PRE-CAST AND PRE-FABRICATED

STRUCTURES

PRANAY BHAVSAR 04
SEJAL BHOLE 05
ROSHANI TAMKHADE 49
ASHAY TANAK 50

INTRODUCTION
The concept of precast (also known as prefabricated) construction includes
those buildings, where the majority of structural components are standardized
and produced in plants in a location away from the building, and then
transported to the site for assembly.
These components are manufactured by industrial methods based on mass
production in order to build a large number of buildings in a short time at low
cost.

The main features of this construction process are as follows:

The division and specialization of the human workforce
The use of tools, machinery, and other equipment, usually automated, in the
production of standard, interchangeable parts and products
Compared to site-cast concrete, precast concrete erection is faster and less
affected by adverse weather conditions.
Plant casting allows increased efficiency, high quality control and greater
control on finishes.
This type of construction requires a restructuring of entire conventional
construction
process to enable interaction between design phase and production planning in
order to
improve and speed up construction.

PRE-CAST AND PRE-FABRICATED STRUCTURES

TYPES OF PRECAST SYSTEMS

Depending on the load-bearing structure, precast systems can be divided
into the following categories:
1- Large-panel systems
2- Frame systems
3- Slab-column systems with walls
4- Mixed systems

1-LARGE PANEL SYSTEMS

The designation large-panel system refers to multistory structures
composed of large wall and floor concrete panels connected in the vertical
and horizontal directions so that the wall panels enclose appropriate spaces
for the rooms within a building.
These panels form a box-like structure. Both vertical and horizontal panels
resist gravity load.
Wall panels are usually one story high. Horizontal floor and roof panels
span either as one-way or two-way slabs.
When properly joined together, these horizontal elements act as diaphragms
that transfer the lateral loads to the walls.
Depending on wall layout , there are three basic configurations of largepanel buildings:
Cross-wall systems
Longitudinal wall systems
Two-way systems

A large-panel concrete building

under construction

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2- FRAME SYSTEMS
Precast frames can be constructed using either linear elements or spatial beam
column sub-assemblages.
Precast beam-column sub-assemblages have the advantage that the connecting
faces between the sub-assemblages can be placed away from the critical frame
regions; however, linear elements are generally preferred because of the
difficulties associated with forming, handling, and erecting spatial elements.
The use of linear elements generally means placing the connecting faces at the
beam-column junctions.
The beams can be seated on corbels at the columns, for ease of construction and
to aid the shear transfer from the beam to the column.
The beam-column joints accomplished in this way are hinged. However, rigid
beam-column connections are used in some cases, when the continuity of
longitudinal reinforcement through the beam-column
joint needs to be ensured.

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3- SLAB-COLUMN SYSTEMS WITH SHEAR WALLS

These systems rely on shear walls to sustain lateral load effects, whereas the
slab-column structure resists mainly gravity loads. There are two main systems
in this category:
Lift-slab system with walls
Prestressed slab-column system
Lift-slab system with walls
In the Lift slab system, the load-bearing structure
consists of precast
reinforced concrete columns and slabs,.
Precast columns are usually two stories high.
All precast structural elements are assembled by means
of special joints. Reinforced concrete slabs are poured on
the ground in forms, one on top of the other. Precast
concrete floor slabs are lifted from the ground up to the
final height by lifting cranes.
The slab panels are lifted to the top of the column and
then moved downwards to the final position.
Temporary supports are used to keep the slabs in the
position until the
connection with the columns has been achieved.

Prestressed slab-column system

The prestressed slab-column system uses horizontal prestressing in two
orthogonal directions to achieve continuity. The precast concrete column
elements are 1 to 3 stories high. The reinforced concrete floor slabs fit the clear
span between columns. After erecting the slabs and columns of a story, the
columns and floor slabs are prestressed by means of prestressing tendons that
pass through ducts in the columns at the floor level and along the gaps left
between adjacent slabs.
After prestressing, the gaps between the slabs are filled with in situ concrete and
the tendons then become bonded with the spans. Seismic loads are resisted
mainly by the shear walls (precast or cast-in-place) positioned between the
columns at appropriate locations.

