PAPER PRESENTATION ON

By
T.V.M.AKHILASH GUPTHA E-mail: akil143.akil !mail."#m 3)4 B.T*"( S+,-*.+& S.DEVI PRIYANKA P$iya%&ami1'3 ya(##."#m

SRI SUN/L01ER 20LLEGE 0/ ENGINEERING 3 TE2HN0L0GY LANKAPALLI4 KRISHNA .Di&+

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 see s to have finally arrived! The usefulness of these products help significantly in speeding up construction by offering ready"to"install building ele ents such as bloc#s , $oist bea s, roof bloc#s and panels is being widely recognised in the industry! %re"fabricated co ponents are beco ing i ensely popular due to the several attractive advantages that they offer, such as off"site fabrication, which allows reduction in construction ti e and this function helps greatly in anaging the schedule of the construction pro$ect! &ue to their low density, the prefabricated co ponents i pose a relatively lighter load on the structure and superior 'uality can also be achieved as these co ponents are anufactured under a strictly controlled environ ent! In recent ti es few innovations in the field of aterials are e(pected to a#e these products even ore popular, user friendly and eco friendly! The present paper discusses on the anufacturing of prefabricated building co ponents using fly ash, and e(plains regarding fabrication, centring, placing, applications and the advantages over the onolithic construction! This paper aims to popularize the promotion of prefabrication building ethodologies for low cost housing by highlighting the different prefabrication co ponents and techni'ues, and the econo ical advantages achieved by its adoption! )! I*TR+&,CTI+*: )!) %refabrication: -%refabrication. is the anufacture of co ponents cast in a factory or on site before being placed in position, asse bling the structural units so that they can be easily and rapidly erected! %refabricated buildings are pre"cut, pre"drilled, and pre" engineered before the actual building is constructed! %refabricated Structures/%0S1 are useful for sites, which are not suitable for nor al construction ethods such as hilly regions, and also when nor al construction aterials are not easily available! Structures which are used repeatedly and can be standardi2ed such as ass housing, storage sheds, godowns, shelters, bus stands, security cabins, site offices, foot over bridges, road bridges, concrete building bloc#s etc!, are prefabricated structures! This paper discussing about the i( proportions f the aterials to anufacture the prefab co ponents and the construction procedure for an ordinary single story residential building! )!3 Criteria for selection of prefab in India: In India, the technology adopted for housing co ponents should be of the order that, the production and erection technology be ad$usted to suit the level of s#ills and handling 0acilities available under etropolitan, urban and rural conditions! In other words, the structural syste s and co ponents selected should ensure ini u aterial ,tili2ation with a(i u structural advantage! 4owever, the co ponent and syste s so designed are to be anufactured and erected by anual eans in villages, se i echanical techni'ues in towns and ore or less fully echanical operations in the etropolitan cities! In urban areas, the concentration of construction activity does not

$ustify prefabrication! A wide variety of roofing ethods to suit these re'uire ents have been developed and used on ass scale in any housing pro$ects such as funicular shell, cored slabs, RCC channel units, precast cellular units, precast RC plan#s and $oists, prefab bric# panels and $oists, RCC $oists and hollow concrete bloc#s! )!5 6aterial used for %refabrication: %refabricated co ponents can be anufactured using any aterials, depends up on the type of structure! 7enerally aterials used are 8ood, Steel, concrete, plastic and co posite aterials !If the structure is wooden house then prefabricated wooden panels, colu ns, posts are used! If the structure is prefabricated steel truss bridge then steel e bers li#e angles, I, 9"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 an ade roc# concrete is also widely used for the anufacturing of the prefabricated e bers! Instead of using co plete ce ent concrete we are replacing the so e 'uantity of ce ent with an industrial waste product li#e flyash! Because of adding the flyash we can get any benefits for the environ ent as well as prefabricated structure! Before going for the advantages of it, first #now the properties of the flyash! )!: 0ly Ash: 0ly Ash is a by"product of a ther al power station, after co bustion of coal and production of power! 0ly Ash is generated fro coal fired generation units! Coal has a do inating role for the power generation in India! %resently there are ;< coal based ther al power plants operating in India! 6ost of the ther al power plants in India use inferior 'uality coal, having low calorific value which after co bustion, leaves behinds a larger per cent of ash! As the power re'uired in industrial and agricultural sectors increase, production of ash increases! 0ly ash contains any to(ic ele ents! Abundant 'uantities of fly ash are being produced by ther al power plants situated all over the world! At present )<< 6T of coal ash is produced annually in India! 0ly ash is a co ple( aterial and its characteri2ation is 'uite difficult! It is observed that the overall che ical co position varies fro particle to particle and fro one sa ple another! =ven initial pulveri2ation of the coal and efficiency of firing have significant influence on the grading of the fly ash produced! It appears that difference in particle si2e distribution> orphology and surface characteristics of fly ash would influence water de and and reactivity! The principal constituents of fly ash are silica /Si+31, Alu ina /Al3+51, Iron o(ide /0e3+51, Calciu o(ide /Ca+1, s all a ounts of agnesiu , sulphur, and unburned carbon! 9et us #now the properties of the 0ly Ash!

