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Principles: (aims)
1) To effect economy in cost
2) To improve in quality as the components can be manufactured under controlled
conditions.
3) To speed up construction since no curing is necessary.
4) To use locally available materials with required characteristics.
5) To use the materials which possess their innate characteristics like light weight,
easy workability, thermal insulation and combustibility etc.
Uses of prefabrication
1. The most widely used form of prefabrication building and civil
engineering is the use of prefabrication concrete & prefabricated steel
sections in structures where a particular part or form is repeated many
times.
2. Pouring concrete sections in a factory brings the advantages of being able
to re-use moulds and the concrete can be mixed on the spot without having
to be transported to and pumped wet on a congested construction site.
3. Prefabricating steel sections reduces on-site cutting and welding costs as
well as the associated hazards.
4. Prefabrication techniques are used in the construction of apartment blocks
and housing developments with repeated housing units.
5. The technique is also used in office blocks, warehouses and factory
buildings.
6. Prefabricated steel and glass section are widely used for the exterior of
large buildings.
7. Prefabricated bridge elements and systems offer bridge designers &
contractors significant advantages in terms of construction time safety
environmental impact constructability and cost.
8. Prefabrication can also help minimize the impact on transfer from bridge
building.
9. Radio towers for mobile phone and other services often consist of multiple
prefabricated sections.
10. Prefabricated has become widely used in the assembly of aircraft and
space craft with component such as wings and fuselage sections often
being manufactured in different countries or states from the final assembly
site.
Advantage of prefabrication
Self supporting readymade components are used so the need for formwork
shuttering and scaffolding is greatly reduced.
Construction time is reduced and buildings are completed sooner allowing on
earlier return of the capital invested.
On-site construction and congestion is minimized.
Quality control can be easier in a factory assembly line setting than a construction
site setting.
Prefabrication can be located where skilled labour, power materials space and
overheads are lower.
Time spent in bad weather or hazardous environments at the construction site is
minimized
Materials for scaffolding is stored partly or in full and used
Availability of precise structure and expect workmanship.
Work time is reduced.
Fewer expansion joints are required.
Interruptions in connecting can be omitted.
Work is done with a better technology.
Less workers are needed.
Members can be used again.
Disadvantages of prefabrication
Careful handling of prefabricated components such as concrete panels or steel and
glass panels is required.
Attention has to be paid to the strength and corrosion-resistance of the joining of
prefabricated sections to avoid failure of the joint
Similarly leaks can form at joints in prefabricated components.
Transportation costs may be higher for voluminous prefabricated sections than for
the materials of which they are made which can often be packed more efficiently.
Large prefabricated structures require heavy-duty cranes & precision
measurement and handling to place in position.
Large groups of buildings from the same type of prefabricated elements tend to
look drab and monotonous. Local Jobs are lost.
Precast construction method over conventional in situ
method
Materials used:
Prefabricated building materials are used for buildings that are manufactured off site and shipped
later to assemble at the final location some of the commonly used prefabricated building. The
materials used in the prefabricated components are many.
The modern trend is to use concrete steel, treated wood, aluminium cellular concrete, light
weight concrete, ceramic products etc. While choosing the materials for prefabrication the
following special characteristics are to be considered.
Light weight for easy handling and transport and to economic an sections and
sizes of foundations
Thermal insulation property
Easy workability
Durability in all weather conditions
Non combustibility
Economy in cost
Sound insulation
Characteristics of materials
Easy availability
Light weight for easy handling and transport and to economies on sections and
seizes of foundations.
Thermal insulation property
Easy workability
Durability to all weather conditions
Non combustibility
Economy in cost
Materials : aluminum, steel, wood, fiberglass and
concrete
Prefabricated metal buildings use galvanized steel and galvalume as the chief materials for
building. Galvalume is a form of steel coated with aluminium zinc. This is to protect the building
against corruption rust and fire. It also provides a study and protective covering to the
prefabricated building. Almost all the components of a metal building such as beams, frames
columns wall & roofs are made of steel. Most fabricated military buildings use steel or
aluminium frames.
