CHAPTER 1

INTRODUCTION

Precast concrete is a construction product produced by casting concrete in a reusable

mould or "form" which is then cured in a controlled environment, transported to the
construction site and lifted into place ("tilt up"). In contrast, standard concrete is poured
into site-specific forms and cured on site. Precast stone is distinguished from precast
concrete using a fine aggregate in the mixture, so the final product approaches the
appearance of naturally occurring rock or stone. More recently expanded polystyrene is
being used as the cores to precast wall panels. This is lightweight and has better thermal
insulation.

Precast is used within exterior and interior walls. By producing precast concrete in a
controlled environment (typically referred to as a precast plant), the precast concrete is
afforded the opportunity to properly cure and be closely monitored by plant employees.
Using a precast concrete system offers many potential advantages over onsite casting.
Precast concrete production can be performed on ground level, which helps with safety
throughout a project. There is greater control over material quality and workmanship in a
precast plant compared to a construction site. The forms used in a precast plant can be
reused hundreds to thousands of times before they have to be replaced, often making it
cheaper than onsite casting when looking at the cost per unit of formwork.

There are many different types of precast concrete forming systems for architectural
applications, differing in size, function, and cost. Precast architectural panels are also
used to clad all or part of a building facades or free-standing walls used for landscaping,
soundproofing, and security walls, and some can be pre-stressed concrete structural
elements. Storm water drainage, water and sewage pipes, and tunnels make use of precast
concrete units.

Precast wall panel types — sandwich, plastered sandwich, inner layer and cladding
panels, many surface finishes are available. Standard cement is white or grey, though
different color can be added with pigments or paints. The color and size of aggregate can
also affect the appearance and texture of concrete surfaces. The shape and surface of the

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precast concrete moulds have an effect on the look: The mould can be made of timber,
steel, plastic, rubber or fiberglass, each material giving a unique finish

1.1 History

Ancient Roman builders made use of concrete and soon poured the material into moulds
to build their complex network of aqueducts, culverts, and tunnels. Modern uses for pre-
cast technology include a variety of architectural and structural applications — including
individual parts, or even entire building systems.

In the modern world, precast panelled buildings were pioneered in Liverpool, England, in
1905. The process was invented by city engineer John Alexander Brodie, a creative
genius who also invented the idea of the football goal net. The tram stables at Walton in
Liverpool followed in 1906. The idea was not taken up extensively in Britain. However, it
was adopted all over the world, particularly in Eastern Europe and Scandinavia.

In the US, precast concrete has evolved as two sub-industries, each represented by a
major association. The precast concrete products industry focuses on utility, underground
and other non-prestressed products, and is represented primarily by the National Precast
Concrete Association (NPCA). The precast concrete structures industry focuses on pre-
stressed concrete elements and on other precast concrete elements used in above-ground
structures such as buildings, parking structures, and bridges. This industry is represented
primarily by of the Precast/Pre-stressed Concrete Institute (PCI).

In Australia, The New South Wales Government Railways made extensive use of precast
concrete construction for its stations and similar buildings. Between 1917 and 1932, they
erected 145 such buildings. Beyond cladding panels and structural elements, entire
buildings can be assembled from precast concrete. Precast assembly enables fast
completion of commercial shops and offices with minimal labour. For example, the Jim
Bridger Building in Williston, North Dakota, was precast in Minnesota with air,
electrical, water, and fibre utilities preinstalled into the building panels. The panels were
transported over 800 miles to the Bakken oilfields, and the commercial building was
assembled by three workers in minimal time. The building houses over 40,000 square feet
of shops and offices. Virtually the entire building was fabricated in Minnesota.

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 CHAPTER 2

LITERATURE REVIEW

N.Dineshkumar , P.Kathirvel (2015) studied the present situation of the precast

construction industry in India. Suggestions for improvement of the industry and study on
cost effectiveness of precast concrete construction for single and multi-story residential
buildings are to be given. A literature survey was carried out in order to obtain the
comparison between the conventional buildings with precast concrete buildings in India
and some field visits are conducted to collect data to investigate the current situation
regarding precast industry in India. In order to compare the cost of precast and in-situ
construction, double storey residential buildings is considered.