)!:!) %hysical %roperties: 0ly ash particles are typically spherical ranging in dia eter fro ) to )?< icrons! The type of dust collection e'uip ent used largely deter ines the range of particle si2e in any given fly ash! The fly ash fro boilers where echanical collectors are used is coarser than fly ash fro electrostatic precipitators!

0ly ash consists of the large part of solid or hollow spherical particles of siliceous and alu inous gas with s all proportions of thin walled, ultifaceted polyhedrousiron content and are irregularly shaped, relatively porous carbon or carbon coated particles! The fineness of fly ash in any a case is to the sa e e(tent as that of %ortland ce ent! The color varies fro light to dar# grey depending upon its carbon contents! The 'uality of fly ash varies fro source to source and is seldo unifor even for the sa e source because of the i portant factors li#e the nature and si2e of coal, the type of co bustion e'uip ent, control of co bustion process, ode of fly ash collection etc! the product fro a odern power plant when wor#ing on base"load is nor ally 'uite consistent! Table"): %4@SICA9 %R+%=RTI=S +0 09@AS4 %roperty Sa ple of AT%SIS 5B)3 Re'uire ent 7rade I 7rade II 0ineness /Blaine C 3Cg 1 :<DE 53<< 3?<< 9i e Reactivity *C 3 <E :!< in 5!< a( &rying Shrin#ageF <<!<<B <!)? a( <!) a( Auto Clave =(pansionF <<!<)? <!B a( <!B a( )!:!3 Che ical %roperties: In Indian fly ashes, contents of Si+3, Al3+5 are relatively higher than 0e3+5, S+5! The crystalline phases were identified as ullite, agnetite, he atite and 'uart2! The che ical co position of fly ash and its particle si2e differ widely for different power plants! This is due to different types of coal used, their various treat ent and different types adopted for co bustion! 7enerally, fly ash is differentiated on the basis of degree of fineness and their carbon contents! Table"3: C4=6ICA9 C+6%+SITI+* +0 I*&IA* 09@ AS4 S!*+! &=SCRI%TI+* +0%R+%=RT@AA=RA7= RA*7= +0 AA9,=S/F1 )! Sio3 ::"?B 3! Al3o5 3)"3; 5! 0e3o5 :")B :! Cao 5"D ?! 6go )"3? D! So5 <!5")!; )!:!5 Advantages and applications of 0ly ash: 0ly Ash is having so any advantages due to their uni'ue properties li#e, G Strength is ore and reduces the per eability! G Corrosive resistances, specific gravity, li e reactivity! G 8or#ability: Several reports suggest that fly ash decreases bleeding and segregation, i proves plasticity and cohesiveness and per its easier placing and finishing of concrete having no air"entraining agent! So e fly ash reduce the water re'uire ents of test ortars, others /generally of high carbon content1 showed increase water re'uire ent above that of control ortars! G It is cheaply available and fulfills all the re'uire ents!

