Concrete II

Concrete-II
Pre-Cast Concrete
Concept of Pre-Stressing and Post-Tensioning
Advantages and Disadvantages
Arch. Aksam Qureshi
COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

Spring 2023, ARC-232 Materials and Construction II
1
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 a complete structure. It is typically
used for structural components such as; wall panels,
beams, columns, floors, staircases, pipes, tunnels,
and so on.
Structural steel frames can provide an alternative for
pre-fabricated structural components, but precast
concrete can be more economical and sometimes
more practical.
Many buildings now include a mixture of both
construction techniques, sometimes incorporating
structural steelwork, in-situ concrete, and precast
concrete elements.

2
Pre-Cast Concrete
Application
Reinforced concrete is usually used for structural systems due to its strength, durability, and
affordability.
Precast concrete is used in the following ways:
• To make beams, columns, floor slabs, foundations, and other structural members for
buildings,
• To make wall or cladding panels for buildings,
• To make precast pre-stressed elements for buildings,
• To make components for infrastructure projects, elements such as bridge spans, metro
line viaducts are often precast in a casting yard,
• To make products such as precast water tanks, septic tanks, drainage chambers,
railway sleepers, floor beams, boundary walls and water pipes,
• As it can be moulded into any shape, it can also be used to create one-off unusual forms
such as sculptures etc.

3
Pre-Cast Concrete
Manufacturing Process
The production of precast concrete elements

takes place under controlled conditions in
enclosed factories. This means that tolerances
can be accurately controlled, waste can be
minimized, and that a denser, stronger and
better quality concrete can be produced.
Formwork:
Concrete is cast into forms and left to cure.
Precast forms are normally made of steel or
plywood. Whereas plywood forms are usually
limited to about 20-50 castings depending
upon the complexity of the form, a virtually
unlimited number of castings can be made by
pre-casting using steel forms.
4
Pre-Cast Concrete
Manufacturing Process
Concrete Cover:
Precast elements generally incorporate steel
reinforcement to resist loading stresses. A
common cause of the deterioration of concrete
structures is the corrosion of this reinforcement.
It is, therefore, important that they are properly
designed and embedded in the concrete.
Admixture:
During the manufacturing process, admixtures can be included in the concrete. These can be
water-reducing, air-entraining, retarders and accelerators (for faster curing time). The purpose of
admixtures is to improve concrete quality in both its fresh and hardened state.
Colored/Pigmented Concrete:
Color pigments can also be added, such as iron oxides (red and brown), chrome oxides (green)
or cobalt oxides (blue).
5
Pre-Cast Concrete
Installation Process
The on-site installation of precast components can be a
high-risk activity involving the use of heavy plant,
cranes and personnel working at height.
Consideration should be given to:

• The method and sequence of assembly and
erection,
• The method of providing temporary supports,
structural connections and joint details,
• Handling and rigging requirements,
• Site accessibility for delivery and storage,
• Crane capacity and working clearance for
hoisting,
• Sample measurement to confirm the accuracy of
critical dimensions,
• Visual inspection of concrete finishes for defects,
• Locations and conditions of lifting inserts for
hoisting.
• To safeguarding against risks when receiving
delivery, moving, and placing units.
6
Pre-Cast Concrete
Connecting Pre-cast Concrete Elements
Precast concrete components can be

connected in a number of ways:
• They can be bolted together. In order to do

this, steel connectors are embedded in the
concrete at the time of casting. This must be
done with great precision,
• They can be grouted or concreted together.
In this method, loops of steel reinforcement are
left protruding out of the precast concrete
members. Two members are placed in position,
and reinforcement is threaded between the
loops. Fresh concrete is then poured around
this reinforcement, in a space left for this
purpose.
7
Pre-Cast Concrete
Habitat 67, Montreal
Moshe Safdie, 1967
In this Canadian housing complex, 354 identical prefabricated concrete units are arranged in random
combinations, forming 146 residences. Habitat ’67 was originally designed as a thesis project for Safdie’s
architecture master’s degree at McGill University.
8
Pre-Cast Concrete
Moshe Safdie, 1967
The concept was to introduce a new lifestyle to guarantee people privacy, fresh air and gardens in order to
resolve the issues caused by overpopulation in urban areas

