CONSTRUCTION PRACTICES WORKSHOP

ACM 34 – SECTION 2
GROUP 4

Topic: 2-Storied Prefabricated Steel Structures Set

Submitted To – Dr. Mayur Jain

Roll Number Name

AP20160 Kunal Deshmukh
AP20162 Aditya Pillay
AP20167 Nupur Deshpande
AP20170 Pushkaraj Deshpande
AP20173 Vaibhav Patel
AP20174 Ishan Ghosh

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AIM
Assembly and erection of a 2-storied elevated prefabricated steel structure.

INTRODUCTION
The concept of precast structures is also known as prefabricated/ modular structures.
Prefabricated construction is the practice of assembling a variety of components of a structure
at a manufacturing site and transporting those sub-assemblies to the location of the
construction jobsite.

1. Ensures Safety –
Since sub-assemblies are created in a factory-controlled environment utilizing dry
materials, there is less risk for problems associated with moisture, environmental
hazards and dirt. This ensures that those on the construction site are less likely to be
exposed to weather-related health risks. There are strict factory processes and
procedures that protect the worker from on-the-job injury.

2. Reduced Site Disruption –

Since many components of a building are completed in the factory, there is
significantly less truck traffic, equipment and material suppliers around the final
construction site. This streamlined approach to construction provides a far more
efficient atmosphere for productivity, and eliminates unnecessary distractions and
interference that are typical of construction sites.

3. Flexibility –
Prefabricated construction can easily be disassembled and relocated to different sites.
This significantly reduces the demand for raw materials, minimizes expended energy
and decreases time overall. Also, it allows for flexibility in the design of the structure
allowing for a limitless number of opportunities. Since prefabricated construction
units can be used in different spaces, its neutral aesthetics is able to blend in with
almost any building type.

EQUIPMENTS AND TOOLS –

Spanners (round-headed and square-headed), Nuts and bolts, level tube, safety harness belt,
safety helmet, hand gloves, base plates, vertical members, horizontal members, cross braces,
metal plates, crow bars, Spirit Bubble tube, heavy construction rope.
TYPES OF SECTION –
Precast concrete structural elements
Precast slabs

Precast Beam & Girders

Precast Columns
Precast Walls, Precast Stairs

Types of pre cast system:

1. Large-panel systems
2. Frame systems
3. Slab-column systems with walls
4. Mixed systems
1. Large-panel systems
 Box-like structure.
 Both vertical and horizontal elements are load-bearing.
 One-story high wall panels (cross-wall system / longitudinal wall system / two
way system).
 One-way or two way slabs.
2. Frame systems
 Components are usually linear elements.
 The beams are seated
 On corbels of the pillars usually with hinged joints (rigid connection is also an
option).
 Joints are filled with concrete at the site.
3. Lift-slab systems
 Partially precast in plant (pillars) / partially precast onsite (slabs).
 One or more storey high pillars (max 5).
 Up to 30 storey high constructions.
 special designed joints and temporary joints.
 slabs are casted on the ground (one on top of the other) – then lifted with crane
or special elevators.

OTHER REQUIREMENTS –
1. Ladders to access different levels while erecting the prefabricated structure.
2. Safety signs and tags at various points to avoid the workers from getting hurt or from
falling objects.
3. Brace poles to prevent swaying and displacement.

PROCEDURE –
1. In this particular exercise there is substructure and superstructure.
2. Four concrete blocks needs to be laid with the foundation bolts already set in concrete.
3. Once this concrete is ready for the superstructure fabrication. Then one by one, each
component at the four corners will be assembled.
4. By Lifting the column section they will match the slots in the baseplate with the
foundation bolts that have been already laid.
5. Once the holes and the bolts have been matched, now the nuts and washers will be
assembled and with the help of the rounded spanners, to secure these nuts on these
foundation bolts.
6. After the assembly of the Vertical Member, the operation of lifting off the horizontal
member begins.
7. Two members have to stand on a frame-type of a ladder and one of them will assemble
the one end of the horizontal member. The other members on the ground will help to lift
the other end of that horizontal member.
8. Once the bolted joints are secured in position. The vertical and horizontal members are
connected. With the help of bolts that are passing through the gusset plates.
9. The channel section has to lift from one end. Once the holes are matched, the bolts and
nuts will be aligned and fixed. Then the second end will be lifted to another corner.
10. Once the holes of the gusset plate and the Structural Member are aligned, the nut bolts are
fixed.
11. The cross-pipe is in place to prevent any accidents that may happen. Now, the vertical
and horizontal members have been assembled. Now the cross precincts that ensure
stability for this structure will be assembled.
12. Angle section is used as a cross bracing element. One end will be fixed and the other end
will be fixed at the base of the vertical Member.
13. Once the structure is ready, we have to check the verticality and the plum of the structure
with the help of bubble tube that has to be fixed on vertical member
14. The central horizontal members, which is a channel section, is now being assembled.
15. Once the frame structure is assembled, the plates will be assembled, when all these
connections have been secured. With the help of bolts, these metal plates which are being
installed will provide the platform.
16. There is the pulley rope attachment that has been provided to lift these plates from the
ground level to the first floor level.
17. Once plates are aligned properly. Then the plates will be fine-tuned with the help of the
crowbar and a screwdriver so that all the plates are in proper alignment and there is no
overlap between the plates.
18. Ladder assembly is also installed for the workmen to come from the ground floor to the
first floor level.