G 0ly Ash can be used for land fillings, soil stabili2ation! G Can be used as a partial replace ent of ce ent, as fine aggregate and as coarse aggregates! G I proves the 3<F to :<F of production in agriculture! G In the anufacturing of Special concretes! G 0inally in the anufacturing of prefabricated co ponents li#e bric#s, bloc#s, inter loc#ing e bers, flooring and wall tiles! 3! %R=0ABRICAT=& C+6%+*=*TS ,S=& I* C+*STR,CTI+*: In a building the foundation, walls, doors and windows, floor and roof are the ost i portant co ponents! These co ponents can be analy2ed individually based on the needs! This will i prove the speed of construction and reduce the construction cost! 3!) 0oundations: Aarious type of foundations nor ally adopted are +pen foundations, Rib foundations, Colu ns and footings and RCC raft foundation! Conventional ethods using in"situ techni'ues are found to be econo ical and ore practical for low cost housing of slu s, which generally consists of low rise structures! In seis ic regions, special attention is re'uired to a#e the foundations continuous using hori2ontal reinforce ent! %refabrication is not reco ended for foundations in nor al situations! 3!3 8alls: In the construction of walls, ra ed earth, nor al bric#s, soil ce ent bloc#s, hollow clay bloc#s, dense concrete bloc#s, s all, ediu and roo si2e panels etc of different si2es are used! 4owever, bric#s continue to be the bac#bone of the building industry! In actual construction, the nu ber of the bric#s or bloc#s that are bro#en into different si2es to fit into position at site is very large! As a result of this, there is wastage of aterial and the 'uality of construction also suffers! Increasing the si2e of wall bloc#s will prove econo ical due to greater speed and less ortar consu ption, which can be achieved by producing low"density bigger si2e wall bloc#s and advantages of industrial wastes li#e blast furnace slag and fly ash, can be ade! Several prefabrication techni'ues have been developed and e(ecuted for walls but these ediu and large panel techni'ues have not proved econo ical for low"rise buildings as co pared to traditional bric#wor#! 3!5 0loor and Roof: Structural floorsCroofs account for substantial cost of a building in nor al situation! Therefore, any savings achieved in floorC roofs considerably reduce the cost of buildings! Traditional cast"in"situ concrete roof involve the use of te porary shuttering, which adds to the cost of construction and ti e! ,se of standardi2ed and opti i2ed roofing co ponents where shuttering is avoided prove to be econo ical, fast and better in 'uality! So e of the prefabricated roofingCflooring co ponents found suitable in any low"cost housing pro$ects are %recast RC plan#s, precast hollow concrete panels, %recast RB panels> %recast RB curved panels, precast concrete panels, and %recast RC channel units!

3!: Thin %recast RCC 9intel: *or ally lintels are designed on the assu ption that the load fro a triangular portion of the asonry above, acts on the lintel! Bending o ent will be 89CB where 8 is the load on the lintel and 9 is the span assu ed for the design purpose! By this ethod, a thic#ness of )? c is re'uired! Thin precast RCC lintels are designed ta#ing into account the co posite action of the lintel with the bric#wor#! The thic#ness of the lintel is #ept e'ual to the thic#ness of bric# itself having a bearing of 35< on either supports! ,se of precast lintels speeds up the construction of walls besides eli inating shuttering and centreing! Adoption of thin lintels results in up to ?<F saving in aterials and overall cost of lintels! 3!? &oors and 8indows: Innu erable types and si2es of doors and windows used in single and si ilar buildings! This involves the use of additional s#illed labour on site and off site and also wastage of e(pensive aterials li#e ti ber, glass etc! =cono y can be achieved by: /i1 Standardi2ing and opti i2ing di ensions> /ii1 =volving restricted nu ber of doors and window si2es> and /iii1 ,se of precast door and window fra es! %R=0ABRICAT=& B,I9&I*7 C+6%+*=*TS C4+8H4ATS B9+CHS AS4 BRICHS R++0 TI9=S I*T=R9+CHI*7 B9+CHS I+IST B=A6S I*T=R9+CHI*7 8A99 B9+CHS %R=0ABRICAT=& B,I9&I*7 C+6%+*=*TS

B9+CHS

5!6A*,0ACT,RI*7 %R+C=&,R= +0 T4= C+6%+*=*TS: 7enerally for the anufacturing of the co ponents these proportions are used, 7@%S,6 3F 9I6= BF