[Synthetic materials are used for the walls & roofs. To provide enhanced security a
combination of both metal and cloth materials are used plastic flooring materials can be
quickly assembled and are very durable]
Prefabricated building materials used for small prefabricated buildings are steel, wood, fibre
glass plastic or aluminium materials. These materials are cheaper than regular brick and concrete
buildings. Materials like steel, fibre glass, wood and aluminium are used as prefabricated
building materials for sports buildings. These materials provide flexibility and are preferred for
making structures and accessories like stands and seats for stadium and gyms.
For making low cost houses prefabricated materials like straw bale, Ferro cement consists
of a cement matrix reinforced with a mesh of closely spaced iron rods or wires. In this
type of construction the techniques used are simple & quick.
Using prefabricated material one can make durable, water and fire resistant and cheap
prefabricated buildings Most of the prefabricated building materials are eco-friendly &
affordable.
MODULAR COORDINATION
The modular coordination is defined as the basic module is in adopted the size of
which is selected for general application to building and its components. The value of the
basic module chosen is 100 mm for maximum flexibility and convenience. The symbol
used for basic module is M
1M = 100mm
The purposes
of modular coordination are
i. To reduce the variety of component size produced
ii. To allow the building designer greater.
Modules
Modules are a standard unit of size used to coordinate the dimensions of buildings and
components. They are of two types:
1. Multi modules
2. Basic modules
Multi modules
Multi modules are standardized selected whole multiples of the basic module different
single T beam has resulted the beam to fall 2 basement down. The beam just placed for
connection.
Basic module
The fundamental module used in modular coordination the size of which is selected for
general application to buildings and components
Modular Grid
A rectangular coordinate reference system in which the distance between consecutive
lines is the basic module or a multimodule. This multimodule may differ for each of the
two dimensions of the grid.
Type of Modular Grid
There are different types of grid patterns which are used to locate the positions and
dimensions of building spaces components are
Elements in building design
Continuous grid
Superimposed grid
Displacement of grid (or) Tartan grids
Interrupted grids as neutral zones.
Continuous grid
Where all dimensions in either direction are based on one increment only.
Superimposed grids
When the modulur grid of 100 mm increment is superimposed on a multi-modulur
grid.
Displacement of grid or tartan grids
Where there is a homogenous and repetitive relation between at least two basic
increments.
Eg:- 1M +2M (or) 3/2 M + 3M
Interrupted grids (or) neutral zones
Where there are non modular interruptions of grids neutral zones are created to
cope with the economics of building design.
REFER
https://www.slideshare.net/sreestr18/prefabrication-and-modular-coordination
PRESTRESSED CONCRETE
Definition of Prestress:
Prestress is defined as a method of applying pre-compression to control the stresses resulting due to
external loads below the neutral axis of the beam tension developed due to external load which is
more than the permissible limits of the plain concrete. The pre-compression applied (may be axial or
eccentric) will induce the compressive stress below the neutral axis or as a whole of the beam c/s.
Resulting either no tension or compression.
Basic Concept
Prestressed concrete is basically concrete in which internal stresses of a suitable magnitude and
distribution are introduced so that the stresses resulting from the external loads are counteracted to a
desired degree.
Terminology
1. Tendon: A stretched element used in a concrete member of structure to impart prestress to the
concrete.
2. Anchorage: A device generally used to enable the tendon to impart and maintain prestress in
concrete.
3. Pretensioning: A method of prestressing concrete in which the tendons are tensioned before the
concrete is placed. In this method, the concrete is introduced by bond between steel & concrete.
4. Post-tensioning: A method of prestressing concrete by tensioning the tendons against hardened
concrete. In this method, the prestress is imparted to concrete by bearing.
The most widely used method for prestressing of structural concrete elements is longitudinal
tensioning of steel by different tensioning devices. Prestressing by the application of direct forces
between abutments is generally used for arches and pavements, while flat jacks are invariably used to
impart the desired forces.
Tensioning Devices
The various types devices used for tensioning steel are grouped under four principal categories, viz.
