PRECAST CONCRETE

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

INDEX
S.N
O.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

CONTENTS
INTRODUCTION
PROCESS OF CONSTRUCTION PRECAST
PRECAST STRUCTURAL SYSTEM
ILLUSTRATIONS-FRAME SYSTEM
PRECAST LOAD BEARING WALL
PRECAST STRUCTURAL ELEMENTS
STRUCTURAL CONCEPT
ILLUSTRATIONS
ADVANTAGES AND BENEFITS
PRODUCTS AND SERVICES
EXAMPLES OF PRECAST BUILDINGS IN INDIA
BIBLIOGRPHY

PAGE NO.
1
2
3
4-7
8-9
10-13
14-16
17
18-19
20
21.
22.

The concept of precast (also known as prefabricated) 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 a large number of buildings
in a short time at low cost.
PRECAST
COMPONENTS
ARE MADE IN A
FACTORY AND
The division and specialization of the human workforce
DELIVERED TO
No space needed on site for storing moulds an reinforcement.
SITE WHERE
The use of tools, machinery, and other equipment, usually automated, in the
THEY ARE LIFTED
STRAIGHT FROM
production of standard, interchangeable parts and products
UNLOADING STRAIGHT ONTO BUILDING
THE LORRY ONTO
Compared to site-cast concrete, precast concrete erection is faster and less
THE BUILDING.

The main features of this construction process are as follows:

affected by adverse weather conditions.

Plant casting allows increased efficiency, high quality control and greater control
on finishes.
BETTER FINISHES
CAN BE OBTAINED
WITH
PRECASTCONCRET
EBECAUSE THE
INSIDE SURFACE OF
THE MOULD IS KEPT
IN GOOD
CONDITION.

INTRODUCTION

MOVING INTO POSITION

FINAL PLACING

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

1.

3. MIX BEING POURED:

Carefully
specifiedconcreteis
placed into the mould.
Many precast works
now employ computer
controlled batching
plants.

1. PRODUCTION OF REINFORCED CAGES AND

MAIN CONNECTIONS:
The precast factory often has specialist
workshops for the manufacture and
maintenance of moulds, and for the
production of jig-built reinforcing cages and
connections.

6. STORAGE OF HIGH-QUALITY UNITS IN

WORKS AREA: The finished precast
components are stacked on clean battens or
plastic pads positioned to suit thedesignof
the component. Care is taken to keep the
stacks vertical and to ensure that battens
are placed directly above one another
within the stack.

2. ASSEMBLY OF
MOULDS: The reinforced
cage is positioned in the
partly assembled mould,
then the remaining
mould section is
completed.

5. PRECAST CONCRETE BEING MOVED

TO THE STORAGE AREA: Once an
appropriate strength has been
reached, the precast units are moved
to the storage area. Units are usually
handled within hours of casting as
part of the rapid production cycle.

4. COMPACTION OF CONCRETE USING

POKER VIBRATOR: To ensure that
optimum density is obtained and that
specified strengths are
achieved,concreteis placed and
compacted using high-frequency
external vibrators or pokers.

7. TRANSPORT TO SITE:

PRECAST CONCRETE PROCESS

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

2.

Depending on the load bearing structures, the most common precast structural systems areSTRUCTURAL
SYSTEMS

FRAME SYSTEMS

LOAD BEARING
WALLS AND
FLOORS

CELL SYSTEMS

1.FRAME SYSTEMS
Frame structures are suitable for buildings which need a high degree of flexibility. Large spans and open spaces can be achieved
without interfering walls.
This system is particularly suitable for shopping malls, multistory car parks, sports facilities, office buildings and industrial
buildings.

2. LOAD BEARING WALLS AND FLOORS

Precast load bearing walls can appear as walls in shafts and cores, cross-walls and load bearing external walls.
Precast wall systems have been used in residential projects. they provide advantages of fast construction ,ready to paint
surface finish, acoustic insulation and fire resistance.
The slabs between walls can either be precast or in-situ flat plate structure.
The aim is to build free open spaces between the load bearing walls and to use partition walls for the internal layout.

3. CELL SYSTEMS
Cell units are feasible for specific uses of a building, for instance, bathrooms and kitchens.
The advantage of the system lies in the speed of construction and high productivity in manufacturing since finishing's
and fittings of the cells are completely done at the factory.

PRECAST BUILDING SYSTEM

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

3.

BEAM TO COLUMN CONNECTION DETAIL

Structurally continuous beamcolumn connection may be

created by passing a tendon from a pocket in the top of
one beam, through the column, to a pocket in the top of
the other beam. The tendon is anchored to a plate in one
pocket as it is tensioned by a jack in the other pocket.

ILLUSTRATIONS-FRAME SYSTEM

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

4.

