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Lecture3 PrecastConcretein
Lecture3
AD01CTS
AD01CTS Building
ADVANCEDCONSTRUCTION
TECHNOLOGYANDSERVICES

AlfrendoSatyanaga

PrecastConcrete PrecastConcrete

Structuralelementsare
Concreteelements,castandcuredina
commonlyreinforced
manufacturingplant,thentransportedtothe withtightlystretched
pretensionedsteel
constructionsite. strands which provide
strands,whichprovide
increasedstructural
efficiency.
Conventionalsteel
reinforcingisaddedfor
resistancetothermaland
othersecondarystresses.

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PrecastConcrete AdvantageofPrecastConcrete

Ontheconstructionsite, Highefficiencyandgoodqualitycontrol.
precastconcrete Durability
elementsareliftedinto
placeandassembledinto Veryrapidspeedoferection
structuralassembliesina Entirebuildingcanbeprecastwalls,floors,beams
processsimilartothat Rapidconstructiononsite
usedforstructuralsteel.
Highquality
Comparedtositecast
concrete,precast Prestressingiseasilydone
concreteerectionisfaster Aestheticversatility
andlessaffectedby
adverseweather Lowmaintenanceandlowcost
conditions. Sustainability

Precastvs
Precastvs In
InCast DisadvantageofPrecastConcrete

Precastatplant
Sitecast Veryheavymembers
notransportation transportationand
elevationcapacitylimits Connectionsmaybedifficult
thesizelimitationis
thesize
dependingonthe Somewhatlimitedbuildingdesignflexibility
g g y
elevationcapacityonly less affected by weather
lessaffectedbyweather
lowerqualitybecause nospacerequirementon Itcannotbeusedfortwowaystructuralsystems
directlyaffectedby thesiteforfabrication
weather unlimitedopportunities Jointsbetweenpanelsarecomplicated
proper,largefree ofarchitectural
appearance Skilledworkmanshipisrequired
spacerequired
optionofstandardized Cranesarerequiredtoliftpanels
components

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PerformanceinUseofPrecastConcrete QualityofPrecastConcrete

Inherentfireresistance Accuracy

Acoustics Highqualityfinishes

Airtightness
Air tightness Consistencyofconcretesupply
Consistency of concrete supply

Vibrationcontrol Controlledenvironment

DesignofPrecastConcrete SustainabilityofPrecastConcrete

Longclearspan Thermalmass/fabricenergystorage

Provendesignandmethodologies Lesswastage

Durable Reusedandrecycled
Reused and recycled

Mouldable Reducenoise

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PrecastConcrete PrecastConcrete

PrecastConcreteSlabs
Usedforfloorandroofdecks.
Deeperelements(towardtheright
below)spanfurtherthanthosethatare
shallower(towardtheleft).
h ll (t d th l ft)
Right:Hollowcoreslabsstackedatthe
precastingplant.
PrecastConcreteBeamsandGirders
Providesupportforslabs.
Theprojectingreinforcingbarswillbond
withconcretecastonsite.
Right:Invertedteebeamssupportedby
precastcolumns.

PrecastConcrete PrecastConcrete

PrecastConcreteColumnsandWall OtherPrecastConcreteElements
Panels Precastconcretestairs(below)
Providesupportforbeamandslab Uniquelyshapedstructural
elements. elementsforasportsstadium
Sincetheseelementscarrymainly
Since these elements carry mainly (right)
axialloadswithlittlebendingforce,
theymaybeconventionally
reinforcedwithoutprestressing.
Or,long,slendermultistory
elementsmaybeprestressedto
provideresistancetobendingforces
duringhandlinganderection
(columnsatright).

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TypeofPrecastSystem LargePanelSystem

boxlikestructure.
1. Largepanelsystems
bothverticalandhorizontal
2. Framesystems elementsareloadbearing.
onestoryhighwallpanels
3. Slabcolumnsystemswithwalls
l b l h ll (crosswallsystem/
longitudinalwallsystem/
4. Mixedsystems twowaysystem).
onewayortwowayslabs.

FrameSystem SlabColumnSystemwithWalls
Slab

Componentsareusually partiallyprecastinplant(pillars)
linearelements. /partiallyprecastonsite(slabs).
Thebeamsareseated oneormorestoreyhighpillars
oncorbelsofthepillars (max5).
usuallywithhinged
ll ith hi d upto30storeyhigh
h h
joints(rigidconnection constructions.
isalsoanoption). specialdesignedjointsand
Jointsarefilledwith temporaryjoints.
concreteatthesite. slabsarecastedontheground
(oneontopoftheother) then
liftedwithcraneorspecial
elevators.

