Section 7 Prefabrication, Systems Building and Mixed/Composite Construction: 7A Prefabricated Concrete
1 SCOPE
This Code (Part 6/Subsection 7A) gives recommendations regarding modular planning, component sizes, prefabrication systems, design considerations, joints and manufacture, storage, transportation and erection of prefabricated concrete elements for use in buildings and such related requirements for prefabricated concrete.
2 TERMINOLOGY
For the purpose of this Subsection, the following definitions shall apply.
2.1 Authority Having Jurisdiction — The authority which has been created by a statute and which, for the purpose of administering the Code/Part, may authorize a committee or an official or an agency to act on its behalf; hereinafter called the ‘Authority’.
2.2 Basic Module — The fundamental module used in modular coordination, the size of which is selected for general application to building and its components.
NOTE — The value of the basic module has been chosen as 100 mm for the maximum flexibility and convenience. The symbol for the basic module is M.
2.3 Cellular Concrete — The material consisting of an inorganic binder (such as lime or cement or both) in combination with a finely ground material containing siliceous material (such as sand), gas generating material (for example, aluminium powder), water and harmless additives (optional); and/or steam cured under high pressure in autoclaves.
2.4 Components — A building product formed as a distinct unit having specified sizes in three dimensions.
2.5 Composite Members — Structural members comprising prefabricated structural units of steel, prestressed concrete or reinforced concrete and cast in-situ concrete connected together in such a manner that they act monolithically.
2.6 Diaphragm — It is a horizontal or nearly horizontal structural system (for example, reinforced concrete floors and horizontal bracing systems), which transmits lateral forces to vertical elements that resist earthquake-induced inertia effects.
2.7 Increments — Difference between two homologous dimensions of components of successive sizes.
2.8 Light-Weight Concrete — Concrete of substantially lower unit weight than that made from gravel or crushed stone.
2.9 Module — A unit of size used in dimensional coordination.
2.10 Modular Coordination — Dimensional coordination employing the basic module or a multimodule.
NOTE — The purposes of modular co-ordination are,
a) to reduce the variety of component sizes produced, and
b) to allow the building designer greater flexibility in the arrangement of components.
2.11 Modular Grid — A rectangular coordinate reference system in which the distance between consecutive lines is the basic module or a multimodule. This multimodule may differ for each of the two dimensions of the grid.
2.12 Multimodule — A module whose size is a selected multiple of the basic module.
2.13 Prefabricate — To fabricate components or assembled units prior to erection or installation in a building.
2.14 Prefabricated Building — The partly/fully assembled and erected building, of which the structural parts consist of prefabricated individual units or assemblies using ordinary or controlled materials, including service facilities; and in which the service equipment may be either prefabricated or constructed in-situ.
2.15 Sandwich Concrete Panels — Panels made by sandwiching an insulation material between two layers of reinforced/prestressed concrete to act as insulation for concrete panels.
2.16 Self Compacting Concrete — Concrete that is able to flow under its own weight and completely fill the voids within the formwork, even in the presence of dense reinforcement without any vibration, whilst maintaining homogeneity without segregation.
PART 6 STRUCTURAL DESIGN — SECTION 7 PREFABRICATION, SYSTEMS BUILDING AND MIXED/COMPOSITE CONSTRUCTION: 7A PREFABRICATED CONCRETE
2.17 Shear Connectors — Structural elements, such as anchors, studs, channels, loops and spirals, intended to transmit the shear between the prefabricated member and the cast in-situ concrete and also to prevent separation at the interface.
2.18 System — It is a particular method of construction of buildings with certain order and discipline using the prefabricated components which are inter-related in functions and are produced based on a set of instructions.
2.19 Unit — Building material formed as a simple article with all three dimensions specified, complete in itself but intended to be part of a compound unit or complete building. Examples are brick, block, floor panel, wall panel, etc.
2.20 Emulative Detailing System — A connection detailing system for precast concrete structures that has structural performance equivalent to that of a conventionally designed, cast-in-situ, monolithic concrete structure
2.21 Jointed Detailing System — A connection detailing system for precast concrete structures that has individual precast components separated from each other but connected using special connections such as welded or bolted plates.
3 MATERIALS, PLANS AND SPECIFICATIONS
3.1 Materials
Use of materials for plain, reinforced concrete and prestressed concrete shall satisfy the requirements of Part 6 ‘Structural Design, Section 5 Concrete, Subsection 5A Plain and Reinforced Concrete and Subsection 5B Prestressed Concrete’ of the Code. Connections and jointing materials shall be in accordance with 8.3.
3.1.1 While selecting the materials for prefabrication, the following characteristics shall be considered:
a) Easy availability;
b) Light weight for easy handling and transport;
c) Strength;
d) Thermal insulation property;
e) Easy workability;
f) Water absorption;
g) Serviceability along with durability;
h) Non-combustibility/fire resistance rating;
j) Sound insulation;
k) Easy assembly and compatibility to form a complete unit;
m) Economy; and
n) Any other special requirement in a particular application.
3.2 Plans and Specifications
The detailed plans and specifications shall cover the following:
a) Such drawings shall describe the elements and the structure and assembly including all required data of physical properties of component materials, material specification, strength of concrete for demoulding, casting/ erection tolerance and type of curing to be followed.
b) Details of connecting joints of prefabricates shall be given to an enlarged scale.
c) Site or shop location of services, such as installation of piping, wiring or other accessories integral with the total scheme shall be shown separately.
d) Data sheet indicating the location of the inserts and acceptable tolerances for supporting the prefabricate during erection, location and position of doors/windows/ventilators, etc, if any.
e) The drawings shall also clearly indicate location of handling arrangements for lifting and handling the prefabricated elements. Sequence of erection with critical check points and measures to avoid stability failure during construction stage of the building.