One Day Workshop

on
“Prefabricated Concrete Structures”
Organized by
Department of Civil Engineering,
Dr. N.G.P. Institute of Technology, Coimbatore

S.Makesh Kumar
Assistant Professor
Department of Civil Engineering
GCT Coimbatore
makeshkumar85@gmail.com
9940701287
04/06/2022

S. Makesh Kumar APCE GCT 1

 Prefabricated Structures
• PEB ( Pre Engineered Building) – steel
• Precast Concrete Construction - Concrete
 Precast Concrete
• Precast concrete is a construction method in
which a construction product produced by
casting concrete in a reusable mould or "form"
which is then cured in a controlled
environment, transported to the construction
site and erected into place.
 PRECAST BUILDINGS
Structural Elements Architectural Elements
• Columns
• Beams • Façade walls
• Load bearing Walls • Handrails & Parapets
• Floor & Roof Slabs • Pergola
• Domes • Copings
• Precast Piles • Arches
• Pocket Foundation
• Staircase Flight & Landing
 PRECAST CONSTRUCTION APPLICATION

Infrastructure
Industrial
• Bridges – Girders & Deck slab • Crane girders & Rails
• Culverts • Ducts & Trenches
• Railway sleepers • Pipe rack & Machine Foundation
• Metro rail & Tunnel segments • Chimneys
• Bunkers & Silos
• Road & Crash barrier

Water supply & Drainage Utility & Landscape

• Tanks – Water, Septic , Retention etc… • Boundary & Retaining walls

• Manholes & Inspection chambers • Benches, Bins & Bollards
• Drains & Trenches • Light poles & Fencing post
• Pipe culverts • Pavers & Kerb stones
PRECAST STRUCTURAL SYSTEMS
PRECAST FRAME SYSTEM
Floor slabs
• Frame system
• Wall system Column

• Dual system

Beam
Footing
PRECAST WALL
Column

PRECAST
WALL

PROPING

PRECAST WALL SYSTEM PRECAST DUAL SYSTEM

STRUCTURAL ELEMENT - COLUMN
STRUCTURAL ELEMENT - BEAM
WALL SYSTEMS
STRUCTURAL SYSTEM
STRUCTURAL SYSTEM
STRUCTURAL SYSTEM
STRUCTURAL SYSTEM
STRUCTURAL SYSTEM
NON – LOAD BEARING CLADDING WALL
SELF SUPPORTING CLADDING WALLS
FACED PANELS
SANDWICH /INSULATED PANELS
SANDWICH /INSULATED PANELS
PRECAST FLOORING
SYSTEMS
TYPES OF PRECAST FLOORS
HOLLOW CORE SLABS
RIBBED SLABS
PARTIALLY PRECAST SLABS
 Materials
• Cement – OPC, PPC, PSC, OPC with supplement cementitious
material (Fly ash, GGBS, Silica Fume, metakaoline)
• Aggregates – FA and CA
• Water
• Chemical admixtures
• Pigments (oxides)
• Reinforcement bar
• Prestressing Tendons
• Grout – water + sand + cementitious material
 Prestressed Concrete
• Prestressed concrete is basically concrete in which internal
stresses of a suitable magnitude and distribution are
introduced so that the stresses resulting from the external
loads are counteracted to a desired degree.
 Advantages
1) Section remains uncracked under service loads
– Reduction of steel corrosion
• Increase in durability.
– Full section is utilised
• Higher moment of inertia (higher stiffness)
• Less deformations (improved serviceability).
– Increase in shear capacity.
– Suitable for use in pressure vessels, liquid retaining
structures.
– Improved performance (resilience) under dynamic
and fatigue loading.
 Advantages
2) High span-to-depth ratios
– Larger spans possible with prestressing (bridges,
buildings with large column-free spaces)
– For the same span, less depth compared to RC
member.
• Reduction in self weight
• More aesthetic appeal due to slender sections
• More economical sections.
 Advantages
3) Suitable for precast construction The advantages
of precast construction are as follows.
– Rapid construction
– Better quality control
– Reduced maintenance
– Suitable for repetitive construction
– Multiple use of formwork ⇒ Reduction of formwork
– Availability of standard shapes.
 Advantages
4) The use of higher strength concrete and high
strength steel results in smaller cross-section.
Minimum grade of concrete for Pretension – M40
Minimum grade of concrete for Posttension – M30
High tensile steel yield strength – 1200 to 2000
N/mm2
Pretensioning
Posttensioning
MANUFACTURING process
IDENTIFY
 MANUFACTURING PROCESS
Mould preparation

Reinforcement/HT wire Transportation

preparation

Accessories services/fixtures
Stacking

Concrete production

Erection
Filling in form

Curing

Demoulding
Wall panel production
Hollow core slab production
Double tee slab1
Double tee slab 2
PRECAST COLUMN
 Methods of manufacture of precast units

• Stand Method:
Moulds remain stationary.
Various processes involved are carried out in a cyclic
order.

