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Building Technology 05 (Cast-In Place & Pre-Cast, Floor System & Roof Slab System, Prestressed Concrete)
Building Technology 05 (Cast-In Place & Pre-Cast, Floor System & Roof Slab System, Prestressed Concrete)
IV. References
I. CAST-IN PLACE & PRE-CAST
The formwork used for cast-in-place concrete defines the final shape of the
structure or product. Plywood and milled lumber are commonly used
formwork material which can be made from waste material. The formwork
can be dismantled easily and reused many times, making it an economical
option.
1
CAST-IN-PLACE APPLICATIONS
Builders design CIP concrete with several unique decorative aggregates to
enhance the structure’s visual appeal, depending on the application. Most of
the time, contractors tend to use cast-in-place, or site-cast, concrete for
their:
Basement walls: CIP concrete walls are common for
basement construction because of their structural integrity and
resistance to moisture and weather damage.
Columns: CIP concrete columns can ease the burden of the structural
load of your building. When mixed with colorful aggregates, they could
also improve the design of a building.
2
ADVANTAGES OF CAST-IN-PLACE CONSTRUCTION
VERSATILITY It may be used to construct a wide variety of different
types of homes and buildings.
3
CAST-IN-PLACE CONSTRUCTION
The general process flow with cast in site Construction starts with formwork
and Reinforcement being prepared and erected. Both form work and
reinforcement need to be in place before any concrete related activity can
begun.
Forms are structural units designed to support and mold freshly placed
concrete while it cures and strengthens. They are generally temporary
however, they are occasionally designed to be left permanently in place
within the structure as stay in place formwork.
Usually within a few days, the concrete is strong enough to support its
design load and the formwork can be removed to be used elsewhere on the
site. Re- shoring is used to replace the formwork and continue to support the
concrete while construction loads are applied to it.
When all the framework and reinforcement are in place,wet concrete then is
delivered and is placed in the form work around the reinforcement. Exposed
concrete surface requiring leveling and smoothing are finished and curing
begins. During curing steps are taken to control the temperature and
moisture levels of concrete.
4
Monolithic concrete placement is
when concrete is deposited in
one large formwork system
which is made up of several
smaller formwork systems each
corresponding to a different
concrete member.
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CAST-IN-PLACE STRUCTURES
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1.2 PRE-CAST CONCRETE
Precast concrete is a form of concrete that is prepared, cast and cured off-
site, usually in a controlled factory environment, using reusable molds.
Precast concrete elements can be joined to other elements to form other
elements to form a complete structure. It is typically used for structural
components such as; walls panels, beams, columns, floors, staircases,
pipes, tunnels, and so on.
Precast concrete members are cast and cured at a precast plant and then
transported to site and only jointing will be done at the site.
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PRE-CAST APPLICATIONS
PRE-CAST INSTALLATION
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ADVANTAGES OF PRE-CAST CONSTRUCTION
This means that the quality of precast components can be very high. Since
the components can be made beforehand, construction can be very quick. In
cast-in-situ construction, engineers have to build each set
of components after the previous set has finished, which does take time,
as concrete generally takes 28 days to reach its full strength.
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PRE-CAST CONSTRUCTION
The concept of precast 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 large number of buildings in a
short time at low cost.
Large-Panel Systems
The designation “large-panel system”
refers to multistory structures
composed of large wall andfloor
concrete panels connected in the
vertical and horizontal directions so that
the wall panels enclose appropriate
spaces for the rooms withina building.
These panels form a box-likestructure.
Both vertical and horizontal panelsresist
gravity load.
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Dry joints are constructed by bolting
or welding together steel plates or
other steel inserts cast into the ends
of the precast panels for this purpose.
The force transfer in structures with
dry joints is accomplished at discrete
points.
Frame Systems
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PRECAST PLANKS ARE INSTALLED PREPARATION FOR CASRING
IN PLACE OF LANDING SLAB TO PRECAST
STAIRCASE
12
PRE-CAST STRUCTURES
13
PRE-CAST CONCRETE BUILDINGS
14
School of Economics and Business, Diego Portales University
(Huechuraba,Chile)
The two buildings share a courtyard but are also linked by subterranean
tunnels. The precast exterior walls are meant to age with time (and last a
lifetime) and a rooftop garden was added to help the building become one
with the landscape.
