Precast Structure

1. INTRODUCTION

1.1 What is Pre-Cast?

Precast concrete is made with concrete cast in a reusable mould or form and
cured in a controlled environment then transported to the construction site
and lifted into place.

1.2 Where is it used?

Everywhere when the needs of the construction industry demand strength,

beauty, integrity and durability, precast/pre-stressed concrete is there. From
bridges of incomparable beauty and sustainability to office buildings that
blend with the environment. From the very latest in
manufacturing/processing plants to high-tech chip fabrication buildings.
Segmental bridges, air port control towers, college dormitories to huge
parking structures, they`re all about pre-cast/pre-stressed concrete.

1.3 What is pre-stressing?

Pre-stressed concrete is a method for overcoming concrete's natural

weakness in tension. It can be used to produce beams, floors or bridges with
a longer span than is practical with ordinary reinforced concrete. Pre-
stressing tendons (generally of high tensile steel cable or rods) are used to
provide a clamping load which produces a compressive stress that offsets the
tensile stress that the concrete compression member would otherwise
experience due to a bending load.

Pre- stressing can be accomplished in two ways.

1.3.1 Pre- tensioned concrete is cast around already tensioned tendons.

This method produces a good bond between the tendon and concrete, which
both protects the tendon from corrosion and allows for direct transfer of
tension. The cured concrete adheres and bond to the bars and when the
tension is released it is transferred to the concrete as compression by static
friction. Pretensioned elements may be balcony elements, lintel, floor, slab,
beam or foundation piles.

1.3.2 Post-tensioned concrete is the one in which tension is induced in the

element after casting the element it is done by means of high strength
tendons which impart tension to concrete when stretched by means of
hydraulic jacks. Pre-stressed concrete is the predominating material for

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floors in high-rise buildings, foundations for residential buildings in soft soil

areas, bridges and in the construction of water towers and water tanks. Post-
tensioning is also used to reinforce the large concrete chambers in nuclear
reactors.

1.4 Advantages of Precast Concrete.

Pre-cast/pre-stressed structural and architectural elements offer several

advantages over competing materials.

1.4.1 Quality Control: Precast/pre-stressed concrete is manufactured in

a controlled environment.

1.4.2 Durability: The high-strength, high-performance concrete that is

utilized in the production process resists weather, fire, corrosion, accidental
damage, fire and vandalism.

1.4.3 Speed of Construction: Pre-cast/pre-stressed concrete lends

itself to compressed construction schedules. Components are manufactured
off-site, allowing for just-in-time delivery systems. Speedy construction means
earlier completion dates which equals earlier occupancy.

1.4.4 Design Flexibility: The combination of standard structural shapes

(double-tees, hollow core, etc.) and the capability of casting custom shapes
give designers maximum flexibility. Economies of scale can be achieved
through repetition while plasticity of concrete allows for unique shapes.

1.4.5 Aesthetics: An infinite variety of sands, cements, aggregates and

pigments combine to achieve endless color, textures and finishes.

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1.5 Comparison Between Precast and RCC

Sr.
R.C.C Precast
no
30% to 40% of total Cross section 100% cross section area is
1
is utilized utilised
Section is uneconomical beyond
2 Economical upto span 25 to 30m
span of 10 to 12m
3 Self weight of section is higher. Self weight of section is lesser.
Cracking and Corrossion problems No cracking and corossion
4
are more. problems.
Reinforcement tendons can be
5 Reinforcement is striaght.
bent or have parabolic shapes.
Tension is developed below The whole cross section is in
6
neutral axis. compression.
Stresses are developed before
Stress are developed only after
7 loading due to pre-compressive
external load is allowed.
load.

Generally, in case of R.C.C structure the execution of the work is carried out
on site itself, but in case of precast first the products are manufactured in the
factory and then erection is done on site.

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2. TYPES OF PRECAST STRUCTURES

Following are the prominent structures built by precast technique.

2.1 Parking Garage.

2.2 Office Building.
2.3 Sports Facilities.
2.4 Warehouse.

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2.1 Parking Garage

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Parking structures are used to park the vehicles in densely populated areas.
Architect; engineer developer and owner have made precast and prestressed
material of choice for their commercial, municipal and institutional parking
needs.
They are subject to moving loads from automobile traffic and the roof level of
a parking structure is exposed to weather so requires consideration of
durability to weather so requires consideration of durability to ensure long
term performance. Precast structures overcome all the above limitation.
Durability chacarctertistics along with low cost, rapid erection in all weather
conditions, unlimited architectural expression long clear spans make precast
concrete the natural choice for parking structures.

2.2 Office buildings

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The benefits of precast concrete are no longer limited to just a few aspects of
design and construction. New advances and product innovations have pushed
precast to the forefront of durable economic building systems. With clear
advantages in increased strength, and load bearing capacity, precast
concrete continues to perform impressively in structural components. Wall
systems and prestressed precast concrete planks and decking speed
construction, meet or exceed most building codes, while at the same time
reduce the load on escalating labour costs. Uniquely designed and intricate
architectural panels feature a wide range of colors textures and special
surface effects of acid-etching, sandblasting, water blasting and grooving
among other innovative techniques. Precast's greatest asset, however, may
be its ability to built faster and more efficiently with significant savings in
overall costs.

