SUMBITTED TO:- SUMBITTED BY:-

PREFABRICATED STRUCTURES Prof. SANJAY MEHRA YUGAL GUPTA

Ar. VARUN JAIN
HINDUSTAN PREFAB LIMITED

Established in 1948 as a department to provide the housing solutions to the

Internally Displaced People and later on converted into a company in 1953.
HINDUSTAN PREFAB LIMITED is a pioneer of Prefab Technology in
India. HPL is a leading CPSE aiming to deliver high tech Project Management
Consultant Services in civil construction projects. As a step forward towards
Prefab Technology, a Prefab Technology Park has been setup in HPL Premises,
New Delhi
Spread in area of approx. 2 Acres amidst green surroundings, a technology park will H
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provide a platform to various innovative prefabricated technology N
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ENTRANCE AND GUIDE MAP OF I
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PREFAB TECHNOLOGY PARK E
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VARIOUS TECHNIQUES USED BY HPL H
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• Monolithic concrete construction N
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• Precast concrete construction U
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• Light gauge steel construction T
• GFRG building system A
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• Precast sandwich panel system
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• Polyurethane foam technology R
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MONOLITHIC CONCRETE CONSTRUCTION I
TECHNOLOGY N
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• The conventional mode of construction is
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RCC framed structure with infill masonry
walls whereas in this system, all walls, S
floors/slabs, stairs together with door & T
window openings are cast in-situ A
monolithically using specifically custom N
designed modular formwork made up of
aluminium/plastics/steel/ composite.
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• The appropriate grade of concrete and
reinforcement is used as per design and the R
entire casting of a modular unit is done in a E
single pour. F
• Being modular predesigned formwork A
system, it acts as a assembly line B
production and enables rapid construction
of multiple/mass scale of units of repetitive
type. L
• In the Monolithic concrete construction I
with aluminium/plastic/stell/composite M
forms system, Concrete walls and slabs are I
cast monolithically at one pour. T
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• The system allows reduction in thickness of H
concrete members below the minimum value I
than the conventional construction, thus N
reducing the consumption of natural resources. D
• Single floor with built up area of about 300 sqm. U
can be completed in two days using the
aluminium formwork system.
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• The technology reduces the cost of repair and
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maintenance compared to conventional system. A
• Walls and slabs are cast in one operation in N
specially designed light weight form/ moulds in
concrete. P
• Concrete is poured in the forms & forms are R
removed after the setting of concrete takes place, E
resulting in box like cubical structure of required
architectural design. F
• The pre-designed formwork also acts some sort A
of assembly line production and enables rapid B
construction of multiple units of repetitive type.
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PRECAST LARGE CONCRETE PANEL SYSTEM H
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Precast Large Construction Panel (PLCP)
system is a structural system comprising of D
various precast elements such as walls, U
beams, slabs, columns, staircase, landing S
and customized elements. T
• There are two types of precast concrete A
elements, namely precast reinforced
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concrete elements and precast pre-stressed
concrete elements, prefabricated in a precast
yard or site. P
• The precast elements are installed on site R
and supported by temporary jacks. Shims E
are used to carefully align the elements and F
grouted after the final adjustments.
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• A typical construction involves
design, strategic yard planning, lifting, I
handling, transportation and assembly T
of precast elements. E
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 LIGHT GAUGE STRUCTURE SYSTEM H
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• Frame is made of cold rolled high strength steel
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sections and EPS panels for walling.
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Internal walls covered with gypsum and cementations
board. Exterior wall Sprayed with cementations S
material directly onto the studs. T
• Faster construction by prefabricated panels. All A
structural components are precisely pre-manufactured N
and simply assembled on site.
• Enhanced Thermal & Acoustic insulation with P
Boarding/Expanded Polystyrene (EPS)
/Rockwool/Vapour Barrier.
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• Eco friendly structure. Superior and sustainable
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performance. Minimum Impact on natural resources. F
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HOUSE CONSTRUCTION
THROUGH LIGHT GAUGE STEEL P
TECHNOLOGY R
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GENERALLY THIS TYPE OF F
CONSTRUCTION IS PREFFERED A
IN LIGHT GAUGE STEEL B
CONSTRUCTION. WALL
PROFILE:- L
• CEMENT BOARD I
• STEEL WALL STUD M
• GLASS WOOL I
•CEMENT BOARD T
VARIOUS WALL PROFILE THAT CAN BE
CONSTRUCTED FROM LIGHT GAUGE STEEL E
CONSTRUCTION SYSTEM D
GLASS FIBRE REINFORCED GYPSUM (G.F.R.G.) PANEL SYSTEM H
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GFRG is an integrated composite building
system using factory made prefab load D
bearing cage panels and monolithic cast in- U
situ RC in filled for walling and floor/ roof S
slabs, suitable for single storey to ten storey T
building.
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• It is made of calcined gypsum plaster,
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reinforced with glass fibres and panels
manufactured to a thickness of 124 mm under
carefully controlled conditions to a length of P
12 m and height of 3m, contains cavities. R
• The panel are being produced at FRBL Kochi E
and RCF Mumbai and being promoted by IIT F
Madras.
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HOLLOW G.F.R.G. PANELS ARE
MANUFACTURED IN THE FACTORIES M
FOR THE CONDUCTS AND THE I
CONCRETE POUR IN IT. T
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PROFILE OF G.F.R.G. PANEL PLACEMENT OF G.F.R.G. PANEL P