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PrecastConcreteBuilding
Carparkframeanddeck
Crosswallconstruction
Volumetricconstruction
Volumetric construction
Hybridconcreteconstruction
Crosswall Construction
Precastwallsandloadbearing
walls
Formultistoreybuilding
Suitableforbuildingwithcellular
g
nature,i.e.hotel,student
accommodation,apartment
Longitudinalstabilityusing
externalwallpanels
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CarParkFrameandDeck
Precastcolumns,precastbeams
andprecastdecks.
Standardbaysizeis15.6mx7.2
m.
400mmthicknesshollowcore
unitand600mmdeepdouble
teeunitesforprestressed
precastdecks.
Precastspandrelpanelsfor
shortenspandistance
AdvantagesofCrosswall
AdvantagesofCrosswall Construction
Highqualityfinishes
Thermalmass
Bathroompods
Acousticperformance
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VolumetricConstruction
Modularprecastconstruction
Forprisoncellblocks,student
hostel,apartment
Benefit:robustness,offsite
, Thermal mass and fire resistance
fittingout,rapidassemblyon
site
Independencefromextremes
ofweather
PrecastConcreteBuilding
AssemblyConcepts
Verticalsupportcanbeprovidedby
precastcolumnsandbeams
(above),wallpanels(below),ora
combinationofallthree.
Thechoiceofroofandfloorslab
elementsdependsmainlyonspan
requirements.
Precastslabelementsarefrequently
alsousedwithothervertical
loadbearingsystemssuchassitecast
concrete,reinforcedmasonry,or
steel.
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HybridConcreteConstruction
Combinationofprecastandincastconcrete
Reducetheoverallconstructiontime
Reducetheamountoftraditionalformwork
Thermalmassandfireresistance
Durability
PrecastConcreteBuilding
AssemblyConcepts
Above:Precastconcrete
structureconsistingofsolid
wallpanelsandhollowcore
slabs.
l b
Below:Asinglestory
warehouseconsistingof
doubleteessupportedby
insulatedsandwichwall
panels.
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PrecastConcreteBuilding PrecastConcreteFloors

AssemblyConcepts Hollowcorefloors

Termodeck
Aparkinggaragestructure
Solidprestressedfloors
p
consisting of precast double
consistingofprecastdouble
teessupportedbyinverted Cofferedfloorunits

teebeamsonhaunched Latticegirderslabs

columns. Beamandblockflooring

Doubleteefloorunits

Hollowcore Floors Termodeck

Thecorecanfunctionasserviceducts Specialistapplicationof
Reducetheselfweightoftheslabs hollowcoreslabs.
Maximizestructuralefficiency Thevoidswithintheslabare
Typical: 1200 mm widths and 110400
Typical:1200mmwidthsand110 400mmdepths
mm depths usedaspartofventilation
system.
Maximizethebenefitsof
thermalmass

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SolidPrestressed
SolidPrestressed Floors CofferedFloorUnits

Typical75mmor100mmthick
Foraestheticpurpose
Designedtobeusedcompositelywithaninsitu
concretestructuraltopping Forservices

LatticeGirderSlabs BeamandBlockFlooring

Wetcastprestressed beams
Thinprecastconcretebiscuitwithalattice
Typicaldepth:150 225mm
girderforreinforcement
Providehighdegreeofinsulationforground
Typicaldepth:150mm 300mm
floors
Actcontinuouslyacrossseveralspans
Beammaybeplaced inpairstoaccommodate
loadingfrompartitions

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DoubleTeeFloorUnits PrecastConcreteElements

Ribbedprecastprestressed concreteunits Column

Typicaldepth:300 800mm
Beams
Carryloadupto16m
Standard width: 2400 mm
Standardwidth:2400mm Twinwall

Stairs

Bathroompods

Balconies

Terracing

Column Beam

Square,rectangular casthorizontally Reinforcedwithsteel(prestressedwithsteel

Circular castvertically strand)

Actcompositelywithfloorormonolithicwith
columns

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Twinwall Twinwall

Twoprecastconcrete Basementwalls
panelsheldapartbya Incombinationwithlatticegirderslabstoform
cellularstructures
latticegirder Corewallsofliftshafts
manufacturedfrom Residentialstructureswithloadbearingparty
steelreinforcement walls

Stairs BathroomPods

Consistsofthinconcretewallsandfloorwitha
Offeraquickmethod singlelayerofreinforcingmesh
forprovidingsafe
Services(electricalconduitsandpipework)can
accessroutesduring
be incorporated into the concrete structure
beincorporatedintotheconcretestructure
construction
Costeffective