The main goals of the work have been achieved. The total cost and total duration for the
double storey residential building have been determined for both prefab and conventional
construction. And also we had known about the advantages and disadvantages of both
prefabrication and conventional construction by the survey conducted in similar
companies. The comparison showed there is enormous cost difference between the
methods, which the prefab is very high when compared to conventional on this type of
individual houses. The prefab construction for individual double storey residential
building cost is 13% more than the conventional construction. This is main drawback for
prefab construction which is not economical to construct in this case. At the same time
the prefab construction is easy to work and reduces the project duration, is reduced by 63
days when compared to the conventional. It’s the main advantages for prefab construction
and also it helps when there is labour shortage. As a result of survey we had known that
the prefab construction have more advantages and procurement in industrialized, heavy
infrastructures. But in individual houses there are lot of constraints and lack of knowledge
its get struggling to implement in our country. At this stage conventional construction is
economical and comfortable when compared to the prefabrication construction.

N. ROSSLEY, F. N. A. A. AZIZ, H. C. CHEW (2014) studied on the connection

between the exterior and interior precast concrete walls. The connection between the
walls is called loop bars connection. Between the looping bars, one transverse bar is

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inserted as to ensure connectivity of all the looping bars. This connection produces a gap
between the walls, which would then be filled with concrete to produce rigid connection.
The main objective of these experimental studies is to determine behaviour of loop bars
connection under shear loading. From a visual observation, most concrete crushing and
spalling was concentrated at the joint. Strut and tie model of loop joint used to model
flow of forces in the connection. The crack showed zigzag pattern and it was developed
as the force from one precast element to the other was being transferred by inclined
compressive struts between overlapping loop bar. The connection shows a ductile
behaviour by producing a few line cracks and having a large deflection to give a warning
before failure. This ductility is within the acceptable ductility of a structure. Therefore, it
is recommended to the construction industry to adopt this kind of connection design
which can be used for medium rise precast building.

Dr.TanutWaroonkun (2011) Construction technology utilizing prefabricated concrete

elements is known as a ‘precast concrete system’. In Western countries, this system has
been widely used in constructing bridges, office buildings and residential buildings. A
precast concrete construction system provides the advantages of construction
effectiveness, high levels of quality control, saving of construction time, minimisation of
skilled labour, reduced manpower requirements on site, and saving in formwork
requirements when compared with the traditional construction method (cast-in-place
concrete). In Thailand, cast-in-place is the traditional construction system that has been
mostly used to this point. Precast concrete floor slabs are the only a prefabricated
elements used widely in Thailand. Only a few parties in the Thai construction market
have adopted fully precast concrete systems. However, many factors have an impact on
the adoption of precast concrete system. This paper presents and analyses a conceptual
model that accommodates the numerous factors impacting the effectiveness of the
adoption process. The results of a survey of 160 construction industry professionals in
Thailand are presented and the significant factors which impact the adoption of precast
concrete systems are determined through statistical analysis. The paper concludes with an
analysis of the significant factors in the adoption of precast concrete elements and system.

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 CHAPTER 3

PRECAST STRUCTURAL SYSTEM

Precast concrete is a structural material that can be used as the primary structural system
of a building transferring roof, floor, and lateral loads. Precast enables designers to
integrate structural and envelope (architectural) systems reducing the total materials,
detailing, costs, construction complexity, and more. The design versatility of precast
concrete allows for almost any shape element, such as curved and radial sections, with
flexibility in connection points and load paths. High strength, pre-stressed concrete
structural members also deliver exceptional load-carrying capacity, which can result in
smaller sections, longer spans, or both when compared to other structural systems. The
design of precast, pre-stressed concrete structures depends on the integration of the
structural system as a whole, the connections, and the individual components. Each aspect
must consider the others as well as the functional requirements imposed by the building
use. It is essential that design loads follow a load path from their point of origin to the
final support or foundation. Although not always required by code, it is desirable to
design the members and their connections to achieve a ductile, rather than a brittle, failure
mode. In addition to resisting gravity loads, a principal consideration in building design is
the lateral force-resisting system. There are a variety of precast concrete designs that can
be used to achieve these goals economically and effectively. Precast structural systems
can be designed as shear wall, moment resisting, or hybrid systems.

