REPORT NO.

- 2

COST EFFECTIVE PRECAST ROOFING AND

FLOORING SYSTEMS.
(BUILDING CONSTRUCTION-VII)

SUBMITTED BY -
NAME- SNEHA DEY
CLASS - 7TH SEMESTER, B.ARCH
ROLL NO-10
GCAP, AZARA.
INTRODUCTION:
● PRECAST METHOD IN BUILDING CONSTRUCTION MEANS THAT
THE BUILDING STRUCTURE IS NOT CASTED IN THE
CONSTRUCTION SITE, SUCH AS CONVENTIONAL METHOD, BUT
CASTED AT THE FACTORY SITE/PLAN OR AT THE SITE LOCATION
,SO THAT THE QUALITY CAN BE MAINTAINED WELL AND CAN BE
PRODUCED MASSIVELY.
● IN THIS PRECAST METHOD, AFTER FABRICATION IS DONE, THIS
PRECAST COMPONENT WILL BE BROUGHT TO THE
CONSTRUCTION SITE/SHUNTED AND THEN ARRANGED INTO A
UNIT OF BUILDING CONSTRUCTION.
● THE ADVANTAGES OF THIS PRECAST SYSTEM ARE:
1. GOOD QUALITY,
2. RELATIVELY SHORTER CONSTRUCTION EXECUTION TIME,
3. ENVIRONMENTALLY FRIENDLY, AND
4. FEWER CONSTRUCTION MATERIALS TO BE THROWN OUT OF THE
CONSTRUCTION SITE.
● BY USING PRECAST METHOD, THEN MUCH COST CAN BE SAVED,
FOR EXAMPLE THE COST OF FORMWORK IS CHEAPER AND THE
OVERHEAT COST IS MORE AFFORDABLE BECAUSE THE TIME OF
IMPLEMENTATION IS FASTER THAN CONVENTIONAL, SO THE
PRECAST METHOD BECOMES MORE EFFICIENT WHEN COMPARED
TO CONVENTIONAL METHOD.
STRUCTURAL DETAILS:
FIG. 3: THE MOST COMMONLY USED STRUCTURAL ANALYSIS METHOD IS THE
FINITE ELEMENT METHOD (FEM).WHICH INCLUDES THE GEOMETRY OF ALL
THE STRUCTURAL PRECAST MEMBERS LIKE COLUMNS, BEAMS, WALLS AND
SLABS. MATERIAL PROPERTIES, SUPPORTS AND CONNECTIONS SHALL BE
MODELLED IN SUCH A WAY THAT THEY REPRESENT THE ACTUAL BEHAVIOUR OF
THE PRECAST STRUCTURE.

FIG. 4: (PRECAST ERECTION DRAWINGS AND DETAILS)-THE ERECTION

DRAWINGS CONTAIN
1. ALL PRECAST CONCRETE MEMBER PIECE MARKS,
2. FULLY DIMENSIONED SIZE AND SHAPE OF EACH MEMBER,
3. LOCATION OF EACH MEMBER WITH RESPECT TO THE BUILDING LINES OR
COLUMN LINES
4. FINISHED FLOORS,
5. DETAILS AND LOCATIONS OF ALL CONNECTIONS.
6. JOINTS AND OPENINGS BETWEEN PRECAST MEMBERS

REFERENCE:https://www.concreteshowindia.com/blog/precast-buildings-design-and-detailing-process/
FIG. 5: PRECAST ELEMENT AND REINFORCEMENT DETAILS (PRODUCTION
DRAWINGS): THE PRECAST PRODUCTION DRAWINGS ARE USED IN THE
PRECAST PLANT TO MANUFACTURE THE PRECAST CONCRETE MEMBERS. THESE
DRAWINGS MUST SHOW EACH PRECAST MEMBER INCLUDING ALL THE
SPECIFICATIONS, DETAILS, DIMENSIONS, INSERTS, REINFORCEMENT DETAILS,
FINISHING ETC.