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1.3 CAST-IN-PLACE VS. PRE-CAST
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CAST-IN-PLACE VS. PRE-CAST
Perhaps the best way to see just how great precast concrete is to highlight
the differences between precast and site cast concrete directly. Here are
some key aspects between the two methods placed side-by-side.
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Full strength: Because concrete gains strength over time, it isn’t fully
strong immediately after drying. However, with precast concrete, that
hardening process takes place before arriving on the job site. That’s not the
case with site cast concrete. Before you can raise the concrete into place,
you have to wait for site cast concrete to harden fully. This can delay
construction and increase costs. It is much more time and cost efficient to
have fully hardened concrete slabs ready to be placed the moment they
arrive.
Furthermore, because precast receives a strength test during quality control
inspections in the factory, you do not need to conduct strength tests on
site. Strength tests are extremely crucial for ensuring that your building is
safe, so if you are doing on site casting, then this is a step that cannot be
skipped.
Cast ahead of time: With precast concrete, you can do the casting of your
materials ahead of time, holding them until they are needed. Unfortunately,
overlapping tasks and improving efficiency is all but impossible with site cast
concrete. Because of the amount of space and labor required for on-site
casting, you generally have to stop construction while you wait for your
materials to be ready. This is a costly way to stand around and wait.
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Insulation: Because precast concrete is factory made, certain elements can
be incorporated within the concrete that cannot be added to site cast
concrete. Added insulation is one of the most common elements. By adding
additional insulation materials within the concrete slab, you can save both
labor and architectural design space when constructing a building. Rather
than hanging and lining the interior of your building with insulation, the slabs
that you lift into place with have the insulating power of traditional concrete
with additional hung insulation.
As more builders are chasing green ratings for their building, both for the
good PR and the energy savings over the life of the building, precast
concrete offers a distinct advantage.
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II. FLOOR SYSTEM AND ROOF SLAB SYSTEM
ONE-WAY SYSTEMS
A one-way reinforced
concrete floor or roof
system consists of members
that have the main flexural
reinforcement running in one
direction. In other words,
reactions from supported
loads are transferred primarily
in one direction. Because they
are primarily subjected to the
effects from bending (and the
accompanying shear),
members in one-way systems FIGURE 1 One-way slab system
are commonly referred to
as flexural members.
The beams, in turn, transfer the loads to the girders, and the girders
transfer the loads to the columns.
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Main flexural reinforcement for
the one-way slabs is placed in
the direction parallel to load
transfer, which is the short
direction. Similarly, the main
flexural reinforcement for the
beams and girders is placed
parallel to the length of these
members. Concrete for the
slabs, beams, and girders is
cast at the same time after the
forms have been set and the
reinforcement has been placed FIGURE 2 Standard one-way joist system
in the formwork. This concrete
is also integrated with columns.
In addition, reinforcing bars are extended into adjoining members. Like all
cast-in-place systems, this clearly illustrates the monolithic nature of
reinforced concrete structural members.
21
TWO-WAY SYSTEMS
As the name suggests, two-way floor and roof systems transfer the
supported loads in two directions. Flexural reinforcement must be provided
in both directions.
22
Similar to the flat plate system is
the flat slab system (Fig. 6).
Drop panels are provided around
the columns to increase moment
and shear capacity of the slab.
They also help to decrease slab
deflection. Column capitals or
brackets are sometimes provided
at the top of columns.
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2.1 FLAT SLAB
Flat slab is a reinforced concrete
slab supported directly by concrete
columns without the use of beams.
Flat slab is defined as one sided or
two-sided support system with
sheer load of the slab being
concentrated on the supporting
columns and a square slab called
‘drop panels’.
flat slab construction with drop panel and column head
Flat Slabs are considered suitable for most of the construction and for
asymmetrical column layouts like floors with curved shapes and ramps etc.