Figure:3.1 Components of Precast Building

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3.1 Advantages of Precast Structures

 Inherent Fire Properties - Concrete has its own inbuilt fire resistance which is
present during all construction phases. Fire resistance is typically achieved
without the application of additional sprays or linings. This is an important
inherent advantage over steel and timber solutions. Precast frames are generally
designed for one-hour inbuilt fire rating. This either totally eliminates or greatly
reduces the need for additional fire protection and the associated costs.

 Economies are generated through reduced requirements for formwork, access

scaffolding and less reliance on wet trades. Reduced on-site supervision by the
main contractor is also a saving. Compared to cast in situ concrete, the following
savings can be expected: Formwork & Scaffolding required are reduced.

 Health & Safety - Once precast floor slabs are installed,they provide a safe
working platform for site operatives. Simultaneously installing precast stairs
offers safe and easy access between floors.

 Reduced Construction Programme, due to speed of construction, gives earlier

return on investment, freeing up the project critical path and allowing earlier
completion. It is estimated that a precast structure takes less time to construct than
a similar cast in situ structure.

 Greater Project Control from a completion/project management perspective and

from a costing perspective.

 Factory Production ensures increased accuracy and quality of finish and decreases
weather dependency. Compared with cast in situ structures, site labour is reduced
using precast.

 Build ability - Precast frames can greatly improve build ability because sensitive
parts of the operation can be moved from the site to the factory.

 Larger Clear Spans - Reducing the number of columns is critically important in

developments such as sports stadia and car parks. Longer spans and shallower
construction depths can be obtained by using pre-stressed concrete beams and
floors.

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  Proven Designs and Methodologies - Precast frame design incorporates proven
designs and methodologies which have been developed over many years.

 Sound Resistance - Precast structures meet the highest standards for resistance to
sound transmission.

 Composite Action – Pre-stressed precast elements act compositely with an in situ

structural screed (topping), combining the benefits of precast and in situ
construction.

 Less Wastage - Precast systems significantly reduce the amount of waste materials
produced on site.

 Loose Reinforcement - The amount of loose reinforcement on site is reduced.

 Air tightness - Air infiltration in precast buildings is minimal because of the

relatively small number of joints in the construction. This factor combined with
the thermal mass of concrete gives excellent thermal performance.

 A Complete Service from design to manufacture to installation is available.

3.2 Disadvantages of Precast Structures

There are some disadvantages to precast concrete they are
3.2.1 High initial investment
For installing a precast concrete plant,heavy and sophisticated machines are necessary
which requires a high initial investment. A large scale of precast construction projects
must be available to ensure sufficient profit.
3.2.2. Transportation issue
The construction site be at a distant location from the precast concrete plant in that case
,theprecast members must be carried to the site using trailers .In many cases, the reduced
costs of precast concrete is compensated by the transportation cost .
3.2.3.Handling difficulties
Proper care and precaution have to be taken for handling precast concrete usually,precast
members are heavy and large which makes it difficult to handle without damage.
Generally
portable or tower cranes are used to handle precast members.

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3.2.4.Modification
Limitation in the case of precast structures. It is difficult to modify the structure for
example if a structural wall is to be modified it will impact stability of the structure.
3.2.5. Sensitive connection works
Assembling of the precast members is one of the key points for ensuring strong structural
behaviour. Connections between several structural members must be supervised and done
properly to ensure the intended behaviour of the connection such as simple semi rigid or
rigid connections. Besides this, faulty connections may lead to water leakage and fail.

Figure:3.2 Comparison between precast and poured concrete

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 CHAPTER 4

TYPES OF PRECAST ELEMENTS

4.1Types of Preacast Elements

4.1.1 Hollow Core Slabs

Pre-stressed precast hollow core slabs are the most widely used type of precast flooring.
The system offers numerous benefits to engineers and architects because it gives
maximum strength with minimum weight, versatility in span / depth ratio, a smooth soffit
and a high speed of erection leading to an economical way to construct floors.