FIG. 6: PRECAST ELEMENT AND REINFORCEMENT DETAILS (PRODUCTION

DRAWINGS): THE PRECAST PRODUCTION DRAWINGS ARE USED IN THE
PRECAST PLANT TO MANUFACTURE THE PRECAST CONCRETE MEMBERS. THESE
DRAWINGS MUST SHOW EACH PRECAST MEMBER INCLUDING ALL THE
SPECIFICATIONS, DETAILS, DIMENSIONS, INSERTS, REINFORCEMENT DETAILS,
FINISHING ETC. ● PRECAST DESIGN
STANDARDS
INDIA
1) IS 11447 CONSTRUCTION
WITH LARGE PANEL
PREFABRICATES
2) IS 15916 BUILDING
DESIGN AND ERECTION
USING PREFABRICATED
CONCRETE
3) IS 15917 BUILDING
DESIGN AND ERECTION
USING
MIXED/COMPOSITE
CONSTRUCTION
REFERENCE:https://www.concreteshowindia.com/blog/precast-buildings-design-and-detailing-process/
PREFABRICATED ROOFING/FLOORING COMPONENTS:
SOME OF THE PREFABRICATED ROOFING/FLOORING COMPONENTS FOUND
SUITABLE IN MANY LOW COST HOUSING PROJECTS ARE:
I. PRECAST RC PLANKS.
II. PREFABRICATED BRICK PANELS
III. PRECAST RB CURVED PANELS.
IV. PRECAST RC CHANNEL ROOFING
V. PRECAST HOLLOW SLABS VI. PRECAST CONCRETE PANELS
VII. L PANEL ROOFING
VIII. TRAPEZON PANEL ROOFING
IX. UNREINFORCED PYRAMIDAL BRICK ROOF

1) PRECAST RC PLANK AND JOISTS ROOFING SYSTEM:

● THIS SYSTEM CONSISTS OF PRECAST RC PLANKS SUPPORTED OVER
PARTIALLY PRECAST JOIST.
● RC PLANKS ARE MADE WITH THICKNESS PARTLY VARYING BETWEEN 3 CM
AND 6 CM.
● THERE ARE HAUNCHES IN THE PLANK WHICH ARE TAPERED. WHEN THE
PLANK IS PUT IN BETWEEN THE JOISTS, THE SPACE ABOVE 3 CM
THICKNESS IS FILLED WITH IN-SITU CONCRETE TO GET TEE-BEAM EFFECT
OF THE JOISTS.
● A 3 CM WIDE TAPERED CONCRETE FILLING IS ALSO PROVIDED FOR
STRENGTHENING THE HAUNCH PORTION DURING HANDLING AND
ERECTION.
● THE PLANKS HAVE 3 NUMBERS 6 MM DIA MS MAIN REINFORCEMENT
AND 6 MM DIA @ 20 CM CENTRE TO CENTRE CROSS BARS.