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Balconies Terracing

Forapartmentcomplexes
Haveintegraldrainageslots
Forterracingingrandstand,stadiumand
auditorium.
Strong,durableandeasytoinstall.
Protectionformvibration.
Protection form vibration

PrecastConcreteCladdingPanels PrecastConcreteCladdingPanels

Selffinishedpanels Advantages:
Appliedfinishpanels Highquality
Individuallysupported Highaccuracy
p
panels On
Ontime
timedelivery
delivery
Selfsupportingpanels Safety
(stackedfacades) Sustainability
Loadbearing Flexible
structuralpanels
Insulation

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SelfFinishedPanels
Self AppliedFinishedPanels
Applied

Tomimicanaturalstone Typicalmaterial:terracota,
Typical150mmthick
glazedbricks,brickslips,
Surfacetreatmentinclude:
g,
bushhammering,abrasive tilesandstonefacings
g
blasting,acidetching,
mechanicalgrinding& Typicalthickness:30 50
polishing,surfaceretarding, mm
rubbing

IndividuallySupportedPanels SelfSupportingPanels
Self

Designedtospaneitherfromcolumnto Stackingonepanelontopeachother
columnorfloortofloor Carryverticalload
Encloselargeareasofthestructure
Enclose large areas of the structure Typicalthickness:150mm
Typical thickness: 150 mm
Thepanelsarefixedtotheframewith Usingframetotietwopanelsinlateral
bracketsforadjustmentsin3direction direction

Frameislightduetolessload

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LoadBearingStructuralPanels
Load Insulation

Partofstructuralframe Fixedtothebackofthe
panel
Cansupportthefloors,slabsandbeams Fixedbetweenconcreteand
theappliedfinishesinthe
Norequirementforperimetercolumnwhich
No requirement for perimeter column which
factory
increasesthefloorarea Fixedbetweentwolayersof
concrete(sandwichpanels)
inthefactory

JointsandConnections JointsandConnections
(BeamtoColumn) (ColumntoFoundation)

Steelbillets Corbelswith Connection

witha recessed betweenbeams Boltedor Projecting Insitupocket
socketed beamend andsinglestory baseplate starterbars foundation
beamend heightcolumns connetion

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JointsandConnections
(ColumntoColumn)
Metalbearingplates
andembeddedanchor
boltsarecastintothe
endsofthecolumns.
Afterthecolumnsare
After the columns are
mechanicallyjoined,
theconnectionis
groutedtoprovidefull
bearingbetween
elementsandprotect
themetalcomponents
fromfireandcorrosion.
JointsandConnections
(WalltoSlab)
Precast concrete structure
consisting of solid wall
panels and hollow core
slabs.
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JointsandConnections
(SlabtoBeam)
Hollowcoreslabsareset
onbearingpadson
precastbeams.
Steelreinforcingbarsare
in inserted into the slab
ininsertedintotheslab
keywaystospanthejoint.
Thejointisgroutedsolid.
Theslabmayremain
untoppedasshown,or
toppedwithseveral
inchesofcastinplace
concrete.
Sitecast ConcreteToppingsoverPrecast
Slabs
Greaterfloorstrength
andstiffness
Greaterfireresistance
Greateracoustic
i l ti
isolation
Alloweasyintegrationof
electricalservicesinto
floorsystem
Createasmoother,
flatterfloorsurface.
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ManufactureofPrecastConcrete
Castinghollowcoreplank
Precastelementsare
manufacturedincastingbeds,
800ftormoreinlength.
Highstrengthsteelstrandsare
Hi h t th t l t d
strungthelengthofthebed
andtensioned.
Conventionalreinforcing,weld
plates,blockouts,liftingloops,
andotherembeddeditemsare
addedasneeded.
Concreteisplaced.
ManufactureofPrecastConcrete
Castinghollowcoreplank
Individualsectionsarelifted
from the casting bed (right) and
fromthecastingbed(right)and
stockpiledtoawaitshippingto
theconstructionsite.
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ManufactureofPrecastConcrete
Castinghollowcoreplank
Oncetheconcretehascuredto
sufficientstrength,thecastings
arecutintosectionsofdesired
length (above)
length(above).
Insomecases,transverse
bulkheadsareinsertedtodivide
thecastingbedintosections
beforeconcreteisplaced.In
thiscase,onlytheprestressing
strandsneedtobecutto
separatethesections(below).
ManufactureofPrecastConcrete
Castinghollowcoreplank
Precastconcreteelementsare
shipped to the construction site
shippedtotheconstructionsite
bytruckanderectedonsiteby
crane.
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ManufactureofPrecastConcrete
Castinghollowcoreplank
Samplehollowcoreslab
sections of varying depths.
sectionsofvaryingdepths.
Atbottomleft,notethe
insulatedsandwichfloorpanel.
MouldforPrecastConcrete
Adjustable
longline
mouldsystems
Flattable
mould
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ManufactureofPrecastConcrete
PrestressingandReinforcingSteel
Manyprecastelementscontain
bothprestressingstrandsand
conventionalreinforcing.
Right:Theprestressingstrands
Ri ht Th t i t d
foranAASHTOgirderare
depressedintoashallowv
shapetomostefficientlyresist
tensileforcesinthebeam.
Shearstirrupsareformedfrom
conventionalsteelreinforcing.
MouldforPrecastConcrete
Tiltingtable
mould
Batterymould
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QualityControl MethodStatement