DETAIL AT A.
(SECTIONAL VIEW)

Topped hollow-core roof slabs supported on beams are

joined to a column with vertical rods. A similar
connection can be used for floor beams resting on
corbels.

ILLUSTRATION 2

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

5.

(c) Short pieces of steel angle are welded to the plates

to join the beams to the columns. Smooth-top hollowcore precast concrete planks are placed on bearing pads
on top of each beam. Grout is poured into the gap
between the ends of the planks to unite loops of
reinforcing that project from the tops of the beams,
reinforcing bars that are inserted through the loops, and
lateral pieces of reinforcing bar that are grouted into the
keys between planks. The end result is a tightly
connected assembly that supports an untopped precast
concrete floor or roof.

The beams in this system of framing rest on concrete corbels that

are integrally cast with the column. The smooth-topped hollowcore slabs are detailed for use without topping. (a) Weld plates are
cast into the column. (b) Beams are placed on bearing pads on the
corbels. There is a weld plate cast into the top of each beam at the
end.

ILLUSTRATION 3

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

6.

This column-to-column connection uses proprietary sleeves

that are cast into the lower end of the upper column section.
Before the sections are assembled (upper left), the lower
ends of the vertical bars from the upper column section,
which reach down to the midheight of each sleeve, are the
only contents of the sleeves.
Assembly of the column sections starts with the placement of a
stack of steel shims in the center of the top of the lower section.
These shims serve to adjust the height of the column and to
maintain a space for grouting between the two sections.

ILLUSTRATION 4

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

7.

Precast concrete walls provide an excellent envelope for low rise commercial and industrial
buildings. They are relatively easy to manufacture, structurally efficient and durable.
Precast walls have been used for seismic load resistance by designing them to emulate cast-in
place shear walls.
This is typically accomplished using ductile vertical reinforcing coupled with splice sleeves to
create continuity across horizontal wall joints.
In adopting the wall thickness, structural adequacy is not the sole consideration. Other factors
to be considered include:
Connection details for supported beams and slabs.
Sound transmission and fire rating.
Joint details at panel-to-panel connections.
Possible future embedded services, which could reduce the concrete area
available.
Based on typical layouts and building configurations, a thickness of 180mm is recommended
for the precast panels.

PRECAST LOAD BEARING WALL

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

8.

PRECAST NON-LOAD BEARING FACADE PANELS

Typically, the wall panels for the front and rear elevations are non-load bearing facade elements. Support of these panels is
achieved by any of the following methods:
The facade panel is connected to main load bearing walls and is designed to carry its own weight between supports.
The facade panel is connected to the floor slab or beam, which is then designed to provide support to the wall.

These panels will typically be designed for vertical loads due to self weight and an
allowance for floor loads, if applicable, in addition to horizontal loads due to external
wind pressures. A typical panel thickness of 120mm is proposed on the basis of
strength considerations and to accommodate window fixings and profiles around the
window perimeter.

PRECAST NON LOAD BEARING WALL

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

9.

PRECAST CONCRETE SLABS

The most fully standardized precast

concrete elements are those used for
making floor and roof slabs.
These may be supported by
bearing walls of precast concrete or
masonry or by frames of steel, site cast
concrete, or precast concrete.

TYPES OF PRECAST SLAB ELEMENTS

FOR SHORT SPANS

AND MINIMUM SLAB
DEPTHS, SOLID SLABS
ARE APPROPRIATE.

PRECAST STRUCTURAL
ELEMENTS

ESTIMATE SIZE

PRECAST SOLID SLAB

DEPTH-90mm to
200mm

PRECAST HOLLOW-CORE
SLAB

DEPTH SPAN
200mm 7.6m
250mm 9.8m
300mm 12m

PRECAST CONCRETE
DOUBLE TEES

COMMON DEPTHS300.350,400,460mm

PRECAST CONCRETE SINGLE

TEE

DEPTH-915mm
SPAN-2.5m

PRECAST CONCRETE
COLUMN

250mm,300mm,,40
0mm,600mm

IN HOLLOW-CORE
SLABS, PRECAST
ELEMENTS SUITABLE
FOR INTERMEDIATE
SPANS, INTERNAL
LONGITUDINAL VOIDS
REPLACE MUCH OF THE
NONWORKING
CONCRETE.

FOR THE LONGEST SPANS, STILL DEEPER

ELEMENTS ARE REQUIRED, AND DOUBLE TEES
AND SINGLE TEES ELIMINATE STILL MORE
NONWORKING CONCRETE.

STANDARD PRECAST CONCRETE BEAM AND GIRDER SHAPES.

PRECAST STRUCTURAL ELEMENTS

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

10.