The advantages of applying flat slabs are many like depth solution, flat
soffit and flexibility in design layout. Even though building flat slabs can be
an expensive affair but gives immense freedomto architects and engineers
the luxury of designing.
This form of construction has become less popular in recent years because
of the limit on economical spans of about 9.5 m for reinforced slabs and
about 12 m for prestressed slabs. Reinforced flat slabs may need to be
sensibly pre-cambered (not overdone) to control deflection.
The plan dimensions of the drop panels are a minimum of 1/3 of the span in
the direction under consideration, usually rounded to the nearest 100 mm.
The overall depth of the drop panel is typically taken as 1.75 to 2 times the
depth of the slab, again rounded to suit timber sizes or the nearest 25 mm.
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VARIOUS FLAT SLAB SYSTEMS
ADVANTAGES
Simple formwork
No beams—simplifying under-floor services outside the drops
Minimum structural depth
Usually does not require shear reinforcement at the columns.
DISADVANTAGES
Medium spans
Generally not suitable for supporting brittle (masonry) partitions
Drop panels may interfere with larger mechanical ducting
Vertical penetrations need to avoid area around columns
For reinforced flat slabs, deflection at the middle strip may be critical.
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2.2 FLAT PLATE
A flat plate is a one- or two-way
system usually supported directly on
columns or load bearing walls. The
principal feature of the flat plate floor
is a uniform or near-uniform thickness
with a flat soffit which requires only
simple formwork and is easy to
construct.
The floor allows great flexibility for
locating horizontal services above a
suspended ceiling or in a bulkhead. The
economical span of a flat plate for low to Flat plate floor system
medium loads is usually limited by the need to control long-
term deflection and may need to be sensibly pre-cambered (not overdone)
or prestressed.
ADVANTAGES
Simple formwork and suitable for direct fix or sprayed ceiling
No beams—simplifying under-floor services
Minimum structural depth and reduced floor-to floor height
DISADVANTAGES
Medium spans
Limited lateral load capacity as part of a moment frame
May need shear heads or shear reinforcement at the columns or larger
columns for shear
Long-term deflection may be controlling factor
May not be suitable for supporting brittle (masonry) partitions
May not be suitable for heavy loads.
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2.3 RIBBED AND WAFFLED FLOOR SLAB
Ribbed and waffle slabs provide a lighter and stiffer slab than an
equivalent flat slab, reducing the extent of foundations. They provide a
very good form of construction where slab vibration is an issue, such as
laboratories and hospitals.
Ribbed slabs are made up of wide band beams running between columns
with narrowribs spanning the orthogonal direction. Normally the ribs and
the beams are the samedepth. A thin topping slab completes the system.
Waffle slabs tend to be deeper than the equivalent ribbed slab. Waffle
slabs have a thin topping slab and narrow ribs spanning in both directions
between column heads or band beams. The column heads or band beams
are the same depth as the ribs.
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Ribbed floors consisting of equally spaced ribs are usually supported directly
by columns.They are either one-way spanning systems known as ribbed slab
or a two-way ribbed system known as a waffle slab. This form of
construction is not very common because of the formwork costs and the low
fire rating. A 120-mm-thick slab with a minimum rib thickness of 125 mm
for continuous ribs is required to achieve a 2-hour fire rating. A rib thickness
of greater than 125 mm is usually required to accommodate tensile and
shear reinforcement. Ribbed slabs are suitable for medium to heavy loads,
can span reasonable distances, are very stiff and particularly suitable where
the soffit is exposed.
Slab depths typically vary from 75 to 125 mm and rib widths from 125 to
200 mm. Rib spacing of 600 to 1500 mm can be used. The overall depth of
the floor typically varies from 300 to 600 mm with overall spans of up to 15
m if reinforced, longer if post-tensioned. The use of ribs to the soffit of the
slab reduces the quantity of concrete and reinforcement and also the weight
of the floor. The saving of materials will be offset by the complication in
formwork and placing of reinforcement. However, formwork complication is
minimised by use of standard, modular, reusable formwork, usually made
from polypropylene or fibreglass and with tapered sides to allow stripping.