Precast manufactures a full range of hollow core slabs with thicknesses ranging from
165mm to 500mm, with longest spans up to 22 meters.

Figure:4.1 Hallow Core Slabs

4.1.2 Pre-Stressed Beams

Precast Bridge Beams are capable of spanning long distances, with maximum spans of
up to 45 meters depending on loads. They can be used for applications such as fly-over
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bridges on motor ways, pedestrian bridges, commercial developments, marine jetties
among many others. They come in a variety of shapes and sizes, depending on the
requirements of a particular job.

Figure: 4.2 Pre-Stressed Beams

4.1.3 Insulated Sandwich Walls

Insulated precast concrete walls consist of two concrete layers joined by stainless steel
connectors with an insulating layer between them. The insulation layer is continuous over
the entire surface area without any thermal bridges and its thickness is determined by the
insulation value required. The thinner external layer can be made in a variety of concrete
colours and surface treatments while the internal, often load-bearing layer is normal grey
concrete. Insulation of walls reduces both construction cost and operating cost. The
operating cost is significantly lower.

 The Developer benefits through reduced initial investment for the cooling systems

 The Owner / Resident benefit through reduced electricity consumption

 The Country benefits through a reduced Carbon Footprint

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 Figure: 4.3 Insulated Sandwich Walls

4.1.4 Solid Walls

Load bearing wall systems are used most commonly in buildings where the room sizes
are small such as low-rise accommodation buildings, villas, hostel buildings and
apartment buildings. External walls of the buildings can be insulated. All internal load-
bearing walls are solid walls while all non-load-bearing walls can either be precast or
done with other systems as preferred.

Figure: 4.4 Solid Walls

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4.1.5 Cladding Panels

Precast concrete panels are reinforced concrete units available in a wide range of mixes,
colours and finishes. Finishes can include acid-etched, smooth or coarse ground, grit or
sand-blasted, rubbed or polished and exposed aggregate. Mixes designed to resemble
natural stone can also be produced. Highly articulated designs can be accommodated by
the mouldable concrete mix.

Figure: 4.5 Cladding Panels

4.1.6 Stairs

Precast Stairs can be placed along with Precast Concrete Flooring giving immediate safe
access to upper floors quickly and efficiently. All precast Stair and landing units are
designed in accordance with relevant BS and ACI codes.

Figure: 4.6 Stairs

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4.1.7 Beams

Precast Beams provide a flexible solution to the structural component of your project.
Precast Beams can be used for a number of applications from parking structures to the
structural framework of commercial buildings. Precast beams are perfect for underground
parking structures where the efficiency of the floor utilization can be increased, reducing
the size of the lot needed. Beams create an ideal framework for hanging Precast Structural
and Architectural Wall Panels and setting Hollow core floors or solid slabs.

Figure: 4.7 Beams

4.1.8 Columns

Precast Columns can be single-tier or multi-tiered as required. Use of precast columns

will expedite the project, as there is no requirement to wait for the curing as there is with
cast-in-situ columns.

Column connections are often made using grouted sleeves, but bolted or socket
connections are also used.

Figure:4.8 Columns

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4.1.9 Boundary Walls

As boundary walls are widely used in the Gulf Region to define the plot limit and to give
privacy to the villas, offices, factories, farms etc., decorative features such as logos,
screens and other contemporary designs can be built into the boundary walls to suit the
need and taste required for individual project. The system also provides almost no
maintenance cost as most of our precast surfaces require only a wash with water to retain
their attractiveness.

Figure: 4.9 Boundary Walls

4.1.10 Tunnel Lining & Segments

Precast Tunnel Lining is commonly used for large diameter tunnels throughout the world.
The manufacture of the large, heavy components to extremely tight tolerances is a
demanding task. We have gained substantial experience in numerous projects in South
East Asia on various types of tunnelling jobs.The tunnelling industry has widely adopted
segmental lining systems for the construction of tunnels. These have made the safe
construction of tunnels in soft ground beneath the water table both technically and
economically feasible.Large segments with extremely stringent dimensional tolerances
require the use of the highest quality steel moulds. The quality is controlled in every stage
of the production from the raw materials and moulds to the workmanship at the shop
floor.