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CONCRETING STRUCTURE
PRECAST SANDWICH PANEL SYSTEM H
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• Panel Building system is a load bearing wall
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construction which is seismic resistant and
thermally insulated. D
• Buildings of any typology or architectural structure, U
ranging from most simple to the most complex one, S
could be constructed. T
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• The base element of the building system is a modular panel
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composed of two electro-welded galvanized steel meshes, T
reciprocally joined by connectors , in the middle of which is a E
suitably shaped foam polystyrene plate. D
High resistance steel meshes composed of bars having
dia. 2.5 to 5 mm. are made in factory. Panels could be H
supplied with meshes having different dia. and different I
geometrical characteristics. N
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POLYURETHANE FOAM (P.U.F.) H
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Polyurethane form is sandwiched between two outer
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skins PPGI sheets and hence is known as PUF
sandwich. PUF insulated panels are used in various D
applications such as cold storage, pack house, U
prefabricated shelters. They are light in weight, S
easy to handle, rigid and sturdy with higher T
mechanical strengths having high fire resistance.
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Corrugated and plain sheets are manufactured in M
factories and then structures can be formed from I
these sheets
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TECHNIQUES H
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DESIGNED BY H.P.L. N
TREMENDOUSLY D
USED IN MARKET U
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• Monolithic concrete A
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construction
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• Precast concrete construction
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• Light gauge steel construction E
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• GFRG building system
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Precast sandwich panel system
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and Polyurethane foam I
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technology are not much used yet
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TYPES MONOLITHIC CONCRETE PRECAST CONCRETE LIGHT GAUGE STEEL G.F.R.G. BUILDING
CONSTRUCTION CONSTRUCTION CONSTRUCTION SYSTEM
DEFINATION The conventional mode of Precast Large Construction Panel (PLCP) Frame is made of cold rolled high GFRG is an integrated
construction is RCC framed system is a structural system comprising strength steel sections and EPS composite building
structure with all walls, of various precast elements such as panels for walling. Internal walls system using factory
floors/slabs, stairs together with walls, beams, slabs, columns, staircase, covered with gypsum and made prefab load
landing and customized elements. cementations board. Exterior wall bearing cage panels and
door & window openings are Sprayed with cementations material monolithic cast in-situ
cast in-situ monolithically using directly onto the studs. RC in filled for walling
specifically custom designed and floor/ roof slabs,
modular formwork made up of suitable for single storey
aluminium/plastics/steel/ to ten storey building.
composite.
SUITABLE Modular structures with high Almost every kind of structure is G+3 structure is feasible in light Structures up to 10
STRUCTURE no. Of repetitions. Any kind of possible in precast concrete gauge steel structure, high rise is not stories can be build
structure even high rise also construction. It would be feasible to suggested in this type of
have large no. Of repetitions in construction as it has less strength to
structural elements withstand with loads