For ribs at 1200-mm centres (to suit standard forms) the economical
reinforced concrete floor span ‘L’ is approximately D x 15 for a single span
and D x 22 for a multi-span, where D is the overall floor depth. The one-way
ribs are typically designed as T-beams, often spanning in the long direction.
A solid drop panel is required at the columns and loadbearing walls for shear
and moment resistance.
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USES AND APPLICATIONS
Savings on weight and materials Long spans
Attractive soffit appearance if exposed
Economical when reusable formwork pans used
Vertical penetrations between ribs are easy.
Soft ground conditions. Extra bored piers or screw piers are
required so that the system is supported on strong ground.
Sloping sites. Waffle slabs are built on flat sites. On sloping blocks, the
ground has to be made level first by digging some of it out or filling
some of it in. Problems arise when some of the dirt dug out is used as
uncontrolled fill onthe low side of the block. All houses, even waffle
slabs, need firm, even support to all parts of the slab.
Highly reactive and extremely reactive clay sites. These sites need stiff
footingsystems to span over the swelling and shrinking soils. Concrete
beams get stronger and stiffer when the depth of the concrete beams
increases but waffle pod void formers tend to max out at 375mm deep
(so providing 475mmdeep beams and ribs with a 100mm slab). Some
designers try to achieve extra slab stiffness by adding more steel
reinforcement. This works but the design process becomes more
complicated.
Cyclonic areas and high wind areas. High winds generate a lot of
pressure onroofs which result in some very concentrated forces in
modern trussed roofs. On a regular sized 200m2 house, some truss
uplift forces are as high as 5 tonnes. In a waffle slab, these forces
need to be resisted only by the weight of the footing system because
there is no skin friction with the ground. 5 tonnes of concrete is about
2 cubic meters of concrete. That’s a lot more concrete than is available
to resist forces at the truss reaction point.
ADVANTAGES
DISADVANTAGES
Depth of slab between the ribs may control the fire rating
Requires special or proprietary formwork
Greater floor-to-floor height
Large vertical penetrations are more difficult to handle.
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2.4 LIFT SLAB
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2.5 SPAN-STRESS FLOOR SYSTEM
This method speeds up construction, and saves on expensive equipment,
since it takes cranes out of the way. Span-stress prestressed Concrete T-
Joist Floor and roofsystem are more compact and light-weight. Easier to
transport and handle.
Span-stress prestressed T-Joist can be used with filler blocks or with
collapsible steelforms or plywood forms. It eliminates or reduces
scaffoldings to the minimum. Length goes from 3.00 meters to 9.00 meters
(Salvan & Buhangin, 1996).
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2.6 SLIPFORM METHOD
Slipform is similar in nature and application to jumpform, but the
formwork is raised vertically in a continuous process. It is a method of
vertically extruding a reinforced concrete section and is suitable for
construction of core walls in high-rise structures – lift shafts, stair shafts,
towers, etc. It is a self-contained formwork system and can require little
crane-time during construction.
This is a formwork system which can be used to form any regular shape or
core. Theformwork rises continuously, at a rate of about 300mm per hour,
supporting itself on the core and not relying on support or access from
other parts of the building or permanent works.
Commonly, the formwork has three platforms. The upper platform acts as
a storage and distribution area while the middle platform, which is the
main working platform, is at the top of the poured concrete level. The
lower platform provides access for concrete finishing.
SAFETY
Working platforms, guard rails, ladders and wind shields are
normally built into the completed system.
Less congested construction site due to minimal scaffolding and
temporary works.
Completed formwork assembly is robust.
Strength of concrete in the wall below must be closely controlled to
achieve stability during operation.
Site operatives can quickly become familiar with health and safety
aspects of their job.
High levels of planning and control mean that health and safety are
normally addressed from the beginning of the work.
OTHER CONSIDERATIONS
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USES AND APPLICATIONS
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III. PRESTRESSED CONCRETE
It is now commonly used for floor beams, piles and railways sleepers, as well
as structures such as bridges, water tanks, roofs and runways.
Generally, prestressed concrete is not necessary for columns and walls,
however, it can be used economically for tall columns and high retaining
walls with high bending stresses.
