PREFABRICATED STRUCTURES (2 marks) UNIT I - INTRODUCTION Need for prefabrication-principles- materials- modular coordinationstandardization- systems- production- transportation- erection.

1. Define prefabrication? Prefabrication means the production away from the building site of components traditionally constructed on site. The components thus prepared are known as prefabrication. 2. What are the types of prefabricates based on i.plan area ii based on weight? Pre fabrication based on plan area i) Small prefabricates : when there plan area do not exceed 2m2 ii) Large prefabricates: when plan area over 2m2 Pre fabrication based on weight light, not exceeding 30kg in weight and meant to be erected by one man Medium weight up to 500kg to be handled with simple mechanical equipment. Heavy , upward of 500kg, the erection of which requires the use of heavy handling plant. 3. What are the types of prefabricates based on shapes. Depending on the shape of prefabricates. They are known as blocks. Panels, frames etc., Blocks: These are units with the preparation as a rule very stable during erection. Panels: Walls or slab units

Frames : Beams and columns 4. What is the need for prefabricates structures? 1) prefabricates structures are used for sites, which are not suitable for normal construction method such as hilly region , and also when normal construction material are not easily available. 2) PFS facilities can also be created at @ near a site as is done to make concrete blocks used in plane of conventional knick. 3) Structures which are used repeatedly and can be standardized such as mass housing, storage sheds, godowns, shelters, bus stand, security cabins, site offices, foot over bridges, road bridges. Tubular structures, concrete building blocks etc., are prefabricates structures. 4. What are the Advantages of PFS? 1) In pre cast construction, similar components are produced repeatedly, resulting in increased productivity and economy in cost too 2) The construction is not affected by rain, wind and other weather elements. 3) The work at the site is reduced to a minimum and therefore work is qualitatively better, more reliable and cleaner. 4) Because of faster completion and reduction in time period of construction, the housed can be occupied earlier, which means early natures on the investments. 5) As the component are ready made and self supporting, shuttering and scaffolding is eliminated, with a solving in a shuttering cost. 6) In PFS there if better QC. Shape and size of precast elements.

5.What are the disadvantages of PFS? 1. Careful handling of prefabricated components such as concrete panels or steel and glass panels is required. 2. Attention has to be paid to the strength and corrosion-resistance of the joining of prefabricated sections to avoid failure of the joint. 3. Similarly, leaks can form at joints in prefabricated components.

4. 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. 5. Large prefabricated sections require heavy-duty cranes and precision measurement and handling to place in position. 6. Larger groups of buildings from the same type of prefabricated elements tend to look drab and monotonous. 7. Local jobs may be lost, if the work done to fabricate the components being located in a place far away from the place of construction. This means that there are less locals working on any construction project at any time, because fabrication is outsourced. 6. What are the Production techniques? The term production techniques describes a series of operation directly concerned in the process of making or more aptly of molding precast units. These techniques grouped into three basic methods of production. 1. The stand system 2. The conveyor belt or production line system. 3. The aggregate system.

7. Explain the stand system Production technique? In the stand system the prefabricates mature at the point where they were molded, While the production team moves to successive stands. The bed on which prefabricates are cast May fixed &movable. 8. Explain the conveyor belt or production line system Production technique? The conveyor belt system of production splits the whole production process in to a series of operation carried out at a separate , successive and permanent points, points to the next may be by means of conveyor belt, trolleys & crane etc., 9. Explain the aggregate system production technique?

The word aggregates describes a large, complex , permanently installed set of machines and mechanical application m which can carryout most of the separate operation involved in casting concrete components.

10. Explain the Erection procedure of PFS building? Before commencing erection, the setting out at the level concerned must be carefully checked with surveying instruments. At the same time, the working of cranes and the correct layout of the cranes track must be checked. Any unevenness of the ground makes it difficult to lay a horizontal cranes track with mainly steep slopes. A rather high embankment is required , and this is both costly and technically difficult. Prefabricates buildings are erected in convenient section which correctly fixed, should be sufficiently rigid in all directions. 11. What are the Aims of prefabrication? Prefabrication is used to affect economy in cost This results in improvement in quality because components can be manufactured under controlled conditions. The spread of construction is increased since no curing period is necessary. Prefabrication helps in the use of locally available materials with required characteristics Use of materials which due to their innate characteristics like lightweight, easy workability, thermal insulation, non combustibility, etc effect economy and improve quality. 12. What are the characteristics of Materials used for construction of PFS? While choosing the materials for prefabrication the following special characteristics are to be considered Easy availability

 Light weight for easy handling and transport and to economies on sections and sizes of foundations Thermal insulation property Easy workability Durability in all weather conditions Non-combustibility Economy in cost Sound insulation 13. What is meant by modular co-ordination? The basic module is to adopted. Basic module is the fundamental module used in modular co-ordination, 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.