09@ AS4 ;5F B+TT+6AS4 C Re aining %+*& AS4

5!) 6i(ing process: The above aterials are i(ed in a grinding C i(er as per proportions and so e water /3"5Fof total wt1 for at least D inutes and then the i(er is pu ped in to the -4ydraulic bric# anufacture unit. and then solid bric#s can be anufacture! In s allscale plants by using -6anual 9eg"line hydraulic achine. is used! But the solid bric#s anufactured using 6echanical unit will give s ooth finish and ore productivity! Then hollow bric#s, colu n bloc#s and bea bloc#s are anufactured using oulds /the oulds are ade with cast iron1 are filled with the fly ash i(er which is prepared previously and hollow bric#s are prepared! The roof bloc#s and $oist bea s are prepared by s#illed labour because these are used for the roof covering! 5!3 Roof bloc#: Roof bloc#s are the roof coving bloc#s, which are placed over the $oist bea s! These are prepared based upon the di ensions of the roo s and the load co ing over the roof! Based up on loads the thic#ness is fi(ed! The shape of the roof bloc#s is shown in figure! It consists of central holes, which acts as a ventilator for the roo ! 5!5 Ioist bea : Ioist bea is the prefab co ponent, which is used as a support for the roof bloc#s! These $oist bea s length and width are decided based on the clear span of the roo s ! These $oist bea s can be laid up to span of )? eters without any supportsC scaffoldings! 0irst these are placed over co pound walls then with a spacing of the width of the roof bloc#s another $oist bea is placed in bCw these bea s roof bloc#s are placed one beside the another as shown then the entire roof is co pleted! These figures show the roof bloc#s and $oist bea s

:! A&AA*TA7=S +0 %R=CASTC%R=0ABRICAT=& C+*STR,CTI+*: G In prefabricated construction as the co ponents is ready ade, selfsupporting, shuttering and scaffolding is eli inated with a saving in

shuttering cost! G In traditional construction, the repetitive use of shuttering is li ited, as it gets da aged due to fre'uent cutting, nailing etc! +n the other hand, the ould for the precast co ponents can be used for large nu ber of repetitions thereby reducing, the cost of the ould per unit! G In prefabricated housing syste , there is saving of ti e as the ele ents 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 i ediately! 8hile in the conventional in"situ RCC slabs, due to props and shuttering, the wor# cannot be done, till they are re oved! Saving of ti e eans saving of oney! G In prefabricated construction, there is better 'uality control, shape and si2e of precast ele ents! Therefore, in structural design, full advantage of properties of ce ent and steel can be e(ploited! There is disciplined use of scarce aterials li#e ce ent, steel and ti ber! G In precast construction, the construction is not affected due to weather, rain, wind etc! G 8e can save 9abour cost of i(ing, placing of concrete! G As the co ponents are light weight they can be transport easily and place and construct ever is needed especially during natural cala ities li#e floods, earth 'ua#es, a$or accidents are ta#es place! G Because of easy of placing, these are ainly used for construction of te porary bridges during wars! G 8e can construct structures which are located in congested places li#e where the lac# of place for storage of aterials and achinery! ?! 84@ S4+,9& 8= %R=0=R %R=0ABRICATI+*J In India, adoption of prefabrication building techni'ues has any erits, li#e availability of aterials, labour, and technical s#ills! Advantages of prefabrication are ultiple as the co ponents are ready ade and self"supporting, shuttering and scaffolding is eli inated, with a saving in shuttering cost! In traditional construction, the repetitive use of shuttering is li ited, as it gets da aged due to fre'uent cutting, nailing, etc! +n the other hand, the ould for the precast co ponents can be used for a large nu ber of repetitions, thereby reducing the cost of the ould per unit! In the prefabricated housing syste , there is saving of ti e, as the ele ents can be cast beforehand during the course of the foundation being laid! =ven after laying slab, the finishes and services can be done below the slab i ediately! In the conventional insitu RCC slabs, due to props and shuttering, the wor# cannot be done till these are re oved! Saving of ti e eans saving of oney! In prefabricated construction, there is better 'uality control, shape and si2e of precast ele ents! Therefore, in structural design, full advantage of the properties of ce ent and steel can be ta#en! There is disciplined use of e(pensive aterials li#e ce ent, steel and ti ber! D! C+*STR,CTI+* %R+C=&,R= ,SI*7 %R= 0AB C+6%+*=TS: 0or case study we consider, single storied residential building consists of :"

