal, reinforced
frame plastics, laminated
parameters such wood
as- Heavy weight frame Heavy steel, concrete
2 Panel Light & medium weight Wood frame, metal
System panel frame & composite
1.the industrialized materials
process used Heavy weight Concrete
2. transportation & panel(factory produced)
Heavy weight panel(tilt Concrete
erection problems, up-produced on site)
3.architectural 3 Box Medium weight Wood frame, light
features System box(mobile) gauge metal,
composite
4.socio-economic Medium weight Wood frame, light
problems must be box(sectional) gauge metal,
composite
considered. Heavy weight Concrete
box(factory produced)
Heavy box(tunnel Concrete
produced on site)
FRAME SYSTEM
 Frame structures may be defined as those structures that
carry the loads through their beams and girders to
column and to the ground.

 Their important feature is the capacity to transfer heavy

loads over large spans.

 Used in the construction of bridges, parking lots,

warehouses, industrial buildings, sport facilities and so
on.
PANEL SYSTEM
 Panel system may be defined as those structures
that carry the load through large floor and wall
panels.

 Concrete panel systems are extensively used in

Europe for high rise building for ease of
construction purpose.

 Used in Hollow core slabs, Interior & Exterior

Wall.
BOX SYSTEM
 Box system may be defined as those
systems that use 3D modules (or boxes)
for fabrication of habitat units.

 The main features of this system are in the

internal stability as it can withstand load
from various directions.

 Require only large prefabricated sections

to be transported or handled at one time.
MODULAR COORDINATION
 A modular building is a pre-engineered structure
that is flexible enough to satisfy virtually any
requirement, it is tougher than standard drywall
construction, expandable, can be relocated and
completely re-usable.
 One obvious advantage that modular
construction has over conventional construction
is cost as not only it can one save up to 35% on
the initial construction costs like labor and
materials, but there are other benefits as well.
 With increasing industrialization to the building
industry, steadily larger parts of buildings are
made up of prefabricated components, delivered
to the building site from the factories.
 Evidently, some sort of dimensional coordination
of these component amongst themselves and
with the design are of paramount importance.
 The full benefit of the PREFABRICATION is
impossible without standardization….AND..
 No effective standardization is possible in the
building industry, without dimensional
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 Organization and many other countries
including INDIA.
MODULAR CO-ORDINATION CONCEPT

Improves Productivity

Through Standardization

Promote Industrialization (component

manufactured in factory)

Less wet work site.

Non dependence on
Less modification on site
unskilled labor
CHARACTERISTICS OF MODULE
 Industrializationfriendly i.e. able to cater for
manufacturing, transportation and assembly
requirements.
 Small enough in term of size in order to provide
the necessary flexibility in design.
 Internationally accepted to ensure that it can be
mass produced to cater for global market.
 Ergonomic i.e. able to improve the efficiency of
people by providing adequate space for human
livings and working conditions.
NECESSITY OF MODULAR COORDINATION
 It provides a practical and coherent: method for
coordinating- the position and dimension of elements,
components and spaces in the planning and design of
buildings.
 To provide guidance to building component sizing
which can reduce(as much as possible)the need to further
trim and shape the materials to fit together in
construction, hence, reducing wastage of labor and
material.
 For mass production of building components in factories
which ensures good and consistent workmanship and
quality.
 To permit standardization, which encourages the use of
standardized building components for the construction of
different types of building.
 DIMENSIONAL COORDINATION is defined as-
A convention for the co-ordination of the dimensions of
building components and incorporating them in their
design, manufacture and assembly by means of a three
dimensional spatial references system of points, lines and
planes to which the position and size of a components may
be related.

 The dimensional coordination is essential because of

the following reasons :-
 To simplify design and documentation procedures and
allow the implementation of computer techniques.
 To achieve optimum efficiency in the manufacture and
use of components and assemblies.
 To avoid cutting or modifying components and
assemblies on site.
 To standardize the profile and detail of joints
between components.
 To Reduce non-standard or dimensionally
incompatible components and assemblies.
 REASONS TO CHOOSE MODULAR CONSTRUCTION OVER CONVENTIONAL
CONSTRUCTION

FEATURE ADVANTAGES BENEFITS

a Pre-Engineered No need for an engg/architect. No hidden design costs.
b Ease of Coordination Ability to supply single source Buying is simple with local
installation through factory-trained support & assistance.
distributor network.
c Appearance Attractive integrated systems Consistent high quality in both
manufactured to your exact. appearance & design.

d Speedy Installation Fewer disruptions to plant Maintains plant productivity

operations. during building installation.
e No Mess No need to seal off areas against Eliminates additional labor costs
dust. & minimizes plant disruption.
f Low Maintenance Pre-finished walls require little Eliminates costly painting &
maintenance beyond occasional other maintenance & repairs.
surface cleaning.
g Durability Reinforced cavity & tough quality Long lasting product will perform
facings decrease chances of damage. for years without deterioration.

h Adaptability Quickly & easily Provides maximum flexibility to

relocatable,expandable & reusable. meet your company's needs.
i Sound Resistance Fire & Sound panels provide Noise level reduction produces a
superior sound deadening. more productive work
environment.
j Accelerated Depreciation is over 7 years vs. 31- Quicker return on investment.
Depreciation 1/2 years for conventional
construction.
SEQUENCE OF ACTIVITIES OF PFS
CONSTRUCTION METHOD