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MATERIALS USED IN PRESTRESSED CONCRETE
Steel Ordinary mild steel and deformed bars are used in RCC are not used in
PSC (prestressed concrete) because their yield strength is not very high. In
the prestressed concrete, loss of prestress (about 20 %) occurs due to many
factors. If mild steel bars or HYSD bars are used then very little prestress
will be left after the losses and will be of no use. Therefore, high tensile
strength steel is used for prestressing. In addition to the high strength, the
steel used in prestressing must have a higher ultimate elongation. Various
forms of steel used for prestressing as follows:
Tendons High strength tensile wires available in various diameters from 1.5
mm to 8 mm. the following table gives the ultimate tensile strength of steel
wires used for prestressing.
Bars High tensile steel bars of diameter 10 mm or more are also used in
prestressing.
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ADVANTAGES OF PRESTRESSED CONCRETE
36
HOW PRE-STRESSED CONCRETE WORKS?
So by now, I have had our concept. We have learned why and when we
should use prestressed concrete. So, how does it work? In the real life, high
tensile strength steel wires are inserted into the beam section and they are
stretched and anchored, then released. Now the steel tendon wants to gain
its original length and tensile stresses are transformed into a
compressive stress in the concrete. Now after loading there are two kinds of
forces on the beam,
Internal prestressing
In this system, a prestressing force is applied to the high tensile steel i.e.
the steel reinforcement. It induces internal compressive stresses in concrete.
it is the most commonly used method because of easy and accurate
application. Internal prestressing can be done by two methods:
Pre-tensioning
Post-tensioning
External prestressing
This method is not commonly used. In this method, the prestressing is done
by adjusting the external reactions (by introducing different support
conditions). The externally prestressing system requires very much accuracy
in the planning and applications. The method of prestressing involves pre-
tensioning and post-tensioning methods.
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3.1 PRE-TENSIONING
38
3.2 POST -TENSIONING
Casting the tendon ducts/sleeves into the concrete before any tensioning
occurs allows them to be readily “profiled” to any desired shape including
incorporating vertical and/or horizontal curvature. When the tendons are
tensioned, this profiling results in reaction forces being imparted onto the
hardened concrete, and these can be beneficially used to counter any
loadings subsequently applied to the structure.
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T Y PE S O F P OST T EN SIO N E D S YS T EM S
COMPONENTS OF BONDED POST TENSIONED SYSTEM SITE IMAGE OF BONDED POST TENSIONED SYSTEM
40
ADVANTAGES OF THIS SYSTEM OVER UNBONDED POST-TENSIONING
Improved crack-control
41
3.2.2 UNBONDED POST TENSIONED SYSTEM
42
APPLICATION OF POST TENSIONG IN INFRASTRUCTURE
Highway Flyovers
Highway Bridges
Metro Rail
Nuclear Power Plants
Cement Silos
Irrigation Plants
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Post Tensioned Flat Slabs
Larger spans can be achieved with
lesser depths and steel. Used in
IT Parks, Commercial Building,
Podium Slabs, Hospitality
Buildings.
Large Cantilevers
Large Cantilevers that are not
possible in RCC can be easily done
using Post Tensioning.
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3.3 PRE-TENSIONING VS. POST-TENSIONING
Sr.No. Pre-Tensioning Post-Tensioning
Pre-tensioning is done in the Post-tensioning can be done in
1 factories thus suitable for precast factories as well as on the site
construction works
In this type of concrete, the pre- In this type of concrete, the
stressing cables called the strands are enclosed within a
strands are tensioned before duct in the form and then
2 casting the concrete and then concrete is casted. The process
concrete is casted enclosing the of tensioning the strands is
tensioned cables. carried out after the concrete
attains its sufficient strength.
Small sections are to be Size of a member is not
3 constructed restricted, long-span bridges are
constructed by post-tensioning
4 Loss of prestressing isn’t less Loss of prestressing isn’t more
(about 18 %) (about 15 %)
In this method, similar In this method, products are
changed according to a
5 prestressed members are structure.
prepared.
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REFERENCES
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concrete-walls/
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