1. PRECAST REINFORCED CONCRETE

FLOOR SYSTEMS:
.The precast reinforced concrete floor beams,
planks, tee beams or beam and infill blocks that
require little or no temporary support and on
which a screed or structural concrete topping is
spread are commonly used with structural steel
frames and may be used for in situ cast floors.
.Precast beams and plank floors that require no
temporary support in the for of centering are
sometimes referred to as self-centering floor.
.The advantage of these precast floor systems is
that there is a saving in site labor.

PRECAST CONCRETE PLANK

FLOOR UNIT:
These comparatively thin, prestressed
solid plank, concrete floor units are
designed as permanent shuttering and
for composite action with structural
reinforced concrete topping. The
units are 400 or 1200 wide,65,75 or
100 thick and up to 9 and half meters
long for floors and 10 meters long for
roofs.

The two most common types are:

PRECAST
PRECAST HOLLOW
HOLLOW FLOOR
FLOOR UNITS:
UNITS:

Theses
precast
hollow
floor
units
Theses precast hollow floor units are
are
generally 400-12200
400-12200
generally
wide,110,150,200,250 or
or 300
300 thick
thick and
and
wide,110,150,200,250
up
up to
to 10
10 meters
meters long
long for
for floors
floors and
and
thirteen
and
a
half
meter
long
for
thirteen and a half meter long for roofs.
roofs.
The
purpose
of
voids
or
hollows
in
The purpose of voids or hollows in the
the
floor unit
unit is
is to
to reduce
reduce dead
dead weight
weight
floor
without affecting
affecting strength.
strength. The
The
without
reinforcement
reinforcement is
is cast
cast into
into webs
webs between
between
hollows.
hollows.

PRECAST STRUCTURAL ELEMENTS

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

11.

PRECAST BEAM AND FILLER BLOCK FLOOR:

This floor system consists of precast reinforced concrete

planks or beams that support precast hollow concrete
filler blocks.
The planks or beams are laid between them and a
concrete topping is spread over the planks and filler
blocks.
The reinforcement protruding from the top of the plank
acts with the concrete topping to form reinforced concrete
beam.
The advantage of this system is that the lightweight
planks or beams and filler blocks can be lifted much more
easily and placed in position than the much larger hollow
concrete floor units.

HOLLOW CLAY AND CONCRETE

FLOOR:

1. A floor system of hollow clay blocks

and in situ cast reinforced concrete
beams between the blocks and
concrete topping cast on centering and
falsework, resisting properties of the
blocks. This floor system is much less
used because of the very considerable
labor in laying the floor.

PRECAST CONCRETE
TEE BEAMS:
Precast prestressed concrete
tee beam floors are mostly
used for long span floors in
such buildings as stores,
supermarkets, swimming pools
and multi-storey car parks
where there is a need for wide
span floors and the depth of
this type of floor is not a
disadvantage. The floor units
are cast in the form a double
tee.

PRECAST STRUCTURAL ELEMENTS

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

12.

FOOTING BELOW PRECAST LOAD BEARING WALLS

PRECAST WALLS

The foundation loads for the precast structural system will be similar to
those for conventional design.
The arrangement of the foundations below the load bearing walls will
be different to those normally adopted for a column and beam structural
system.
The desirable arrangement should provide a relatively uniform support
along the length of the wall and minimize the eccentricity effects
due to any possible misalignment of the walls relative to the
foundations.
In the case of a footing foundation
system, the recommended solution is a
continuous strip footing below the load
bearing walls, as shown in Figure.

GROUT

GROUND BEAM
AND SLAB

FOOTING

Similarly, a raft foundation system, as shown in Figure I. will provide

a uniform support to the load bearing walls and excellent resistance
to eccentricity effects.

I. PRECAST LOAD BEARING WALL

ON STRIP FOOTING OR RAFT
FOUNDATION

II. PRECAST LOAD BEARING

WALL ON PILED FOUNDATION

For a piled foundation, uniform support along the full length of the
wall can be provided by adopting piles at closer spacing with a first
storey capping beam. This solution is unlikely to be economical. The
recommended approach is shown in Figure II. which is based on the
following structural concept:
Within the precast concrete wall, zones are designated as load
bearing and no-load bearing.
Piles are located below the load bearing zones only.
The piles are preferably provided in groups of two or more, located
on each side of the wall centerline. If single piles are necessary, first
storey beams are required in the transverse direction to accommodate
any possible eccentricity effects.

PRECAST FOUNDATION

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

13.

Based on considerations of buildability, economy and standardization of precast components, the structural concept
developed consists of:
Conventional foundations comprising footings, raft slab or piles and pile caps.
Cast in-situ first storey, typically reinforced concrete beam and slab system.
Precast concrete load bearing walls.
Precast concrete non-load bearing faade panels.
Precast concrete floor system, either:
- Precast concrete beams and precast slabs (reinforced concrete or
prestressed) with a composite in-situ topping
or Precast concrete walls with precast concrete slab system

PRECAST PRESTRESSED SLABS SPANNING BETWEEN WALLS WITH COMPOSITE IN-SITU TOPPING FOR 1ST STOREY

STRUCTURAL CONCEPT

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

14.