PrecastconcretemustbemanufacturedaccordingtoISO
Factorstobeconsideredbeforepreparingthe
9001standard
Keyareasofqualitycontrolinclude: methodofstatement:
Testcertificateformaterials
Safety
Compressivestrengthtesting
Compressive strength testing
Consistence(workability)testing Handling/cranageandtransportation
Mouldstandardandqualitychecks
Siteerection(procedure,programme,sequence)
Correctpreparationofreinforcementcages/strands
check
Castincomponentsandfittingchecks
Dimensionalchecks bothbeforeandaftercasting
Qualityoffinishinspection

Accessandcranage
Accessandcranage CostAnalyses

Factorstobeconsideredforchoosingacrane Insitu Precast

andfinalizingtheconstructionsequence: Material Material
Publicandonsitesafety Girders =S$21,463.00 Slabgirders =S$50,765.00
Deckpanels=S$7,999.00 Deckpanels=S$0
Componentsizesandweights
Reinfsteel
Reinf steel =S$3,135.00
= S$ 3 135 00 Reinfsteel
Reinf steel =S$724.00
= S$ 724 00
Maximumreachofthecranefromsetup
Concrete =S$4,180.00 Concrete =S$965.00
positiontofinalcomponentinstallation
Labor =S$5,522.00 Labor =S$4,884.00
Anyconstraintssuchasoverheadpowerlines Equipment =S$500.00 Equipment =S$4,000.00
Availabilityofsecurestandingareasforcranage Totalarea =1,140sqft Totalarea =1,140sqft
Groundbearingpressuresforcraneloads Totalcost =S$42,799.00 Totalcost =S$61,338.00
Costpersqft =S$37.54 Costpersqft =S$53.80
Costsaving=(53.80 37.54)/37.54=43.31%

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TutorialQuestions
1. Precastconcreteproductsandsystemsareused
extensivelyininfrastructureandcivilstructuresand
areintensivelystudiedbyindustryandacademia.
Whatisprecastconcrete?Describebrieflythe
advantagesanddisadvantagesofthisproduct.
Precastconcretecanbeusedasslabandbeam.State
differentformsofslabandbeamthatyoucanusein
buildingconstruction.
TutorialQuestions
3. Slabforflooringsystemcanbemanufacturedin
factoryusingprecastconcrete.State4typesoffloor
systemusingprecastconcreteandtheapplicability
ofeachsystem.
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TutorialQuestions
2. Latesttrendconstructiontechnologyutilizesnew
systemsofprecastconcrete:crosswall construction,
volumetricconstructionandhybridconcrete
construction.Defineandstatetheadvantagesof
thosethreesystems.
TutorialQuestions
4. Onestructuralelementconstructedusingprecast
concreteistwinwall.Definethiselementandwhere
thissystemcanbeapplied.Forfabricationofprecast
concrete,itisrequiredspecialmouldinfactory.
Describe4differenttypesofmouldforprecast
concrete.
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TutorialQuestions TutorialQuestions

Insitu Precast
5. Twomethodsareproposedbycontractorfor
Material Material
constructingresidentialbuilding.Seethefollowing Girders =S$15,000.00 Slabgirders =S$35,000.00
Deckpanels=S$5,000.00 Deckpanels=S$0
costsofeachitemsforeachmethod.Calculatetotal
Reinfsteel
Reinf steel =S$4,500.00
= S$ 4 500 00 Reinfsteel
Reinf steel =S$500.00
= S$ 500 00
cost,costpersqftanddeterminewhichmethodis Concrete =S$5,000.00 Concrete =S$1,000.00
cheaper.Howmuchcostsavingcanbeobtained Labor =S$6,500.00 Labor =S$3,500.00
Equipment =S$500.00 Equipment =S$2,000.00
betweentwomethods? Totalarea =1,250sqft Totalarea =1,250sqft

THANKYOU

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