roo s constructed with prefab co ponents and co pared with onolithic construction! Steps for construction using prefabricated co ponents: )! The foundation is constructed as usual onolithic construction procedure> here also we can use fly ash bloc#s for supporting walls! 3! 0or construction of colu ns a specially ade colu n bloc#s are available which is having central gaps, which are useful for placing of the reinforce ent! 5! All the load bearing and internal walls are constructed with solid fly ash bric#s and hollow bric#s! :! The corners $oints can be constructed using inter loc#ing wall bric#s! ?! After co pletion of the roo height bea bloc#s are laid over the walls, which are acted as a bea s for the building! D! Roof is constructed as e(plained in roof bloc#s and $oist bea s! ;! After placing all the roof bloc#s and $oist bea s, a D wire esh is laid over the entire roof then lean i( of ce ent ortar is laid over it and the total thic#ness of the roof should be restricted to : inches only! B! Being long spans of $oist bea s are available we can lay the roof for all the roo s at a ti e so that econo ically we can save the anpower! E! After hardening of 5 days curing is to be done for two days! Then the finishing of walls and floors are to be done! Since the bric#s used are fly ash, the plastering ce ent can be ini i2ed! Then the construction is co pared with onolithic construction G So by using prefab co p!, we can save the aterials up to :<F!

G Co e for cost of construction is about 3?"5<F we can save! G 8e can get ore strength with less weight! G 8e can control the te perature variations! G 8e can save )?F of labour cost! The figure shows the roof bloc# and $oist bea lay out

;! 9I6ITATI+*S +0 %R=0ABRICATI+*S: As the coin has both faces prefabricated construction is having so e drawbac#s, As the precast ele ents have to behave onolithic on erections, e(tra reinforce ent ay be necessary in so e cases!

=(tra reinforce ent is re'uired to ta#e care of handling and erection stresses! Te porary props ay be re'uired in so e cases, before the in"situ concrete $oints achieve strength! The crac#s ay develop at the $oints between the precast and in"situ concrete due to shrin#age and te perature stresses! To overco e the , e(tra steel is re'uired across the $oint! As there are chances of lea#ageCseepage through the $oints between the precast co ponents, e(tra care is re'uired to a#e the lea# proof! The greater cost of transporting precasting units as co pared with transporting aterials! The additional technical proble s and cost of site connections of precast ele ents, precast construction is used in all types of structures: Industrial buildings, residential and office buildings, hall of si2able span, bridges, stadiu s and prisons! C+*C9,SI+*S: 6ass housing targets can be achieved by replacing the conventional ethods of planning and e(ecuting building operation based on special and individual needs and accepting co on deno inator based on surveys, population needs and rational use of aterials and resources! *o single approach and solution is available which can satisfy the co unity at large! 4owever, what is ideal and desirable is to have a syste , which can provide choice for people and also appropriate techni'ues to eet the situation! The essence lies in the syste approach in building ethodology and not necessarily particular construction type or design! Adoption of any alternative technology on large scale needs a guaranteed ar#et to function and this cannot be established unless the product is effective and econo ical! %artial prefabrication is an approach towards the above operation under controlled conditions! The ethodology for low cost housing has to be of inter ediate type less sophisticated involving less capital invest ent! The 7ovt! of India has to populari2e these co ponents and the i ple ent the at least for low cost 7ovt! houses! %eople should be ore aware about these products and save the environ ent by using the ther al waste in a better anner!

-,se the Ther al 8aste in proper way and gets the =cono ical Construction.
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)! -%rafabricated structures Ka case study. by charl !h, $evan!p vol !D, 3<<), -structural engineering $ournal.! 3! %refabricated structures by Charan singh! 5! www!prefabricate!co