PRECAST CONCRETE

CONSTRUCTION
MOHAMMAD TAUWAB DANISH
B. ARCH 4TH YEAR SFS
What is Precast Concrete?
Precast concrete means a concrete member that is cast and cured at a
location other than its final designated location. The use of reinforced
concrete is a relatively recent invention, usually dated to 1848 when
jean- Louis Lambot became the first to use it. Joseph Monier, a French
gardener, patented a design for reinforced garden tubs in 1868, and
later patented reinforced concrete beams and posts for railway and
road guardrails.
 :

INTRODUCTION + + +/- Additives

CONCRETE MIX DEPENDS ON :

Compactibility
Workability Mobility
5 categories: Stability or cohesiveness
•Very high Water content in concrete mix
•High
•Medium Nature of aggregate particles
•Low (shape, surface, porosity)
•Very low
Strength
Finished surface
Consistency
Durability = Quality of material, environmental effect
SPECIFICATION OF CONCRETE
FEATURES
• 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.
Comparison
Site-cast Precast at plant
No transportation Transportation & elevation
capacity is limiting the size
The size limit is depending on Higher, industrialized
the elevation capacity only. quality -less affected by
weather
Lower quality because directly No space required on the
affected by weather site for fabrication
Proper, large free space Unlimited opportunities of
required architectural appearance
Option of standardized
components
Design concept for precast concrete buildings

The design concept of the precast

buildings is based on
• build ability.
• Economy
• standardization of precast components
Precast concrete structural elements
• Precast slabs
• Precast Beam & Girders
• Precast Columns

• Precast Walls

• Precast stairs
Types of pre-cast system
• Large-panel systems
• Frame systems
• Slab-column systems with walls
• Mixed Systems
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.
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.
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.
Lift-slab procedure
• pillars and the first package (e.g. 5 pieces) of slabs prepared at ground level
• lifting boxes are mounted on the pillars + a single slab lifted to the first-floor level.
• boxes are sequentially raised to higher positions to enable the slabs to be lifted to
their required final position - slabs are held in a relative (temporary) positions by
a pinning system
Slabs
Flat slab -
• Thickness of 4", 6" and 8"
• Spans up to 25’-0“
• Standard panel width =4’-
0"
• Typical designations = FS4
(FS = Flat Slab, 4 =
thickness of slab
Hollow Core slab-
• Thicknesses of 4", 6", 8", 10"
and12“
• Spans up to 40’-0“
• Standard panel width =4’-0“
• Typical designations = 4HC6
(4 = panel width in feet, HC=
Hollow Core, 6 = slab
thickness in inches)
Beams
Rectangular Beam (RB)-
• Typical beam width = 12" or16"
• Spans up to50’-0"
• Typical designation = 16RB24 (16 = width in inches, 24= depth ininches)
"L" and "IT" (inverted "Tee") beams (LB and IT)-
• Typically used tosupport slabs, walls, masonry, and beams
• Typical beam width= 12"
• Depths of 20", 28", 36", 44", 52" and 60"
Double Tee Beam (DT)-
• Combination beam and slab
• Spans up to 100’-0“
• Typical width= 8’-0"
• Depths of 12", 18", 24" and32"
• Designation=8DT24+2(8=width in
feet, 24=
• depth, +2 = 2"topping)
• Single Tee Beam (ST)-
• Combination beam and slab
• Spans up to120’-0“
• Typical width =8’-0"
• Typical depths of 36" and48"
• Designation = 8ST36+2 (8 =
width in feet, 24 = depth, +2=
2"topping)
Walls
Wall panels available in standard 8’-0" widths. Can be flat, or have
architectural features such as window and door openings, ribs, reveals,
textures, sandwich (insulation built-in), sculptured, etc.
Assembling….
Column to column connection
Beam to column connection
Beam-slab joints
Wall to slab connection

Precast concrete structure consisting of solid wall panels and hollow

core slabs.
Methods of Attachment of Precast Concrete
Members:
Weld Plates
The most common method
of attachment of precast
members is by use of steel
weld plates. Typically, the
precast members have
embedded plates that can
be used as welding surfaces
for loose connecting plates
or angles (see below):
Rebar and Grout
Used typically with
slabs, reinforcing bars
are spliced into slabs
and grouted in place
(see below):
Advantages Of precast concrete construction
• 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 intensive
• Reduce wastage of materials
• Easier management of construction sites
• Better overall construction quality
• Ideal fit for simple and complex structures
Disadvantages of Precast Concrete
Construction
• Very heavy members Camber inbeams and slabs
• Very small margin for error
• Connections may be difficult
• Somewhat limited building design flexibility
• Because panel size is limited, precast concrete cannot be used for two-way
structural systems.
• Economics of scale demand regularly shaped buildings.
• Need for repetition of forms will affect building design.
• Joints between panels are often expensive and complicated.
• Skilled workmanship Is required in the application of the panel onsite.
• Cranes are required to lift panels.
Limitations
• size of the units.
• location of window openings has a limited variety.
• joint details are predefined.
• site access and storage capacity.
• require high quality control.
• enable interaction between design phase and production planning.
• difficult to handling & transporting.
Popular Uses of Precast Concrete
• Concrete curtainwalls
• As an exterior cladding (may include exposed aggregate)
• For structural walls
• Ability to precast in three dimensions allows precast panels to form
parts of mechanical systems
Scheduling
• emplacement of hollow core floor slabs 300 m2/day
• erection of pillars/columns - 8 pieces/day
• emplacement of beams - 15 pieces/day
• emplacement of double tee slabs - 25 pieces/day
• emplacement of walls - 15 pieces/day
• construction of stair and elevator shafts 2 floors/day
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. o
Reduce adverse environmental impact on sites.
• Enhance quality control of concreting work. o Reduce the amount of
site labour. o Increase worker safety.
• Other impediments to prefabrication and preassembly are increased
transportation difficulties, greater inflexibility, and more advanced
procurement requirements.