OBSERVATIONS –
1. The entire structure will be bolted connection structure.
2. While securing bolts two people should hold vertical members so that it doesn’t fall
on the workmen who are working below.
3. The vertical and horizontal members are connected with the help of bolts which are
passing through gusset plate.
4. The cross pipes are placed to prevent any accidents that may happen.
5. When the structure is ready, we have to check the verticality and plumb of the
structure.
6. Pully rope attachment is used for lifting the plates from ground level to first floor
level.
7. Ladder assembly should be installed for workmen to access first floor level.
8. A senser is installed to stop the overflow of water supply in the tank.

APPLICATIONS OF PREFABRICATED CONSTRUCTION –

1. This type of fabrication is used in office blocks, warehouses and factory buildings.
2. Two storey fabrication sections reduce on site cutting and welding costs as well as the
associated hazards.
3. Prefabrication Steel structures are widely used for the exterior of large buildings.
4. Prefabrication saves engineering time on the construction site in civil engineering projects.
5. Prefabrication has significant advantages in terms of construction time, safety,
environmental impact, constructability, and cost.
6. Prefabrication can also help minimize the impact on traffic from bridge building.
7. Prefabrication techniques are used in the construction of apartment blocks, and housing
developments with repeated housing units.
8. Detached houses, cottages, log cabins, saunas, etc. are also sold with prefabricated
elements.
9. In the house constructions as well, prefabricated steel structures are used in modern
methods as shown in photo below.

ADVANTAGES –

 Savings due to the ability to progress work as a parallel operation in a factory and on
a construction site.
 Factory tolerances and workmanship is of a higher quality and consistency to that
achieved on site.
 Reduce wastage of materials
 Independence from adverse weather and winter working.
 An alternative means of production where there may be shortages of local skilled labor.
 The factory environment can allow better safety than the construction site.
 Quick erection times
 Possibility of conversion, disassembling and moving to another site
 Possibility of erection in areas where a traditional construction practice is not possible or
difficult
 Low labor intensity.
 Easier management of construction sites
 Better overall construction quality
 Ideal fit for simple and complex structures

DISADVANTAGES –

 Maximum load capacities of site craneage and temporary gantries.

 Additional cost of temporary bracing for transportation and/or lifting or permanent
framing to support prefabricated assemblies.
 Additional cost of pre-assembly in the factory prior to dismantling for transport and
delivery.
 The in-situ work abutting prefabricated assemblies requires a higher degree of accuracy
than is normally associated with on-site building work to avoid interface problems.
 A mistake in the mass production of prefabricated elements ahead of the
measurable site work is a serious risk.
 Factory production requires predictable and consistent demand,
whereas construction tends to require large numbers at the same time, then none.
 Location of window openings has a limited variety.
 Requires high quality control.
 Difficult to handling & transporting.
 BOQ –

Sr.No Particulars Quantity Unit Rate Amount Remark

(Rs)
1. L shaped Steel a. Vertical member- 4 Rs Rs. 40 per kg 7,800 Considering
Angles b. Cross bracing- 8 a. 65 kg Height,
b. 130 kg
Length and
width as 14
feet
2. C shaped Channel a. Edge horizontal Rs Rs. 45 per kg 14,220
member- 4
b. Central horizontal a. 156
member- 2 b. 78
c. Intermediate c. 82
horizontal member- 7
3. Metal Plates 710 kg Rs. 43 per kg 30,530 -
4. Gusset Plates 5.2 kg Rs. 43 per kg 224 -
5. Ladder assemble 190 kg Rs. 85 per kg 16,150 -
6. HSFG Bolt nut 60 Nos. Rs. 60 per Nos. 3,600 -
7. Labour charges 8 Nos. 450 per labour 3,600 -
per day
8. Miscellaneous - Rs Rs. 1000 1,000 -
cost
Total 77,124

CONCLUSION –
The use of prefabrication and preassembly is estimated to have almost doubled in the last 15
years, increasing by 86%. The use of precast concrete construction can significantly reduce
the amount of construction waste generated on construction sites. Reduce adverse
environmental impact on sites.
 Enhance quality control of concreting work.
 Reduce the amount of site labour.
 Increase worker safety.
 Other impediments to prefabrication and preassembly are increased transportation
difficulties, greater inflexibility, and more advanced procurement requirements.