ADVANTAGES • Use of same grade of concrete • All structural members are • Very less time consuming • Similar to precast
reducing the errors in the manufactured as per designers choice • 1 floor can be finished in 1 day concrete construction
strength of the structure • No error in the strength of any member only but structural elements
• Reduces the cost of in the precast structure • Less no. Of workers are used are light in weight thus
maintenance • No time consumed structural elements • Less and light weight equipments making ease in
• Easy and feasible to have are just fix on the site are used construction
repetitive and modular • Best type of construction now a days • No sort of modularity. Structures • Has more strength than
construction units for high density multi repetitive with no sort of repetition can also light gauze steel
• Less width of walls are structures be easily constructed. construction
constructed saving plinth area • Conducts can be installed easily in • Conducts can be
the frame itself installed easily in the
frame itself

DISADVANTAGES • Time consuming • Transportation cost is high • Highly skilled labour is needed • not feasible for high
• Only rigid and cubical • Structural elements are heavy thus • Walls are hollow and are weak in rise construction
structures with large no. Of cranes and hydraulic lifters are strength • highly skilled labour is
repetitions are feasible. necessary in this type of construction • For construction above 1 floor needed
• After concreting workers has • Highly skilled labours are needed steel column and supporting • reinforcing and
to wait till the concrete has to • Not feasible for small construction structures has to be placed to take concreting has to done
dry projects the load to withstand the
• Waterproofing has to be done as structure thus making it
floor slabs are not able to stop water cost ineffective
INTELLIGENT BUILDING SYSTEM
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INTELLIGENT BUILDING SYSTEM N
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COMPRISES OF:- E
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• USE OF ECO- FRIENDLY BUILDING N
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MATERIAL
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• BUILDING AUTOMATION U
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• INTELLIGENT BUILDING SYSTEM D
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• MANAGEMENT SYSTEM N
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• LIFE SPAN AND FUTURE DIRECTION
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USE OF ECO -FRIENDLY BUILDING MATERIAL I
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Today many people that are building or remodeling their houses choose to use eco-friendly building materials. An eco- T
friendly building material is one that increases the efficiency of energy used and reduces impact on human well-being and E
the environment. There are many different materials that can be used that are eco-friendly; from foundation, to insulation, L
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to interior and exterior wall finishes, flooring, and countertop materials. Conventional Eco-friendly materials:-
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• Bamboo Based Particle Board & Ply Board, Bamboo Matting
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• Bricks sun dried E
• Pre-cast cement concrete blocks, lintels, slab. Structural and non- N
structural modular elements T
• Calcined Phospho-Gypsum Wall Panels
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• Calcium silicate boards and Tiles U
• Cellular Light Weight Concrete Blocks I
• Cement Paint L
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• Clay roofing tiles
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• Water, polyurethane and acrylic based chemical admixtures for N
corrosion removal, rust prevention, water proofing G
• Epoxy Resin System, Flooring, sealants, adhesives and admixtures
• Ferro-cement boards for door and window shutters
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• Ferro-cement Roofing Channels
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• Fly-ash Sand Lime Bricks and Paver Blocks T
• Gypsum Board, Tiles, Plaster, Blocks, gypsum plaster fibre jute/sisal E
and glass fibre composites M
• Particle Boards I
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• Polymerised water proof compound
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• Polymerised water proof compound E
• Portland Pozzolana Cement Fly-ash / Calcinated L
Clay Based L
• Portland Slag Cement
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• RCC Door Frames
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• Ready Mix Cement Concrete N
• Rubber Wood Finger Joint Board T
• Stone dust
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• Water proof compound, adhesive, Polymer, Powder
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• Marble Mosaic Tiles I
• MDF Boards and Mouldings L
• Micro Concrete Roofing Tiles D
• Laminated Wood Plastic Components
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BUILDING AUTOMATION I
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Building Automation describes the
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functionality provided by the control L
system of a building. A building I
automaton system (BAS) is an G
example a distributed control system.
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The control system is a computerized,
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intelligent network of electronic
devices, designed to monitor and B
control the mechanical and lighting U
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systems in building. BAS core
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functionality keeps the building D