14. What are the Advantages of standardization? Easier design Easier manufacture Easier erection and completion 15. What are the Factors influencing the standardization the most rational type of member for each element is selected from the point of production from the assembly serviceability and economy The number of types of elements will be limited and they should be used in large quantities. To the extent possible the largest size to be used which results in less number of joints The size and the number of the prefabricates is limited by the weight in overall dimension that can be handled by the transportation. Hence it is preferable to have all the prefabricates approximately of same weight very near to the lifting capacity of the equipment.

16. What are the Prefabrication systems?

The word system is referred to a particular method of construction of buildings using prefabricated components which are inter related in functions and are produced to a set of instructions. With certain constraints, several plans are possible, using the same set of components. The degree of flexibility varies from system to system.

17. What are the Types of prefabricated construction systems? 1. Open prefab system a. partial prefab open system b. full prefab open system 2. Large panel prefab system

18. What are the methods for Manufacture of precast concrete elements? 1. Factory prefabrication 2. Site prefabrication

UNIT II - PREFABRICATED COMPONENTS 1. What are the types of wall systems? 1. Cross wall system 2. Longitudinal wall system a. Homogeneous walls b. Non-homogeneous walls 2. What are the prefabricated structural units? 1. Walls and columns 2. Lintels 3. Door and window frames 4. Roofing and flooring elements 5. Stairs 3. What is meant by box type construction? In this system room size units are prefabricated and erected at site. Toilet and kitchen blocks could also be similarly prefabricated and erected at site. This system derives its stability and stiffness from the box units which are formed by four adjacent walls. Walls are jointed to make rigid connections among themselves. The box unit rests on plinth foundation which may be of conventional type or precast. 4. Write briefly about Types of Wall Panels? The simple way of classification of precast wall panel is based on their size or the materials of which they are made. They can be classified. According to size, as small and large, or as narrow vertical stirrups or as broad horizontal bands.

The material that are used for precast wall panel are bricks, hollow clay blocks, normal density concrete, light weight metal, gypsum, plastic, and timber. 4. What is the classification of precast large panel? Structural scheme with precast large panel wall can be classified as: 1. Cross wall system 2. Longitudinal wall system

5. What is the classification of precast concrete walls? Homogeneous wall -Which could be solid, hollow or ribbed Non-Homogeneous walls -These could be composite or sandwich panels. 6. What are the types of precast floors? Depending up on the composition of units, precast flooring units could be homogeneous or non- homogeneous. Homogenous floors could be solid slabs, ribbed or waffle slabs. Non homogeneous floors could be multi layered ones with combinations of light weight concrete or reinforced / prestressed concrete with filler blocks. 7. Write about Prefabricated Roofing and flooring elements Prefabricated reinforced concrete battens and plain concrete tiles can be used for roofing and flooring for flat roofs, instead of wooden section and brick tiles. For sloping roof, precast reinforced and prestressed concrete triangulated trusses can be used. Plain concrete or lightly reinforced concrete can be used in the form of precast shells for roofing.

8. What is Shear wall? A wall designed to carry horizontal forces acting in its plane with or without vertical imposed loads thus assuring the stability of the building.

UNIT - III DESIGN PRINCIPLES

1. What is disuniting of structures? The solution for the problems connected with the transportation and placing of structures demands the disuniting the larger member in to smaller members.

2. At what point in the members disuniting should be done? Disuniting can be done at corners or points of minimum moments, to make the hoisting of these smaller members possible using simpler equipments.

3. What are the advantages of disuniting of structures? Easy to transport the members from casting yard to site. Ease in placing in required position.

4. What are the disadvantages of disuniting of structures? The identifying joint location is a problem in disuniting of structures. In frames it is easy to disunite at corners but it is the point of maximum bending moments. 5. Explain joint flexibility?

While disuniting structures the member is designed as semi rigid frame ie., in which the columns and beams are connected in such a way that there is some flexibility at the joints. Joint that holds two parts together so that one can swing relative to the other.

6. Explain joint deformation. Since joints in the structures of disunited members are flexible some deformation is allowed at the joints. Joint deformation refers to how the joint behaves in regard to the far field stresses. 7. How does the material used in construction affects the design of the element? In the production of prefabricated structures we can have strict quality control, so we can utilize the entire strength of materials with minimum factor of safety. It will lead to economical deign and dimension of structures. But while design allowance should be given for the stresses developed during handling the members.

UNIT IV JOINTS IN STRUCTURAL MEMBERS

1. What are the importances of joints in precast structures when compared to castin-situ structures? In cast-in-situ structures the joints are provided to relieve the stresses due to temperature and shrinkage and also to accommodate the construction sequence for placement of concrete. But in case of precast structures apart from the above reasons we require joints to connect various elements of structures.

