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PREFABRICATION

 It is the practice of assembling components of a structure in a factory or other manufacturing


site, and transporting complete assemblies or sub-assemblies to the construction site where
the structure is to be located.
 Prefabs are composite materials, manufactured by combination of materials of different
properties such as plastics, concrete and steel.
 These are specifically designed for longer practical period of applications or usage.
 Prefabricated building is a type of building that consists of several factory-built components
or units that are assembled on-site to complete the unit.
 In prefabricated construction, only the foundations are constructed on the site, while sections
of walls, floors and roof are prefabricated (assembled) in a factory (possibly with window and
door frames included), transported to the site, lifted into place by a crane and bolted together.
 Time and cost are saved.
 The method finds application particularly where the structure is composed of repeating units
or forms, or where multiple copies of the same basic structure are being constructed.
PLATTENBAU: LARGE-PANEL SYSTEM BUILDING

 Plattenbau (plural Plattenbauten) is the German word for a building whose structure is
constructed of large, prefabricated concrete slabs.
 The word is a compound of Platte (in this context: panel) and Bau (building).
 Although Plattenbauten are often considered to be typical of East Germany, the prefabricated
construction method was used extensively in West Germany and elsewhere, particularly in
public housing.
 In English it is called large-panel system building or LPS.

A house being built with


prefabricated concrete panels
Classification of panel system

Large panel systems- panels are greater Classification by size


than 2m^2
small panel systems- panels are smaller
than 2m^2

Heavy panel systems-lifting equipment is Classification by weight


required
Light weight panel system-panels can be
lifted without equipment
Wooden panel system Classification by material
Metal panel system
Plastic panel system
Combined panel system
LARGE PANEL SYSTEMS

 Solid Panel System 0 (SPS 0)


The production method is very simple and requires the lowest
investment. The site area should be close to the production
plant. The assembly of the components as well as the joining
on the site is very simple. If necessary the climatic insulation
can be added very easily.
 Suitable for max. 4 floors
 Smallest wall thicknesses possible
 Very simple production method
 Lowest investment for production plant
 Solid Panel System 1 (SPS 1)
This system is a stronger version where the joints between
wall-to-wall and wall-to-ceiling slab can be fixed by welding
or/and stirrups and filled with in-situ concrete.
 Suitable for max. 8 floors
 Wall thickness 120 mm
 Joints can be fixed with stirrups or by welding
 Little need for in-situ concrete to fill out the joints
 Simple production method
 Fast assembly on site
 Solid Panel System 2 (SPS 2)
The SPS 2 is suited to higher buildings and can also be
used in earthquake zones. The external walls can
alternatively be manufactured as sandwich elements for
any climatic conditions. It has been used for 18-storied
apartment buildings in South Korea,
 Suitable for more than 8 floors
 Wall thickness 140 mm and more
 Applicable for earthquake zones
 Hollow Panel System (HPS)
HPS-components can be produced in factories which are equipped with
turnover tables for turning slabs through 180° (usually used for double
wall production). The walls and the floor slabs are made in such a way
that a hollow core remains in the middle. This means that the load
bearing strength is preserved while materials and weight savings are
achieved. The joints are both, simple and powerful. Both sides of the
walls are 100% bubble free and smooth (no manual smoothing required).
 Suitable for max. 12 floors
 Wall thickness 120 - 200 mm
 Registered patent
 Material savings due to hollow core
 Weight savings for transport and assembly
 Smooth and bubble-free surface on both sides
 Also usable for hollow core ceiling slabs
 No special steel girders necessary
 Double Panel System (DPS)
This is similar to the HPS, but the hollow cores will be filled
with in-situ concrete on site. Regarding the structural
calculation, the DPS has exactly the same properties like
conventional concrete construction, but demonstrates the
advantage of prefab elements. Again, all surfaces are
smooth. Suitable for high-rise or earthquake resistant
buildings
 Wall thickness 160 - 240 mm
 Registered patent
 Smooth and bubble-free surface on both sides
 Weight savings for transport and assembly
 No special steel girders necessary
 Easier production compared to HPS
Skeleton Systems
 Skeleton systems are often used for industrial and
commercial buildings as well as residential buildings with
special requirements.
 Skeleton System 1 (SS 1) The height of the buildings
depends on the structural calculation requirements.
Stiffening will be provided by additional reinforcement and
in-situ concrete. Faster progress on site and better
quality than in conventional construction are guaranteed.
Floor height is flexible
 Graticule up to 6 x 6 m
 Bracing can be done conventional or with prefab elements
 High output of living area in the factory
 Especially capable with pile foundation
 Can be produced on pallets with a length of 6 m
 Skeleton System 2 (SS 2 - "Folding System")
This system is similar to the SS 1 but has the advantage that it
is not limited to other than the structural requirements.
Additional reinforcement and in-situ concrete is required on
site. The patented "folding system" makes manufacturing very
easy. With a small additional investment, every prefab plant
that produces on pallets can be adapted to produce according
to the Folding System. Registered patent
 Floor height is flexible
 Graticule up to 10 x 10 m
 Bracing can be done conventional or with prefab elements
 Easy production of columns and beams through folding system
 Can be produced on pallets with a length of 10.5 m
 Weight savings for transport and assembly
PREFAB HOMES