climate within a specified range, I
provides lighting based on the N
occupancy schedule, and monitors
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system performance and device failures and provides email and/or text notifications to building engineering staff. The S
BAS functionality reduces building energy and maintenance costs when compared to a non-controlled building. A Y
building controlled by a BAS is often referred to as an intelligent building system.
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LIGHTING SYSTEM I
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Lighting can be turned on and off with bas based on time T
of day, or on occupancy sensors, photo sensors and E
timers. One typical example is to turn the lights in a L
space on for a half hour since the last motion was sensed.
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A photocell placed outside a building can sense darkness,
and the time of day, and modulate lights in outer offices I
and the parking lot. G
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HVAC SYSTEM N
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Heating, Ventilation and Air Conditioning, and Indoor Air Quality HVAC systems are generally controlled by
building automation systems that can: humidity, temperature and air flow speeds
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SECURITY I
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The security system includes controlling access, surveillance and communication. Access control Access control restricts T
how and when people enter and/or exit an area. Your particular needs will determine how that is accomplished. Access E
Control Systems allow people or vehicles into a restricted area via identification through coded keys, magnetic cards, or L
biometric readers such as hand, face, voice, finger or retina readers. These systems are used in many businesses, hotels
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and apartment complexes.
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• Finger Print Lock G
• Voice and Video Intercom  E
• Code Based Access System N
• Swipe Card Access System
• Biometric Access System  
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LIFE SAFETY AND D
SURVILLIENCE I
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 Life Safety and Surveillance Intelligence
with respect to life safety in an intelligent
building consists of the use of high S
technology to maximize the performance Y
of fire alarm and security systems while at S
the same time minimizing costs. Life safety
factors involved in intelligent buildings
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include: - E
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WATER MANAGEMENT SYSTEM I
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WATER EFFICIENT PLUMBING T
Reducing indoor water use in residences and businesses can be accomplished through water- efficiency standards for
plumbing fixtures. Generally, the standards impose a maximum on the amount of water used per flush by toilets and
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urinals and per minute by faucets and showerheads. In the United States, these amounts or flow rates are described as L
gallon per flush (gpf) or gallon per minute (gpm). Efficiency standards also typically leave it to fixture manufacturers to L
meet these goals without compromising performance. The standards can also apply to the sale and installation of I
plumbing fixtures in addition to their manufacture. Today, nine states have their own mandatory standards for plumbing G
fixtures while others are using financial incentives, community planning efforts, and water conservation requirements for
public buildings to promote the adoption of efficient fixtures. E
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 DRAINAGE SYSTEM
Drainage is the natural or artificial removal of surface and sub-surface water from an area. The internal drainage of most S
agricultural soils is good enough to prevent severe water logging (anaerobic conditions that harm root growth), but many Y
soils need artificial drainage to improve production or to manage water supplies.
WATER RECYCLING
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Most buildings use municipal drinking water for all uses, but many applications (such as irrigation, toilet flushing, T
decorative fountains) do not require it. Wastewater recycling is the reuse of water after it is no longer potable. E
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ADVANTAGES AND DISADVANTAGES OF INTELLIGENT BUILDINGS I
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THE INTELLIGENT BUILDING HAS FOLLOWING ADVANTAGES: T
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• Higher level of security and safety
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• Simplified operation for users and administrators I
• Simpler staff tracking G
• Reduced administration costs E
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• Smartcards-single card for security and cash transactions
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• Reduced system costs by sharing infrastructure
• Easier integration into university systems B
• Information can be delivered to all the interested parties in the manner they need U
• Increased mobility-not tied to a specialist workstation
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• Training is minimised, use standard operating environments. 
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THE INTELLIGENT BUILDING HAS FOLLOWING DISADVANTAGES: N
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• Increased complexity of system
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• Very high initial cost Y
• Normal building last longer than intelligent building. S
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