1. Mechanical devices: The mechanical devices generally used include weights with or without
lever transmission, geared transmission in conjunction with pulley blocks, screw jacks with
or without gear devices and wire-winding machines. These devices are employed mainly for
prestressing structural concrete components produced on a mass scale in factory.
2. Hydraulic devices: These are simplest means for producing large prestressing force,
extensively used as tensioning devices.
3. Electrical devices: The wires are electrically heated and anchored before placing concrete in
the mould. This method is often referred to as thermo-prestressing and used for tensioning of
steel wires and deformed bars.
4. Chemical devices: Expanding cements are used and the degree of expansion is controlled by
varying the curing condition. Since the expansive action of cement while setting is restrained,
it induces tensile forces in tendons and compressive stresses in concrete.
Prestressing System:
1. Pretensioning system:
In the pre-tensioning systems, the tendons are first tensioned between rigid anchor-blocks cast on
the ground or in a column or unit –mould types pretensioning bed, prior to the casting of
concrete in the mould. The tendons comprising individual wires or strands are stretched with
constant eccentricity or a variable eccentricity with tendon anchorage at one end and jacks at
the other. With the forms in place, the concrete is cast around the stressed tendon.
2. Post-tensioned system:
In post-tensioning the concrete unit are first cast by incorporating ducts or grooves to house the
tendons. When the concrete attains sufficient strength, the high-tensile wires are tensioned by means
of jack bearing on the end of the face of the member and anchored by wedge or nuts. The forces are
transmitted to the concrete by means of end anchorage and, when the cable is curved, through the
radial pressure between the cable and the duct. The space between the tendons and the duct is
generally grouted after the tensioning operation.
Most of the commercially patented prestressing systems are based on the following principle of
anchoring the tendons:
1. Wedge action producing a frictional grip on the wire.
2. Direct bearing from the rivet or bolt heads formed at the end of the wire.
3. Looping the wire around the concrete.
LOSSES IN PRESTRESS
The initial prestressing concrete undergoes a gradual reduction with time from the stages of transfer
due to various causes. This is generally defined as total “Loss of Prestress”. The various losses are
explained below:
Pretensioning
GENERAL PRINCIPLES
(i) Structures should not be brittle or collapse suddenly. Rather, they should be tough, able to deflect or deform a
considerable amount.
(ii) Resisting elements, such as bracing shear walls, must be provided evenly throughout the building, in both
directions side-to-side, as well as top to bottom.
(iii) All elements, such as walls and the roof, should be tied together so as to act as an integrated unit during
earthquake shaking, transferring forces across connections and preventing separation.
(iv) The building must be well connected to a good foundation and the earth. Wet, soft soils should be avoided, and
the foundation must be well tied together, as well as tied to the wall. Where soft soils cannot be avoided, special
strengthening must be provided.
(v) Care must be taken that all materials used are of good quality, and are protected from rain, sun, insects and other
weakening actions, so that their strength lasts.
(vi) Unreinforced earth and masonry have no reliable strength in tension, and are brittle in compression. Generally,
they must be suitably reinforced by steel or wood.
CATEGORIES OF BUILDINGS
For categorizing the buildings with the purpose of achieving seismic resistance at economical cost three parameters
turns out to be significant:
(i) Seismic intensity zone where the building is located.
(ii) How important the building is and
(iii) How stiff is the foundation soil
A combination of these parameters will determine the extent of appropriate seismic strengthening of the building.
SEISMIC ZONES
In most countries, the macro level seismic zones are defined on the basis of seismic intensity scales in this guide, we
shall refer to seismic zones:-
ZONE A:- Risk of widespread collapse and destruction
ZONE B:-Risk of collapse and heavy damage
ZONE C:-Risk of minor damage
IMPORTANCE OF BUILDING
The importance of the building should be a factor in grading it for strengthening purposes and the following
buildings are suggested as specially important.
IMPORTANT- Hospitals, clinics, communication buildings, fire and police stations, water supply facilities,
cinemas, meeting halls, schools, cultural treasures such as museums, monuments and temples etc.