9
Pre-Cast Concrete
Moshe Safdie, 1967.

10
Pre-Cast Concrete
Sydney Opera House, Australia
Designed by Jørn Utzon, a Danish architect whose design won him in 1957. It wasn’t complete until 1973,
debuting its “billowing sails” on the Sydney skyline. It took Utzon’s team four years just to figure out a way to
build those distinctive sails, but they ultimately settled on a complex system of precast elements.
11
Pre-Cast Concrete
Sydney Opera House, Australia
The group essentially refined the molding process so integral to precast, creating a set of ribs that could provide the
foundation for the arching shells built on top of pedestals. Only one piece of the roof was cast in place; the rest? Precast.
This Modern Expressionist design is now a UNESCO World Heritage Site and remains one of the most recognizable
structures in the world.
12
Pre-Cast Concrete
Jubilee Church, Tor Tre Teste, Rome 2003
Architects: Richard Meier & Partners, New York, USA
Designed to look like a ship, the south side of the
church features three large curved walls of pre-cast
concrete. Meier claims to have designed the church
to minimize thermal peak loads inside. The large
thermal mass of the concrete walls controls internal
heat gain; the result is less temperature variation,
and supposedly more efficient use of energy.
The walls also contain titanium dioxide to keep the
appearance of the church white.
The three curves are made up of pre-cast concrete
segments, post-tensioned in place. They are free-
standing and wind load is compensated by a
cantilevering effect through the curve. The walls
have an inner and outer shell. The inner cavity is
filled with Styrofoam for insulation qualities and
provides rigidity with the lowest amount of weight.

13
Pre-Cast Concrete
Architects: Richard Meier & Partners,
New York, USA

14
Pre-Cast Concrete
Architects: Richard Meier & Partners,
New York, USA

15
Pre-Cast Concrete
Perot Museum of Nature and Science, Dallas, USA
Architect: Morphosis 2012
Built to bring a simple cube and plinth into high relief, the Perot Museum showcases a precast-concrete panel façade that's
both striated and refined. ... 656 precast panels, typically 8 by 30 feet (and weighing up to 16,000 pounds at 9′ inches thick)
were made with wood-framed rubber molds to keep façade costs lower.

16
Pre-Cast Concrete
Giving shape to concrete, Morphosis Architects explored the material’s potential through the Perot Museum of Nature and
Science in Dallas. Built to bring a simple cube and plinth into high relief, the Perot Museum showcases a precast-concrete
panel façade that’s both striated and refined.

17
Pre-Cast Concrete
As a material investigation integrating structure and formwork, the elegant cladding solution was made possible through
computer-aided modeling and collaboration with Gate Precast of Hillsboro, Texas.

18
Pre-Cast Concrete
Palazzo Italia, Milan
Architect: Nemesi & Partners Srl, Mailand/Rom 2015
The intricate paper-like exterior of this intriguing building is yet another stunning example of what precast can do. As the only
permanent structure from Italy’s 2015 World Expo, the Palazzo is 35 meters high and its exterior is made of 700 precast
panels.
19
Pre-Cast Concrete
Palazzo Italia, Milan
Architect: Nemesi & Partners Srl, Mailand/Rom 2015
One might not expect concrete to appear so delicate or to work well as a layered architectural element, but this building
proves the opposite. The concrete itself is suited to this kind of intricate effect, and it includes within it a photocatalytic
compound that, when activated by UV light, helps break down pollutants.
20
Pre-Cast Concrete
Broad Museum, Los Angeles 2015
Architects: Diller Scofidio + Renfro
Structural engineering firm:
Leslie E. Robertson Associates
• The Museum's airy "veil" features hundreds

of conical light openings, was achieved using 2500
individual panels of glass-fiber-reinforced concrete
(GFRC) panels,
• The use of GFRC enabled the creation of
complicated 3-D shapes out of concrete while
keeping the weight of the facade to a minimum,
• The entire structure was designed with 3-D
modeling software.
• This building covers as area of 120,000 square ft.