Prefabs: can be used for permanent, semi permanent or temporary applications.

Applications:
 Schools, Residential Units, Shopping Center, Telephone Booths, Toilets & Bathroom, Police Station

Features:
 Highly Durable
 Water proof
 Termite proof
 Most reasonable
 High Impact Strength
PREFABRICATED HOUSING

 The term 'prefabricated' may refer to buildings built in components (e.g. panels), modules (modular
homes) or transportable sections (manufactured homes), and may also be used to refer to mobile homes.
Although similar in nature, the methods and design of the three can vary wildly.
 Modular homes are homes that are created in sections, and then transported to the home site for
construction and installation. These are typically installed and treated like a regular house, for financing,
appraisal and construction purposes, and are usually the most expensive of the three. Although the
sections of the house are prefabricated, the sections, or modules, are put together at the construction
much like a typical home.
 Manufactured homes refer to homes that are built onto steel beams, and are transported in complete
sections to the home site, where they are assembled.
 Mobile homes are, quite simply, homes built on wheels, that are able to be moved from place to place.
PREFAB BUILDINGS
THE CRYSTAL PALACE, LONDON
 First large-scale prefabricated ferrovitreous (iron and glass) structure- designed by
Joseph Paxton
 Built in nine months
 Built with prefabricated truss & prefabricated iron parts

The interiors of the building The front entrance of the Crystal Palace
PREFAB BUILDINGS
THE DYMAXION HOUSE
 Designed by Buckminster Fuller
 Emphasized on prefab construction
 It has a strong underlying structural agenda and
expresses a seamless transition from wall to
roof in its form.
 Built from prefabricated lightweight fiber
components developed from double curvature
geometries that can be assembled on site

Interior of Dymaxion House showing structural details. Visible are the


partially assembled aluminum ceiling, struts and exterior skin as well
as single central post which supports the entire structure and carries
utilities and plumbing.
USES

 Most widely-used form of prefabrication in building and civil engineering is the use of prefabricated
concrete and prefabricated steel sections in structures where a particular part or form is repeated
many times.
 Prefabricating steel sections reduces on-site cutting and welding costs as well as the associated
hazards.
 Prefabrication techniques are used in the construction of apartment blocks, and housing developments
with repeated housing units.
 The technique is also used in office blocks, warehouses and factory buildings.
 Prefabricated steel and glass sections are widely used for the exterior of large buildings.
 Prefabrication saves engineering time on the construction site in civil engineering projects. This can be
vital to the success of projects such as bridges and avalanche galleries, where weather conditions may
only allow brief periods of construction. Additionally, small, commonly-used structures such as concrete
pylons are in most cases prefabricated.
 Modern lattice towers and other services are also commonly assembled of prefabricated elements.
 Prefabrication has become widely used in the assembly of aircraft and spacecraft, with components such
as wings and fuselage sections.
CONSTRUCTION MATERIALS USED

 Steel
 Aluminium
 Timber
 Asbestos
 Concrete
 Glass
ADVANTAGES

 Self-supporting ready-made components are used, so the need for formwork, shuttering and scaffolding is
greatly reduced.
 Construction time is reduced and buildings are completed sooner.
 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 labor is more readily available and costs of labor, power,
materials, space and overheads are lower.
 Time spent in bad weather or hazardous environments at the construction site is minimized.
 Less waste may be generated and in a factory setting it may be easier to recycle it back into the
manufacturing process.
 Moulds can be used several times.
DISADVANTAGES

 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 sections require heavy-duty cranes and precision measurement and handling to
place in position.

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