Prefabricated modular structures using ECC technology

Prefabricated modular housing structures have become a promising alternative to site-built structures with equal or higher engineering quality and durability. Major advantages of this technology are fast and cost-efficient construction, reduced labor requirements, and superior quality control due to factory production. The modular design of these prefabricated structures offers the opportunity for research and application of innovative composite materials and structural concepts. Engineered Cementitious Composites (ECC) in combination with light gage steel joists have been utilized in the development of modular wall and floor panels for prefabrication of housing structures. The need for steel reinforcement in conventional reinforced concrete thin shell construction creates a technological difficulty as the placement of the reinforcing steel is very labor intensive and proper positioning of the reinforcing mats is difficult. The use of fiber reinforced Engineered Cementitious Composites (ECC) helped eliminate these constraints and lead to more economical and structurally reliable floor and wall elements. The ECC/light gage steel floor panel is a novel precast, modular panel system consisting of an ECC slab and light gage steel joists integrally cast with the slab. The unique features of this panel system are: 1) Light weight due to reduced slab thickness and use of light gage steel joists, 2) Modularity and precast construction method of the system, 3) Reduced cost, 4) Applicability in steel and concrete frame systems, masonry and wood construction, 5) Fiber reinforcement eliminates the need for steel reinforcing bars or welded wire mesh, and 6) Highly effective crack control can be provided by the fiber reinforcement.