REFERENCE:https://www.devalt.org/images/L2_ProjectPdfs/PLANK-JOIST-ROOFING-SYSTEM.pdf
 REFERENCE:https://www.researchgate.net/publication/303330847_PRECAST_CHANNEL_UNIT_FOR_FLO
OR_ROOF#:~:text=Precast%20Channel%20Unit%20is%20a,stone%20walls%20and%20RCC%20beams.
2) PRECAST CHANNEL UNIT:
● IT IS A FULL SPAN PRECAST RCC UNIT, TROUGH SHAPED INSPECTION . IT
CAN BE USED FOR FLOORS AND ROOFS SUPPORTED ON SUITABLE
STRUCTURES LIKE BRICK/STONE WALLS AND RCC BEAMS.
● IT DOES NOT REQUIRE ANY INTERMEDIATE TEMPORARY PROPS OR
SUPPORTS, SINCE THE UNIT IS STRONG ENOUGH TO SUPPORT THE LOAD,
● NOMINAL WIDTH OF THE UNIT IS VARIES FROM 300 MM TO 600 MM,ITS
DEPTH FROM 130 MM TO 200 MM AND A MINIMUM FLANGE THICKNESS
OF 30 MM.
● THE LENGTH OF THE UNIT MAY BE ADJUSTED TO SUIT THE SPAN TO BE
COVERED, BUT THE MAXIMUM LENGTH IS RESTRICTED TO 4.2 M FROM
STIFFNESS CONSIDERATIONS.
3) PRECAST THIN RIBBED SLAB
● PRODUCT: PROCESS FOR MAKING THIN RC RIBBED SLABS AT SITE.
● APPLICATION: FOR FLOOR & ROOFS IN SINGLE AND MULTI-STOREY
RESIDENTIAL AND OTHER TYPES OF BUILDINGS.
● FEATURE: THIN RC RIBBED SLAB CONSISTS OF PRECAST/CAST-IN-SITU RC
RIBS 110X200 MM2, SPACED AT 1200 MM/CC WITH 50 MM THICK CAST
IN-SITU RC FLANGE ABOVE. IN CASE OF HEAVILY LOADED FLOORS AND
ROOF, THE SIZE AND REINFORCEMENT OF THE RIBS AND FLANGES ARE
INCREASED APPROPRIATELY. ITS USE EFFECTS SAVING OF 22% IN OVERALL
COST.
● COMMERCIALISATION: TECHNOLOGY RELEASED FREE AND IS BEING
ADOPTED IN A NUMBER OF RESIDENTIAL AND SCHOOL BUILDINGS IN THE
COUNTRY.
● ECONOMY: 1000 M2 TOTAL FLOOR/ROOF AREA IN REPEATED DESIGN OF
HOUSES INDICATIVE INVESTMENT : RS. 0.80 LAKH.
● INVESTMENT: MOULDS, SHUTTERING PANELS, MIXERS, VIBRATORS.
● EQUIPMENT: CEMENT, STEEL, AGGREGATES.
● RAW MATERIALS: CEMENT, STEEL, AGGREGATES.
REFERENCE:https://www.csir.res.in/ruralsectors/precast-thin-ribbed-slab
 REFERENCE:https://cbri.res.in/precast-rc-waffle-units/
4) PRECAST WAFFLE SLABS:
WAFFLE UNITS ARE OPEN BOX TYPE PRECAST RC UNITS, UPTO 1.2 M IN SIZE.
CASTING OF UNITS IS DONE IN STEEL/TIMBER MOULDS WITH STEEL WELD
MESH REINFORCEMENT. AFTER CURING, THEY ARE ASSEMBLED OVER THE
SHUTTERING IN A GRID PATTERN LEAVING A SPACE OF 10 TO 17 CM BETWEEN
THE UNITS.

TECHNICAL SPECIFICATIONS:
● CEMENT REQUIREMENT : 41.5KG/M2
● STEEL REQUIREMENT : 7.7KG/M2

SALIENT FEATURES
● USES GREEN TECHNOLOGY WITH LOWER CARBON FOOTPRINT AND
LOWER EMBODIED ENERGY.
● CAN BE CAST AND ASSEMBLED MANUALLY OR BY USING MACHINES FOR
LARGER HOUSING PROJECTS.
● PREFERRED IN CONSTRUCTION OF TWO-WAY SLABS OF LARGE SPAN
(ABOVE 90 M).
● SAVES CONSTRUCTION COST AND TIME.
● INCORPORATED IN BIS CODES, CPWD AND SEVERAL STATE SCHEDULES.
● IMPLEMENTED IN U.P., M.P., UTTARAKHAND, A.P., HARYANA ETC FOR
THE CONSTRUCTION OF SEVERAL HALLS.
● OFFERS AESTHETICALLY PLEASING CEILING.

ECONOMIC ASPECTS
● COST EFFECTIVE, SAVES UPTO 30% CONSTRUCTION COST WITH RESPECT
TO RCC SLABS
 REFERENCE:https://www.nordimpianti.com/brochures/eng/pdf_mr/3.4_ENG_Prestressed_Slabs.pdf
5) PRESTRESSED SLABS:
● PRESTRESSED SLABS ARE PRESTRESSED CONCRETE ELEMENTS THAT HAVE
A CONSTANT CROSS SECTION.
● THEY ARE MANUFACTURED USING HIGH TENSILE STRENGTH PRESTRESSED
STRANDS OR SINGLE WIRE WHICH ARE EMBEDDED WITHIN THE ELEMENT.
● THE PRODUCED ELEMENTS HAVE HIGH LOAD RESISTANCES THANKS TO A
LOW WATER/CEMENT RATIO OF CONCRETE FROM 0.32 TO 0.38. IN FACT
TO PRODUCE THE SAME PROFILES USING TRADITIONAL METHODS WOULD
REQUIRE HIGHER WATER/CEMENT RATIOS AND NEED EXPENSIVE
FORMWORKS
 REFERENCE-https://www.researchgate.net/publication/303330860_PREFAB_BRICK_PANEL_SYSTEM_FOR_ROOFING_FLOORING