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 Figure: 4.10 Tunnel Lining & Segments

4.1.11 Box Sections, Drains, Culverts, Chutes, Trenches

Precast reinforced concrete box culverts are primarily used for transmitting storm water
and for short-span bridges. Box culverts are manufactured in standard section lengths,
with other lengths available on request. Our industry-leading Super Box culverts,
consisting of stacked top and bottom boxes, are designed for increased flow or where
longer spans or higher rises are required.

Precast Drain channels and boxes can be used for efficient storm water management and
drainage solutions. These can be covered or open as required. Precast trenches are
normally used for laying and the protection of electrical cables.

Figure:4.11 Box Sections

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4.1.12 Bridge Beams & Girders

Precast Beams are commonly used for long span bridge and girder structures throughout
the world. The beams are either pre-tensioned or post tensioned as per the Engineer’s
detail.

Our range of precast concrete bridge girders are manufactured to precise tolerances.

Utilization of precast ensures easy installation, minimizing on-site time and disruptions to
traffic. Production in a factory environment ensures high workmanship and quality
products. Our full range of standard bridge girders include:

 Y and SY beams

 TY and T beams

 M and UM beams

 U beams

 Box beams

Figure: 4.12 Bridge Beams

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4.1.13 Precast Railway Sleepers

Precast Railway Sleepers are another highly demanding precast component due to
extremely high tolerances and quality requirements. As our group is an approved supplier
to railway authorities in South East Asia, our technical expertise will ensure we can
produce sleepers according to any international standard, speed or loading requirement.

Figure: 4.13 Precast Railway Sleepers

4.1.14 Retaining Wall Structures

Designed to provide a cost-effective, versatile solution for a wide variety of earth

retention and material storage uses, Precast retaining wall units are available in a tailor-
made range of widths and heights as required for each purpose specifically

Figure: 4.14 Retaining Wall

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 CHAPTER 5

TYPES OF PRECAST SYSTEMS

Depending on the load-bearing structure, precast systems can be divided into the
following categories:

 Large-panelsystems

 Framesystems

 Slab-column systems withwalls

 Mixed systems

5.1 Large Panel System

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 horizontalelements

act as diaphragms that transfer the lateral loads to the walls.

Depending on wall layout, there are three basic configurations of large-panelbuildings:

 Cross-wallsystems

 Longitudinal wallsystems

 Two way systems

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Figure: 1.17A large-panel concrete building under construction

1.18 Precast shear wall structure

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5.2 Frame system

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. The components of a precast reinforced concrete frame are shown inFigure.

Figure: 1.19Frame System

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5.3 Slab Column System 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 withwalls

• Pre-stressed slab-columnsystem

Figure: 1.20 A lift-slab building

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.

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 CONCLUSIONS

• This type of construction can be done anywhere within a short period of time with
high quality and durability. The quality and durability is high because these precast
elements are cast at high controlled conditions.

• This construction decreases the man power as the machinery play a major role in
the construction from bar bending to casting and erection.

• The main challenge in this construction is connection of precast elements which is

done by some high standard materials and also by some structural design given by the
designer.

• Safety plays a major role in the precast construction as the erection of precast
elements is a tough job. This construction is advisable for the fast development with high
standard of construction.

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 REFERENCE

[1] Precast and Prestressed Concrete, PCI Design Handbook.

[2] IS 15916-2011 Building Design and Erection Using Prefabricated Concrete.

[3] Dinesh kumar and Kathirvel P (2015)., ‘comparative study on prefabricated

construction with cast in situ construction of residential building’ – International Journal
of Innovative Science Engineering and Technology, vol.2, No.4, pp.527-532.

[4] Rinkesh Patel and Dr.Neeraj Sharma, ‘Study of prefabrication in India’ –

International Journal of advanced research in Engineering, Science and Management,
ISSN: 2394-1766

[5] https://www.inventaa.com/content/building-products

[6] https://www.dubaiprecast.ae/products.

[7]Prestressed Concrete by N. Krishna Raju

[8] Design of Prestressed Concrete Structures by T.Y. Lin (Author), Ned H. Burns
(Author)

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APPENDIX

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