21
Pre-Cast Concrete
Broad Museum, Los Angeles
Structural engineering firm: Leslie E. Robertson Associates

22
Pre-Cast Concrete
Broad Museum, Los Angeles
Structural engineering firm: Leslie E. Robertson Associates

23
Pre-Cast Concrete
Concept of Pre-Stressed Concrete
Pre-stressed concrete is a form of concrete used in construction which is "pre-stressed" by being placed
under compression prior to supporting any loads beyond its own dead weight.
This type of concrete is made by incorporating steel into the concrete structure during the manufacturing
process. This may include steel cables, bars or other steel materials. While the steel is under tension, the
concrete is cast around it. During the concrete curing process, the concrete will bond to the steel. The tension
on the steel is then released, and the concrete is compressed to create additional strength in the material.
Types of Pre-stressed Concrete:
• Pre-Tensioned Concrete
• Post-Tensioned Concrete
Pre-Tensioning:
In Pre- tensioning, lengths of steel wire or cables are laid in the empty mold and stretched. The concrete is
placed and allowed to set, and the cables are released, placing the concrete into compression as the steel
shrinks back to its original length.
Post-Tensioning:
In post-tensioning, the steel in the concrete is stretched after the curing process. Pre-stressing places a
concrete member in compression; these comprehensive stresses counteract the tensile bending stresses of
an applied load. The process was developed by the French engineer Eugène Fressinet in the early 20th
century.
24
Pre-Cast Concrete
Advantages of Precast Pre-Stressed Concrete
Pre-casting is good at producing large numbers of identical components. For example, building
an affordable housing project with identical apartments could use pre-casting to produce wall
slabs and floor slabs for all the apartments, and then lift them into place and connect them.
As it is done in a purpose-built pre-casting yard or factory, it makes construction easier for the
following reasons:
• Maintenance Free, Precast concrete does not require painting and is free from corrosion. Its
durability extends building life. Lower construction cost,
• Column-Free Long Spans, with fewer columns and more usable floor space, precast, pre-
stressed concrete provides greater freedom for space utilization. Longer span lengths
increase the usable unencumbered floor space in buildings and parking structures,
• Thinner slabs, which are especially important in high-rise buildings where floor thickness
savings can translate into additional floors for the same or lower cost,
• Fewer joints since the distance that can be spanned by post-tensioned slabs exceeds that of
reinforced construction with the same thickness,

25
Pre-Cast Concrete
Advantages of Precast Pre-Stressed Concrete
• Fewer joints lead to lower maintenance costs over the design life of the structure, since joints
are the major locus of weakness in concrete buildings,
• Fabrication of pre-cast elements during permitting and/or site preparation saves time
resulting in fast efficient construction regardless of weather conditions,
• Pre-cast components can be erected in winter conditions, maintaining tight schedules,
• With total precast systems, speedy erection allows the contractor to enclose the building
quickly, giving interior trades faster access,
• Fire Resistant; Pre-cast components are naturally fire protected, because they will not burn.
Pre-cast's inherent fire resistance eliminates the messy and time-consuming fireproofing
required for a steel structure and subsequent repairs caused by other trades.

26
Pre-Cast Concrete
Dis-advantages of Pre-cast Concrete
There are a few main disadvantages of precast concrete construction:
• Since each piece is made separately, the structural frame or system is not monolithic or
continuous like regular concrete construction. The joints between pieces create structural
discontinuity. The forces of the building will pass through these joints, so they have to be
designed to transfer these forces safely and properly,
• As the building is made of discrete components, the joints between adjacent members have
to be sealed with special sealants to make them waterproof. Each precast component is
usually large and heavy. This means that cranes are required to lift them in position; these
cranes are required to operate over the entire building volume,
• Since there will only be a few cranes at site, the time taken by the cranes to pick up a piece
and shift it to its final position becomes critical in determining the building schedule.

27
Pre-Cast Concrete
The Paramount Apartments,
San Francisco 2001

28
Pre-Cast Concrete
San Francisco 2001

29
Pre-Cast Concrete
San Francisco, 2001
A 39 Storied Pre-Cast Pre-Stressed Concrete Apartment Building
The Paramount (located in San Francisco, California) is the tallest concrete structure in addition
to being the tallest precast, pre-stressed concrete framed building in Seismic Zone 4 (a double
record).
It is the first major high-rise building to be braced by an architecturally finished exposed precast
concrete ductile frame. The reinforcement used to create this seismic ductile frame includes
post-tensioning and high-strength reinforcing steel. All this represents a major milestone in the
development of precast/pre-stressed concrete.
The building is basically an apartment complex, although the lower floors accommodate retail
space, vehicle parking, and recreational amenities.

30

Concrete II

Uploaded by

Copyright:

Available Formats

You might also like

Concrete II

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Concrete II

Uploaded by

Copyright:

Available Formats

Concrete-II

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

The production of precast concrete elements

Consideration should be given to:

Precast concrete components can be

• They can be bolted together. In order to do

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

• The Museum's airy "veil" features hundreds

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

There are a few main disadvantages of precast concrete construction:

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

COMSATS University Islamabad, Lahore Campus 2nd Year-Semester IV,

You might also like