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PRECAST CONCRETE STRUCTURAL ELEMENTS

PRE-CAST SLAB

PRE-CAST BEAMS AND GIRDERS

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TYPICAL CONNECTION OF PRECAST CONCRETE

ELEMENTS
COLUMN TO COLUMN CONNECTION

BEAM TO COLUMN CONNECTION

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PRE-CAST COLUMNS

PRE-CAST WALLS

PRE-CAST OTHER ELEMENTS

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SLAB TO BEAM CONNECTION

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DESIGN CONCEPT FOR PRECAST CONCRETE

STRUCTURES
In

design of precast members and connections, all loading and restraint

conditions from casting to end use of the structure should be considered. The
stresses developed in precast elements during the period from casting to final
connection may be more critical than the service load stresses.
Special attention should be given to the methods of stripping, storing,
transporting, and erecting precast elements.
When precast members are incorporated into a structural system, the forces and
deformations occurring in and adjacent to connections (in adjoining members
and in the entire structure) should be considered. The structural behavior of
precast elements may differ substantially from that of similar members that are
monolithically cast in place. Design of connections to transmit forces due to
shrinkage, creep, temperature change, elastic deformation, wind forces, and
earthquake forces require special attention.
Details of such connections are especially important to insure adequate
performance of precast structures.
Precast members and connections should be designed to meet tolerance
requirements. The behavior of precast members and connections is sensitive to
tolerances. Design should provide for the effects of adverse ccombinations of
fabrication and erection tolerances. Tolerance requirements should be listed on
contract documents, and may be specified by reference to accepted standards.
Tolerances that deviate from accepted standards should be so indicated.

PRE-CAST AND PRE-FABRICATED STRUCTURES

All details of reinforcement, connections, bearing elements, inserts, anchors,

concrete cover, openings and lifting devices, and specified strength of concrete
at critical stages of fabrication and construction, should be shown on either
the contract documents prepared by the architect/engineer of record or on the
shop drawings furnished by the contractor.
Whether this information is to be shown on the contract documents or shop
drawings depends on the provisions of the contract documents. The shop
drawings should show, as a minimum, all details of the precast concrete
members and embedded items. The contract documents may specify that
portions of connections exterior to the member are also to be shown on the
shop drawings.
The contract documents may also require the contractor to provide designs for
the members and/or connections.
The contract documents should show the loads to be considered in design of
the precast concrete elements of the structure, and they should indicate any
special requirements or functions (for example: seismic loads, allowance for
movements, etc.) that should be considered in design assigned to the
contractor. In this case, the shop drawings should include complete
details of the connections involved.

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CONNECTION BETWEEN SLABS

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CORNER CONNECTION OF WALL PANELS

CONNECTION OF WALL PANELS TO COLUMNS

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SITE LOCATION
Sagar Darshan - Dream Apartments
Sagar Darshan, Palm Beach, Navi Mumbai
(Maharashtra)
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CONNECTION FOR BEAM, SLAB AND WALL SECTION

CONNECTION BETWEEN WALL TO WALL PLAN

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1

CONNECTION FOR WALL TO WALL AND SLAB SECTION

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CONNECTION FOR BEAM TO COLUMN

CONNECTION FOR BEAM TO COLUMN SECTION

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COLUMN TO BEAM CONNECTION

SECTION

ANCHOR BOLT DETAIL

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SLAB TO PRECAST
NON LOAD BEARING
WALL CONNECTION
DETAIL

PARAPET WALL DETAIL

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COLUMN BEAM CONNECTION

SECTION

LOAD BEARING PANEL TO PANEL CONNECTION

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PANEL TO PANEL CONNECTION

WALL PANEL TO SLAB CONNECTION

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PANEL TO PANEL AND SLAB CONNECTION

PANEL TO GROUND BEAM CONNECTION SECTION

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PANEL TO PANEL AND SLAB CONNECTION

CORNER CONNECTIONS

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SLAB AND BEAM CONNECTION

SLAB AND WALL CONNECTION

SECTION

PRECAST PANELS SECTIONS

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COLUMN TO FOUNDATION CONNECTION

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COLUMN TO FOUNDATION CONNECTION

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VOID IN SLABS

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STAIRCASE DETAIL
SECTION

STAIRCASE SECTION

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PRE-CAST AND PRE-FABRICATED STRUCTURES

PRECAST BEAMS IN A STADIUM

PRECAST STAIRCASE SLAB

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CASE STUDY KHALAPUR FACTORY

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PRECAST FOOTING DETAILS

PRECAST COLUMN DETAILS

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COMPOUND WALL DETAILS

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PRE-CAST AND PRE-FABRICATED STRUCTURES