• Flow Method:
Precast unit is in movement according to various process.
Processes are carried out in an assembly line method.
 Precasting method
• Individual Mould Method
• Battery Form Method
• Stack Method
• Tilting Mould Method
• Long Line Prestressing Bed Method
• Extrusion Method
Individual Mould Method
 easily assembled out of bottom and sides

 Mould - Timber or steel.

 Needle or mould vibrators

 Capable of taking prestressing force

Individual Mould Method

USES
• Ribbed slabs
• Beams,
• Window panels
• Prestressed railway sleepers.

ADVANTAGES
• Strengthening of c/s possible.
• Openings are possible in two planes.
Battery Form Method

shuttering panels may be adjusted in the form of a battery at the

required thickness of the concrete members.
Battery Form Method

 Weckenmann has supplied a Vertical Casting Machine where a

total of 10 chambers can cast upto 20 walls at a time.

 The elements can be of varying thickness adjusted by a

hydraulic system which controls the opening sizes.

 Each of the chambers are fit with form vibrators thus reducing
the manpower required for casting.

 This machine occupies less space than regular tables and is

ideal for casting solid walls of any size.
Battery Form Method
USES:
 Interior wall panels
 reinforced concrete battens,
 roof and floor slabs.

DIMENSIONS AND WEIGHTS:

 Length=18m.
 Breadth=3m.
 Mass=5t.

ADVANTAGES:
 Suitable for mass production of wall panels due to reduced
shuttering cost.
 Autoclave or trench steam curing may be adopted.
Battery mould
Extrusion Method
 Long concrete mould with constant cross-section where
concreting and vibrations are done automatically.

USES:
– Roof slabs
– hollow cored slab

DIMENSIONS:
Length: Any desired
Breadth:<2m
Height:<3m
EXTRUDER
Titling Mould Method
Vertically skipped using hydraulic jacks.

USES:
• Exterior wall panels where special finishes are required on one face or
for sandwich panels.
Tilting mould
Titling Mould Method
 Horizontal casting tables from Weckenmann are used for production of
Wall elements.

 The tables have high grade machined steel forms which produces a
mirror like surface on the elements.

 The tables have hot water pipes under the deck for steam curing and
form vibrators to provide proper compaction.

 The tilting is done using hydraulic jacks and are designed to lift upto 20
tonnes of precast product.

 These tables eliminate the need for surface lifters thus keeping the
surfaces of the walls clean for erection.
Long Line Prestressing Bed Method
For pretension member

USES:
• Double Tees
• Ribbed slabs
• Purlins
• Piles
• Beams.
 Loads
• Dead load
• Live load
• Wind load
• Seismic or Earthquake load

Load Combination
Analysis
Analysis
Analysis
Analysis
DESIGN
PRECAST STRUCTURAL CONNECTIONS
COLUMN – FOUNDATION CONNECTION
COLUMN – COLUMN CONNECTION
COLUMN – BEAM CONNECTION
COLUMN – BEAM – COLUMN CONNECTION
WALL CONNECTION DETAILS
WALL TO WALL TIE DETAIL
WALL CONNECTING LOOP
WALL CONNECTING LOOP
SLAB TO WALL/BEAM CONNECTION
STORAGE OF PRECAST
ELEMENTS
 Storage Area
 Easy access

 Handling of the precast elements.

 Well drained to avoid any differential ground settlement.