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2.3 Sports Facilities

Modern sports facilities enhance community activities and stimulate

economic development. Precast concrete provides a variety of distinctive,
durable affordable choices. It provides durability, efficiency, comfort and
cost-effectiveness. It also offers a wide range of structural and architectural
shapes to provide design flexibility and aesthetic value. Floors, ramping and
mezzanine systems are also designed with precast products. Double tees,
prestressed solid slab and hollow core plank are commonly used for their
ability to span greater distances between intermediate beam bracing. These
products are utilized to minimize the structural depth of the floor system.
Other structural supporting elements include precast columns, raker beams
and other support beams, column, which can support the precast raker
beams, are generally located at a typical span to maximize production
repetition. Raker beams produced in a quality, controlled plant environment
can greatly minimize chance of error. The raker, which supports the seating,
set the elevation for the rows. Rectangular support beams can be used to
support flooring systems, stairway areas or to brace the raker beams.

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2.4 Warehouses

A warehouse is a commercial building for storage of goods. Warehouses are

used by manufacturers, importers, exporters, wholesalers, transport
businesses; customs, etc.They are usually large plain buildings in Industrial
areas of cities and towns. They come equipped with loading docks to load and
unload trucks, or sometimes are loaded directly from railways, airports, or
seaports. They also often have cranes and forklifts for moving goods.

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3. SPECIALIZED FLOORING SYSTEMS

Specialized prestressed concrete flooring systems for all domestic,

commercial and industrial applications is done by using hollow core slabs and
beam and block flooring system.

A hollow core slab is a precast, prestressed concrete member with

continuous voids. Hollow core slabs are to handle. Continuous voids in the
hollow core help to reduce weight and therefore, cost and as a side benefit to
use for concealed electrical or mechanical runs. Hollow core slabs are sound
proof and fire resistant.

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3.1 Advantages

1. Quick to install
2. Simple all weather construction.
3. Draught proof, rot proof and fire resistant.
4. Eliminates problems due to clay heave and shrinkage.
5. Better thermal insulation.
6. Immediate safe working platform.

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4. VARIOUS PRECAST ELEMENTS

4.1 Column

It is a vertical element which carries the load of structure and distributes the
load equally to the foundations. Column support girders and or spandrels at
all levels.
These are two types of columns.
Interior Columns
Exterior Columns.

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4.2 Double Tee (DT)

1. Primary horizontal precast element, bearing on columns or walls.

2. Name arises from peculiar cross section.
3. Consists of two vertical legs symmetrical about a center line with
a flange of varying widths that is used to connect multiple pieces
together.
4. DT has the ability to span large distances and carry significant
loads.
5. Used as flooring and roofing in parking structure separating the
main bays.

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4.3 Girder

Girder is a floor element, bearing on columns or walls providing bearing on

two sides for tees.

There are two types of Girder.

1. Inverted Tee Girder-called IT girder due to its inverted tee

shaped cross section.
2. L-Girder- usually found at stair towers, seperating the tower
from the main garage.Ledgeis at one side of the bottom of
throat.

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4.4 Spandrels

Spandrel is a beam type element, bearing on columns or walls and running

parallel to floor elements.

Architectural finishes are provided on the exterior exposed faces of

spandrels.

Following are the types of Spandrels:

1. Non-load bearing spandrel-Found on the main structure and do
not support any other element.
2. Load bearing spandrel-Found on the exterior of the main
structure and provide bearing on one side for tees and, in some
cases, solid slabs.

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4.5 Stairs

It is a member that connects two floor levels.

There are two types of stair.

1. Stair with landing.
2. Stair without landing.

Formwork

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Erection

4.6 Wall Panels

1. Wall panels located along the outer boundary of the structure are
called Exterior wall panels.
2. Wall panels located inside the structure are called as Interior wall
panels.
3. Wall panels designed to resist lateral forces are called as “shear
walls”.

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4. Panels are used to support stair, DT, floor slabs.

5.

Transportation Process

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This is the process in which the units are transported from site through
trucks for erection process.

6. Erection Process

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When these units are brought on site, the process of erection takes place by
assembling the units to connect them through welding process.

7. CONNECTIONS

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Importance of joints in precast construction

The complexity of joints in precast concrete construction present challenges

to the designer.
Prefabrication is done in three stages.

1. Casting of components- slabs, beams, column on construction site or

factory.
2. Erection of precast components.
3. Assembling components in proper position, alignment, through proper
joints

Principle requirements of connections (joints)

1. Connection must be adequate structurally.

2. Means of connection between adjacent members must allow safe and
speedy erection.
3. Physical details of joints and connection must permit economic
manufacturing.
4. Spacing must be provided for welding, insertion of gaskets and similar
operations in formation joints and connection.

Principle means of connection between precast elements.