MMRDA EASTERN FFREEWAY PROJECT

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ABOUT THE PROJECT

The Eastern Freeway Project provides a direct link between the Eastern Express
Highway and south Mumbai. It will be a 22-km high-speed corridor from
Chhatrapati Shivaji Maharaj Vastu Sangrahalaya right up to Eastern Express
Highway through the relatively less-congested roads of the Mumbai Port Trust
area. This freeway will drastically reduce travel time between Colaba in south
Mumbai and the eastern suburbs like Ghatkopar and Mulund. The four-lanes EFP,
which will start near the Chhatrapati Shivaji Maharaj Vastu Sangrahalaya, will go
on to the Mumbai Port Trust road before joining the EEH via the Anik-Panjrapole
link road, near Wadala, a distance of 12km. Of these, 9km will be elevated. This
project will consist of twin tunnel on BARC Mountain and will be approximately
half a kilometre in length each with 17 metres in width and 10 metres in height; it
will have four carriageways in each tunnel. Work on this freeway already started in
January 2008. This project will cost Rs. 650 crore

COMPONENTS OF FREEWAY

SITE LOCATION

PRE-CAST AND PRE-FABRICATED STRUCTURES

CASTING YARD SETUP

A casting yard is set up for casting
and storage of pre cast segments
prior to erection. It contains a
concrete batching plant, fabrication
yard, reinforcement jigs, and casting
beds. Supplementary concrete supply
is provided by an off - site plant
when required.
CASTING YARD LAYOUT

The casting yard brings factory

controlled production techniques,
efficiency and quality control to the bridge
construction. Casting of segments in a
separate area also removes casting
operation from the construction critical
path and reduces the overall construction

PRE-FAB YARD LAYOUT

time.
ADVANTAGES:
Environmental disturbance is reduced as all works are carried out

away from site.

Quality can be maintained.
Proper shape of segments can be obtained.
Casting of segment proceeds while piling works and other civil
works are carried out. Hence shorter duration of construction is
achievable.

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MATERIAL SUPPLIER:
READY MIX PLANT

Ready-mix concrete is concrete that is manufactured in a factory or batching plant,

according to a set recipe, and then delivered to a work site, by truck mounted
intransit mixers. This results in a precise mixture, allowing specialty concrete
mixtures to be developed and implemented on construction sites. Ready-mix
concrete is sometimes preferred over on-site concrete mixing because of the
precision of the mixture and reduced work site confusion. However, using a predetermined concrete mixture reduces flexibility, both in the supply chain and in the
actual components of the concrete.

STEEL YARD

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COMPONENTS OF BRIDGE:
SEGMENT

I-GIRDER

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FACTORY PROCESS FOR PRE-CAST : 1. SEGMENT

BED ALIGNMENT

FIXING OF REBAR
CAGE IN A JIG

FIXING OF END/OUTER
SHUTTER TO SOFFIT

SHIFTING OF REBAR
CAGE ON THE BED
FIXING OF
BULKHEAD

MAKING OF BULKHEAD

CONCRETING

DE-SHUTTERING AND
CURING

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FACTORY PROCESS FOR PRE-CAST : 2. I-GIRDER

CABLE PROFILE OF I GIRDER

REINFORCEMENT FIXING
OF I GIRDER

SHUTTERING OF I GIRDER
CONCRETING OF I GIRDER

STRESSING OF I GIRDER

DESHUTTERING OF I GIRDER

GROUTING OF I GIRDER

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COMPONENTS OF
LAUNCHING GIRDER
MAIN BOX GIRDER
FRONT SUPPORT
MIDDLE SUPPORT
REAR SUPPORT
REAR TROLLEY
SLIDER BEAM
COUNTER WEIGHT
FIXED MOUNTED HOIST
PLATFORM / WALK WAYS

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ERECTION OF PRE CAST : 1. SEGMENT

LIFTING ASSEMBLY

SEGMENT LIFTING

SEGMENT GLUING
STRESSING OF SEGMENT

SPAN LOADING

SHIFTING OF LAUNCHING
MACHINE
GROUTING

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PRE CAST CONCRETE PANEL FOR ABRTMENT

CONCRETING OF PRE CAST PANEL

SHUTTERING OF PRE CAST PANEL

BACKFILLING

PLACING OF FIRST LAYER OF

PRE CAST PANEL

COMPACTING FIRST LAYER

OF SOIL

ERECTING OF SECOND LAYER OF

PRE CAST PANEL

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ERECTION OF PRE CAST : 1. I GIRDER

LIFTING OF
I GIRDER

PLACING OF
I GIRDER

CASTING OF SLAB IN BETWEEN

OF THREE I GIRDER

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PRE CAST FACIA PANELS

REINFORCEMENT OF
CRUSH BARRIER

SHUTTERING OF FACIA PANEL

SHUTTERING AND CONCRETING

OF CRUSH BARRIER

DESHUTTERING AND CURING OF

CRUSH BARRIER

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