ORDINARY:-Housing, hostels, offices, warehouses, factories etc.
CHOICE OF SITE
The choice of site for building from the seismic point of view is mainly concerned with the stability of the ground.
The following are important:
1) Stability of slope: hill side slopes liable to slide during an earthquake should be avoided and only stable slopes
should be chosen to locate the building. Also it will be preferable to have several blocks on terraces than have one
large block with footings at very different elevations. A site subject to the danger of rock falls has to be avoided.
2) Very loose sand or sensitive clays:-These two types of soils are liable to be destroyed by the earthquake so much
as to lose their original structure and thereby undergo compaction. This would result in Large unequal settlement
and damage the building. If the loose cohesions soils are saturated with water they are apt to lose their shear
resistance altogether during shaking and become liquefied.
CONCEPT OF ISOLATION
For reduction of coefficient of friction between the structures and its foundation, one suggested technique is to place
two layers of good quality plastic between the structures and its foundation so that the plastic layers may slide over
each other.
FOUNDATIONS
For the purpose of making a building truly earthquake resistant, it will be necessary to chose an appropriate
foundation type for it .since loads from typical low height buildings will be light, providing the required bearing area
will not usually be a problem. The depth of footing in the soil should go below the zone of deep freezing in cold
countries and below the level of shrinkage cracks in clayey soils.
FIRM SOIL
In firm soil conditions, any type of footing can be used. It should be of course have a firm base of lime or cement
concrete with requisite width over which the construction of the footing may start. It will be desirable to connect the
individual reinforced concrete column footings in zone A by means of RC beams just below plinth level intersecting
at right angles.
SOFT SOIL-
In soft soil, it will be desirable to use a plinth band in all walls and where necessary to connect the individual
column footings by means of plinth beams suggested above. It may be mentioned that continuous reinforced
concrete footings are considered to be most effective from earthquake considerations as well as to avoid differential
settlements under normal vertical loads. These should ordinarily be provided continuously under all the walls.
Continuous footings should be reinforced both in the top and bottom faces, width of the footing should be wide
enough to make the contact pressures uniform and the depth of footing should be below lowest level of weathering.
GENERAL PLANNING AND DESIGN ASPECTS
Plan of building
(i) Symmetry: The building as a whole or its various blocks should be kept symmetrical about both the axes.
A symmetry leads to torsion during earthquakes and is dangerous, Symmetry is also desirable in the placing and
sizing of door and window openings, as far as possible.
(ii) Regularity: Simple rectangular shapes, behave better in an earthquake than shapes with many projections.
Torsional effects of ground motion are pronounced in long narrow rectangular blocks. Therefore, it is desirable to
restrict the length of a block to three times its width. If longer lengths are required two separate blocks with
sufficient separation in between should be provided.
(iii) Separation of Blocks: Separation of a large building into several blocks may be required so as to obtain
symmetry and regularity of each block.
For preventing hammering or pounding damage between blocks a physical separation of 3 to 4 cm throughout the
height above the plinth level will be adequate as well as practical for upto 3 storeyed buildings.
The separation section can be treated just like expansion joint or it may be filled or covered with a weak material
which would easily crush and crumble during earthquake shaking. Such separation may be considered in larger
buildings since it may not be convenient in small buildings.
(iv) Simplicity: Ornamentation involving large cornices, vertical or horizontal cantilever projections, facia stones
and the like are dangerous and undesirable from a seismic viewpoint. Simplicity is the best approach. Where
ornamentation is insisted upon, it must be reinforced with steel, which should be properly em- bedded or tied into
the main structure of the building.
Note: If designed, a seismic coefficient about 5 times the coefficient used for designing the main structure should be
used for cantilever ornamentation.
(v) Enclosed Area: A small building enclosure with properly interconnected walls acts like a rigid box since the
earthquake strength which long walls derive from transverse walls increases as their length decreases.
(vi) Separate Buildings for Different Functions: In view of the difference in importance of hospitals, schools,
assembly halls, residences, communication and security buildings, etc., it may be economical to plan separate
blocks for different functions so as to affect economy in strengthening costs.