PRECAST PRESTRESSED SLABS SPANNING

BETWEEN WALLS WITH COMPOSITE IN-SITU
TOPPING FOR 2ND STOREY

PRECAST PRESTRESSED SLABS SPANNING

BETWEEN WALLS WITH COMPOSITE IN-SITU
TOPPING FOR ROOF

STRUCTURAL CONCEPT

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

15.

WORKERS GUIDE TWO HOLLOW-CORE SLABS,

LOWERED BY A CRANE IN WIRE ROPE SLINGS,
ONTO THE PRECAST CONCRETE BEAMS THAT WILL
SUPPORT THEM.

A FULLY PRECAST BUILDING FRAME UNDER

CONSTRUCTION. A POURED CONCRETE TOPPING
WILL COVER THE HOLLOW-CORE SLABS AND THE
BEAMS TO CREATE A SMOOTH FL OOR AND TIE
THE PRECAST ELEMENTS TOGETHER.

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

16.

DOUBLE-TEE SLAB ELEMENTS

SUPPORTED ON A FRAME OF PRECAST
COLUMNS AND L-SHAPED GIRDERS

DOUBLE-TEE SLAB ELEMENTS

SUPPORTED ON A PERIMETER OF
PRECAST CONCRETE LOADBEARING
WALL PANELS AND AN INTERIOR
STRUCTURE OF PRECAST COLUMNS
AND INVERTED TEE BEAMS.

HOLLOW-CORE SLAB
ELEMENTS
SUPPORTED ON
PRECAST CONCRETE
LOADBEARING WALL
PANELS.

ILLUSTRATIONS

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

17.

FLEXIBILITY OF SHAPE AND

FORM: Concrete can be molded into
any shape, hence it is used to provide
custom made design solutions.

STRENGTH: precast exterior cladding can be

easily designed to handle structural building
loads.

DURABILITY: Studies
have shown that concrete
products can provide a
service life in excess of 100
years.

BENEFITS AND ADVANTAGES

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

18.

DESIGN-BUILD EFFICIENCY: Precast

concrete provides an efficient delivery

model for your project; allowing building
construction to proceed while the design is
developed.
ESTHETICS: An unlimited array of
colorings, textures and patterns can be added
to the concrete mix, or textured paints of any
color may be used, for exceptional effects.

ENERGY EFFICIENCY: The thermal mass inherent to

precast concrete lends itself to energy efficiency and reduces
the heating and cooling peaks and loads; often necessitating
less costly mechanical systems.
ENVIRONMENTALLY FRIENDLY: An inherent
characteristic of precast concrete is its natural resistance
to mold, greatly reducing health concerns from VOCs
and off gassing. With these environmentally friendly
advantages, precast concrete satisfies a growing demand
for sustainable design and construction. Additionally,
precast concrete structures are completely recyclable
making their impact on the environment minimal.
BENEFITS AND ADVANTAGES

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

19.

AGRICULTURAL
PRODUCTS

CEMENTERY
PRODUCTS

UTILITY
STRUCTURES

PRODUCTS
INCLUDE:
BUNKER
SILOS ,CATTLE
FEED
BUNKS,CATTLE
GAURDS ETC

PRODUCTS AND SERVICES

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

20.

SANTUSHTI HOMES AT BHIWADI

250 affordable homes
G+3 Storied 3 Blocks
Load bearing Precast walls
Precast Solid Slabs (room size)
Site Based Precast Plant
Design Approved by IIT Delhi

COMMUNE-1 AT
BANGALORE

LAKESIDE AT CHENNAI

550 apartment scheme

Basement +G+13
Load bearing Precast walls
Precast Solid slabs
Site based Precast Plant

300 apartment scheme

Stilt + 4 Storied 6 Blocks
Load bearing Precast walls
Precast Hollow-core slabs
Dedicated Precast Plant
Design Approved by IIT Delhi

MARVEL SANGRIA AT PUNE

Commercial Building of 250,000 sqft
Shops at Ground & Mezzanine floor
B+G+3 Storied 3 Blocks
Load bearing Precast walls
Precast hollow-core slabs
Precast Portal Frames at all floors
Precast Retaining Walls at Basement
Precast Plant located at Pune

EXAMPLES OF SOME PRECAST BUILDINGS IN INDIA

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

21.

ebooks.narotama.ac.id
McKay
www.bca.gov.sg
www.fpcaweb.org
www.researchgate.net
precast.org

ARUSHI BANDHU
SECOND YEAR A
ROLL NO. 5

22.