1. Welding connection, bars, plates and bolted connection,

2. Prestressed connection.
3. Connection made by bolts, bolted brackets and plates.

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8. AGENCIES INVOLVED

A clear understanding of the responsibilities of each agency involved is an

important part of a successful precast concrete project. When roles are
defined, and the design/construction team is in sync, the process flows more
efficiently and greater economic and aesthetic benefits are realized. The
various agencies involved are,

 Owner
 General Contractor
 Architect
 Structural Engineer of Record
 Precaster
 Specialist Precast Engineer
 Detailers

General Architect Structural Engineer of Detailing

Contract Record Firm
Owner or

Precaster Erection
Crew

8.1 General Contractor

The GC is responsible for the construction means, methods, techniques and

procedures and has the authority and responsibility to implement the design
intends of the contract documents. The GC ensures the smooth and efficient
handing of submittal documents and the co ordination between subs.
Meetings are scheduled among the design team as required to resolve
construction and erection related conflicts.

8.2 Architect

The role of the architect is to develop the building design concept, establish
the overall geometry and select the appropriate building materials and
finishes. Drawing should clearly define the extend of the precast panels,
finishes, joints, corners, reveals and slab edge. Allowing the precaster to
suggest configurations and the opportunity to select which joints are 'false'
and which are 'real' will achieve greater economy and flexibility.

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Specifications and drawings should describe general performance criteria

and clearly define the scope and responsibilities of all parties. Once the
precast subcontract is awarded, the architect is asked to approve samples
and mock-ups and to respond tp aesthetic questions raised by the
construction team. The architect also reviews all submittals, requests for
information and the precast shop drawings to assure their overall
conformance with the contract documents.
8.3 Structural Engineer of Record

The Engineer of Record (EOR) is responsible for the overall structural design
of the completed facility. The EOR specifies the building framing systems,
loading criteria, applicable codes and any other special requirements the
precaster must consider in the design. This includes providing suggestion
connection concept, load points for bearing and tieback connections and any
special thermal or deflection limitations that need to be considered. While the
design of the connections is left to precaster,it is important that the bearing
locations and supplemental framing necessary to support the precast are
noted on the structural drawings. Supplemental support items such as
kickers, stiffners, out riggers and brackets are generally furnished and
installed by the steel supplier and designed by the EOR, so it is crucial they
are shown on the contract documents. This will allow them to be shop
installed for fireproofed before the precaster is on the site. The EOR also
defines and establishes interfacing details to other trades so that the extent
of the precast scope is clearly defined. When the precast shop drawings are
submitted, the EOR reviews them to ensure overall conformance with the
contract documents and to verify that the magnitude and location points
agree with the original design intent, It is always recommended that the EOR
involve the precaster early to help determine the most efficient connection
concepts.

8.4 Precaster

The precaster manufactures the precast units in accordance with standard

requirements for quality and maintains a safe and efficient production
facility. He provides embedded materials for connections, as well as loose
erection hardware for the attachment of precast panels to the building frame.
He either subcontracts or self-performs the erection in a safe manner, in
accordance with the predetermined delivery schedule. He ensures the
efficient and expeditious close out of the project, working to resolve punch-
list items to the satisfaction of the owner.

8.5 Specialist Precast Engineer

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The specialist precast Engineer performs component and connection designs

of the precast units and coordinates the interfacing with other trades. He has
to have a thorough knowledge of specifications, architectural and structural
drawings, and all correspondence on the project. He uses the contract
documents and specs to develop a comprehensive set of erection drawings
and shop drawings that are submitted to the GC for approval. He ensures
that all products conform to production, transportation and erection
department standards, practices and applicable codes. He also provides the
correct number of samples and mock-ups as needed to maintain a consistent,
high-quality product.

8.6 Detailer

Detailer performs all detailing functions including erection drawings, shop

drawings, material lists, and other as may be required. He ensures that these
drawings and list conform to production, transportation and erection
department standards and practices. He also provides preliminary hardware
details and quantities as early as possible and issues final material list when
erection drawings are approved. He has to have a thorough knowledge of
precast Engineer’s calculations and precaster’s standards. He is highly
skilled and understands every aspect of a present concrete operation. He sets
and maintains time schedules consistent with precaster’s needs and erection
department’s capabilities.
9. Conclusion

This seminar gives us the brief information that precast structure can shorten
the project timetable six to eight weeks when compared with steel and even
more when compared with casting place concrete construction. These
savings can be critical in bringing a new building into a competitive
marketplace or in meeting a tenant's need for occupancy on a specific date. A
total precast system's speed helps keep projects on track. Precast concrete
building systems are becoming a popular choice for many construction
projects. Architectural and structural precast, prestressed concrete
components can be combined to create the entire building.

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10. References

 Google.com
 Wikipedia.com
 Advance Construction Technique & Equipments
 Fundamental of Precast Structure.
 http://www.hanson.com.au/
 http://www.precaststructures.com/
 http://www.hansonpc.biz/aboutus/aboutus.shtml
 http://www.hansonpc.biz/casestudies/regency-case.shtml
 http://www.freepatentsonline.com/4669240.html
 Precast Concrete Structure (Multi-storey)- Kim. S. Elliott
 Building Structure- James. E. Ambrose

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