 Erection sequence planned

 Stock atleast for three days requirement for erection works

 Storage of precast slabs & beams

• Horizontal stacking of slab , beam, column units should be

done with SUITABLE PACKERS or SUPPORT SPACERS.
• Storage support position for beams and planks should be
within 300mm from the lifting points.
• Do not use more than two support points in
particular for pre stressed element such as
hollow core slab.
• This is the wrong method of storing the slab,
because 3 supports are used.
• The packers should not misaligned as shown
below.
 STORAGE OF WALL PANELS

• Wall panels should be stored vertically and braced in

position by A-FRAMES or RACKING SYSTEM
shown below.
 STORAGE OF DIFFERENT PRECAST
ELEMENTS
• Storage of façade wall panels
• Precast beams and columns:
• Storage of precast hollow core slab and beam
 Parapet walls

Precast planks: Precast Household Shelters:

• Examples for improper storage & stacking:
• The storage area should be preferably be close to the
location where the precast elements to be installed to
minimise the risk of damage by handling.

• Should be stored near the final position of the

easy handling.
Transportation of Precast Element
• 40 ft trailer – 20 to 25 tons
• Well balanced and tied properly using belts or chains
• Rubber pads shall be used instead of timbers to have
the cushioning effect while travelling on rough roads
• Vertically cast wall elements – A frame fixed on the
trailer
• 75 ft long trailer low bed trailer width 3 m
• Self loading truck – smaller element –lesser weight
Transportation
Transportation
Transportation
Transportation
Protection Measure
Temporary Strengthening of Wall
Panel
Gantry Crane
 EOT Crane
• EOT(Electric Overhead Travelling) cranes run on the squares
bars at the higher levels over the steel / concrete beams
which will be resting on the columns.
 Hydra Crane
• capacity 10 tons to 30 tons
• handling precast elements @ plant and site
• carries the loads and moves on the wheels to reach the
required destinations.
Telescopic cranes
CRAWLER CRANE
TOWER CRANE
Lorry Mounted Crane
 Selection of Crane
• Crane access
• Maximum weight of the precast elements
• Boom length of the crane, height of the building / structure
were the precast elements supposed to be erected
• radius of the boom and where the crane shall be parked
• position of the trailers / lorries parking
• storage area of the precast elements
• ground conditions, suitable MS plates shall be used
when the ground conditions are not stable / firm
• load charts of the cranes must be studied well.
 Handling Devices for lifting
• Lifting Beam shall be used to lift longer
panels which may tend to bend while lifting
elements

• Spreader beams shall be used to lift hollow

core slab which is similar to lifting beam but
the clutch will be movable and operated using
a motor
Handling Devices for lifting
Spreader Beam
 Handling Devices for lifting
Chain Block D Shackles Hand Block

Hand Blocks or chain blocks shall be used in various places

such as for lifting the staircase flight where the chain/rope
used has to be staggered
 Handling Devices for lifting

Four Legged chain

 Handling Devices for lifting
Ring Clutch
Other accessories for Erection Works
 Shim plates
• Used for adjusting the horizontal alignment and vertical alignment
for all precast members
• Thickness from 1 mm to 10 mm
• Size 50 mm x 50 mm to 100 mm x 100 mm
• Materials – M. S. Plate or Hardened plastic.
 Anchor Fasteners
• Used to fix the temporary supports either in the precast member
or on the floors
• used wall plugs size varies from 12mm, 16mm, 20 mm.
 Neoprene pads/strips
• Used to place in beam or slab bearings
• wide 25 mm to 50 mm
• thickness 3 to 5 mm
Using shimplate they are adjusted verticallity
Erection of Beam
Grouting
 Hoisting Method of Beam

Columns are usually first handled in horizontal position. Slings are attached to the inserts at the
top to facilitate the rotation of the elements to vertical position, before hoisting and placing to
Their designated location
Hoisting Method of Slab
Hoisting Method of Wall Panel
Hoisting Method of Beam
Installation of vertical members
 Installation of vertical members
•
Installation of vertical members
Installation of vertical members
Installation of vertical members
Installation of vertical members
Installation of vertical members
Installation of Beam
Installation of Precast Beam
Installation of Precast Slab
Casting of In-situ Joint between Precast Beam
and Precast Slab
Installation of Hollow Core slab
The End….
extras
IDENTIFY
Shop Drawing To be Provided by The Design Department

Mould Fabrication Shall be done as per the Drawings

Rebar Cages Shall be prepared as per the drawings

Fabricated rebar cages to be placed in the mould and All

other Cast-in-item to be placed in positions

Concrete is done as perthe grade and quantity Mention in

the Shop drawings
The Product produced is being released from the mould
when the required strength is achieved

The product is stored at stock yard where required curing

is also taken care

The product is delivered to the site when it is requested

by making Necessary delivery challans