2. What is the need for expansion joint in precast structures. Expansion joints allow expansion and contraction of a member without generating potentially damaging forces within the member itself or the surrounding structures.

3. What are the connections? In a precast members to overcome operational difficulties the member are disunited into smaller elements. Connections are used to get required structures by joining the separate smaller elements.

4. What are the different types of connections? There are two types of connections 1. Wet connections (with mortar or in-situ concrete) 2. Dry connections (with welding and bolting)

5. What are the points to be considered while designing the connections? 1. Loading under working conditions 2. Stability of structures 3. Load conditions during construction. 4. Effects of shrinkage, creep and temperature 5. Unequal settlement 6. What are the different connections made in a prefabricated structure. i.Column to column connection ii.beam to beam connection iii.Main beam to secondary beam connection.

7. What are the different types of joints? Expansion joints Contraction joints Crack control joints 8. What are the materials used for concrete joints. Flexible board Dowels Sealants 9. Based on the location within a building, how connections can be classified? Based on the location within a building connections are classified into vertical and horizontal joints. Vertical joints connect the vertical faces of adjoining wall panels and primarily resist vertical seismic shear forces. Horizontal joints connect the horizontal faces of the adjoining wall and floor panels and resist both gravity and seismic loads.

10. What are the functions of joints? Joints between internal and external wall panels shall be designed to resist the forces acting on them with out excessive deformation and cracking.They shall also be able to accommodate the deviations in the dimensions of the wall panels during production and erection.

UNIT V DESIGN FOR ABNORMAL LOADS

1. What is progressive collapse? Progressive collapse is a situation where local failure of a primary structural component leads to the collapse of adjoining members which in turn leads to additional collapse.

2. Define Degree of Progressivity. It is defined as the ratio of total collapsed area or volume to the area or volume damaged directly by the triggering event.

3. What are the approaches to avoid progressive collapse? Redundancy or alternate load path Local resistance Interconnection or continuity 4. What are the special requirements for building in High Seismic Zones? Large panel building in high seismic zones are recommended to be constructed with closed symmetrical layout. The height of the building shall generally restricted to 10 storeys in Zone IV and 7 storeys in Zone V. The vertical and horizontal joints for wall panels shall be designed as keyed joints.

5. What are provisions made in a Prefabricated R C floors in a cyclone prone zone? Prefabricated R C elements of various designs placed side by side where as R C slabs are rigid in their own planes, the other types will require their integration through diagonal bracing or topping R C screed (structural deck concrete). Structural deck concrete of grade not leaner than M20 should be provided over pre-cast components to act monolithic with them.

6. What is strong column weak beam concept? In a building a column is more important than a beam, because it supports the load till the foundation. If a beam breaks it will result in a partial collapse but if a column breaks it will result in catastrophic failure. That is the reason why we have to always design our columns stronger than beams.

PREFABRICATED STRUCTURES (16 marks) UNIT - I INTRODUCTION 1. What are the types of Prefabricates? 2. What are the Production techniques? 3. What are the methods for Manufacture of precast concrete elements and explain briefly. 4. What is the process involved in manufacture of PFS? 5. What are erection stresses? How are they reduced or eliminated? 6. What are the importance aspects considered during hoisting, erection and transportation of precast element?

UNIT -II PREFABRICATED COMPONENTS 1. Classify the structure of building based on the load distribution and briefly explain the different types of such prefabricated building. 2. Explain the methods of construction of roof and floor slab. Also explain the precautions taken during the manufacturing process. 3. What is the necessity of providing shear walls in the precast structures? Also discuss the different types of shear walls. 4. Write briefly about types of wall panels. 5. Write briefly about precast concrete columns. 6. Write about the structural behavior of precast structure.

UNIT - III DESIGN PRINCIPLES 1. Discuss the necessity of disuniting of structures and explain in detail with sketch. 2. Explain the problems in design because of joint flexibility. Discuss with regard to various location. 3. Why should we give allowance for joint deformation and explain in detail. 4. What are the precautions taken during the disuniting the structures?

UNIT IV JOINTS IN STRUCTURAL MEMBERS 1. Explain expansion and contraction joint in retaining wall. 2. What are the essential requirements of joints in precast construction? 3. What are the recommendations for the design of an expansion joint? 4. Give the recommendations for the detailing the precast element in respect of the connections and erection. 5. Explain about column to column connection. 6. Explain about beam to beam connection.

UNIT V DESIGN FOR ABNORMAL LOADS 1. Mention in detail the codal provision for considering the effect of earthquake and cyclones. 2. Explain strong column and weak beam. 3. When does a progressive collapse occurs? Why is it very critical to avoid progressive collapse of structures? 4. Explain the procedure for calculating equivalent design loads when the structure is subjected to earthquake loading. 5. What are the methods to avoid the progressive collapse? Explain each briefly?