6) PREFAB BRICK PANEL:

● PREFAB BRICK PANELS ARE MADE OF FIRST CLASS BRICKS AND
REINFORCED WITH TWO MS BARS OF 6 MM DIA.
● THE JOINTS ARE FILLED WITH EITHER M20 CONCRETE OR CEMENT
MORTAR 1:3 (1 CEMENT: 3 COURSE SAND).
● THE LENGTH OF THE BRICK PANELS VARIES FROM 900 MM TO 1200 MM
DEPENDING UPON THE ROOM SIZE, BUT THE WIDTH IS NORMALLY KEPT
AT 530 MM TO ALLOW 36 TO 40 MM WIDE GAP BETWEEN THE BRICKS
FOR PLACING REINFORCEMENT WITH PROPER COVER AND FOR LAYING
CONCRETE.
● THE TWO PANELS ARE PLACED IN POSITION WITH A GAP OF 2 TO 4 CM IN
WIDTH WHICH IS THEN FILLED WITH CEMENT CONCRETE.
7) PRECAST CONCRETE DOOR AND WINDOW FRAMES
● PRECAST CONCRETE DOOR AND WINDOW FRAMES COMPRISE OF
SEPARATE RCC MEMBERS CORRESPONDING TO THE SIDES OF THE
OPENING.
● THE HORIZONTAL MEMBER JOINS WITH VERTICAL MEMBERS THROUGH
INTERLOCKING PROFILES WHEN INSTALLED AT SITE.
● THE MEMBERS ARE MINIMALLY REINFORCED USING WIRE
REINFORCEMENT.
● BEING REINFORCED CONCRETE, THE TOP MEMBER OF THE FRAME IS ALSO
CAPABLE OF ACTING AS A LINTEL OVER A DOOR OR WINDOW.
● THE PROFILE OF FRAMES IS SIMILAR TO WOODEN FRAMES WITH THE
OPTION OF SINGLE AND DOUBLE REBATES
REFERENCE-https://www.devalt.org/images/L2_ProjectPdfs/PRECAST-CONCRETE-DOOR-AND-WINDOW-FRAMES.pdf?Oid=320
8) PRECAST CONCRETE MANHOLE COVER AND FRAME

● A MANHOLE COVER IS A REMOVABLE PLATE FORMING THE LID OVER THE

OPENING OF A MANHOLE, TO PREVENT ANYONE OR ANYTHING FROM
FALLING IN, AND TO KEEP OUT UNAUTHORIZED PERSONS AND MATERIAL.
● THE BEARING SURFACES OF MANHOLE FRAMES AND COVERS ARE
MACHINED TO ASSURE FLATNESS AND PREVENT THEM FROM BECOMING
DISLODGED BY TRAFFIC.
● THE SPECIFICATIONS OF PRECAST CONCRETE MANHOLE COVER AND
FRAME IS AS PER IS: 12592:2002 AS GIVEN BELOW
● GRADES AND TYPES :

MANHOLE COVERS AND FRAMES SHALL BE OF THE FOLLOWING FOUR GRADES

AND TYPES:

REFERENCE:https://www.iitk.ac.in/ce/test/Materials/28.html

9) FERROCEMENT DOOR/WINDOW FRAME:

APPLICATION:BUILDING CONSTRUCTION AND
FURNISHING.
FEATURE:FERROCEMENT DOOR
SHUTTERS/WINDOW FRAMES BRING DOWN THE
COST OF JOINERY. THESE ARE STRONG, DURABLE,
TERMITE RESISTANT AND LESS PRONE TO FIRE
AND WEATHERING. THESE OFFER A SAVING OF
ABOUT 30-40% OVER CONVENTIONAL SECOND
CLASS DEODAR WOOD ITEMS
REFERENCE:https://www.csir.res.in/ruralsectors/ferrocement-doorwindow-frame
THANKYOU.