PRECAST CONCRETE CONSTRUCTION SYSTEM

-Harsh Bhansali
INTRODUCTION
PRECAST CONCRETE IS A FORM OF CONCRETE THAT IS PREPARED, CAST AND CURED OFF-SITE,
USUALLY IN A CONTROLLED FACTORY ENVIRONMENT, USING REUSABLE MOULDS. 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.

APPLICATIONS
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 PRODUCTS SUCH AS PRECAST WATER TANKS, SEPTIC TANKS, DRAINAGE

CHAMBERS, - RAILWAY SLEEPERS, FLOOR BEAMS, BOUNDARY WALLS AND WATER
PIPES.

• TO MAKE WALL OR CLADDING PANELS FOR BUILDINGS.

• TO MAKE COMPONENTS FOR INFRASTRUCTURE PROJECTS: ELEMENTS SUCH AS

BRIDGE SPANS, OR METRO LINE VIADUCTS ARE OFTEN PRECAST IN A CASTING YARD.

• TO MAKE PRECAST PRE-STRESSED ELEMENTS FOR BUILDINGS.

 MANUFACTURING PROCESS

A Brief Overview of the Precast Concrete Production Process :

Preparing the Forms :

First, we prepare the forms. This part of the precast concrete production
process includes choosing the concrete mix, determining concrete
thickness, and installing rebar for steel reinforcement.

Mixing and Pouring :

Depending on the project and the precast product itself, pouring

concrete can be a complex procedure. Our engineers have already
determined the matrix, the amount of reinforcement, and the final shape
of the product. The batching (or mixing of raw material) process includes
sampling to test the concrete for strength.

Curing :

Once pieces are prepared and poured, the finished product is set aside
to cure, based on strength specificities engineered and determined
beforehand. Each piece of fresh and cured concrete — now shaped into
a form that permits a wide variety of precast concrete
structures: retaining walls, culverts, catch basins — leaves our production
center ready to be installed.
ADVANTAGES OF PRECAST CONSTRUCTION

Saves Construction Time: Precast Concrete construction saves time, the

risk of project delay is also less. The precast concrete casting can be
carried on simultaneously with other works on site such as
earthwork, survey, etc. and thus saves time.

Quality Assurance: The key factors which regulate the quality of

construction such as curing, temperature, mix design, formwork, etc.
can be monitored for Precast Concrete. So, improved quality
construction can be performed.

Usage of Prestressed Concrete: By using pre-stressed precast, structural

materials of high strength and load-bearing capacity can be achieved,
which can result in greater clear span, reduced size of the cross-section
of structural members, etc.

Cost-effective: The simplified construction process reduces the time,

increases the productivity, quality and safety and thus the cost is
reduced.

Durability: Precast Concrete structure has a longer service time period

and minimal maintenance. The high-density Precast Concrete is more
durable to acid attack, corrosion, impact, reduces surface voids and
resists the accumulation of dust.

Aesthetics: As the structures are prefabricated in a controlled factory

environment, several combinations of colors and textures can be used.
A wide range of shapes and sizes are available to choose from with
smooth finishing and thus the aesthetical value of products are
increased.

Safe Construction Platform: No raw materials have to be stocked in site

for Precast Concrete construction. It reduces the requirement of
traditional formworks and props, wastage, workers, etc. and thus
provides a safe working platform.
DISADVANTAGES OF PRECAST CONSTRUCTION

High Initial Investment: For installing a Precast Concrete plant, heavy

and sophisticated machines are necessary which requires a high initial
investment. A large scale of precast construction projects must be
available to ensure sufficient profit.

Transportation Issue: The construction site can be at a distant location

from the Precast Concrete plant. In that case, the precast members
must be carried to the site using trailers. In many cases, the reduced
costs of Precast Concrete is compensated by the transportation cost.

Handling Difficulties: Proper care and precaution have to be taken for

handling precast concrete. Usually, precast members are heavy and
large which makes it difficult to handle without damage. Generally,
portable or tower cranes are used to handle precast members.

Modification: Limitation In case of precast structures, it is difficult to

modify the structure. For example, if a structural wall is to be dismantled
for modification it will impact the overall stability of the structure.

Sensitive Connection Works: Assembling of the precast members is one

of the key points for ensuring strong structural behavior. Connections
between several structural members must be supervised and done
properly to ensure the intended behavior of the connection such as
simple, semi-rigid or rigid connections. Besides this, faulty connections
may lead to water leakage and fail sound insulation.
INSTALLATION
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 THEREFORE TO SAFEGUARDING AGAINST RISKS WHEN
RECEIVING DELIVERY, MOVING, AND PLACING UNITS.

CONSIDERATION SHOULD BE GIVEN TO:

• THE METHOD AND SEQUENCE OF ASSEMBLY AND ERECTION.

• THE METHOD OF PROVIDING TEMPORARY SUPPORTS.

• STRUCTURAL CONNECTIONS AND JOINT DETAILS.

• TOLLERANCES.

• 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.

PRECASTING – SITE / FACTORY

PRECASTING CAN BE CARRIED OUT AT A CASTING YARD, IN OR NEAR THE SITE, OR IN A
FACTORY. A KEY ASPECT OF DETERMINING WHETHER TO USE SITE OR FACTORY PRECASTING IS
TRANSPORT COSTS. FACTORY WORK OFFERS SUPERIOR QUALITY FOR OBVIOUS REASONS, SO
IF THERE IS A FACTORY CLOSE TO THE SITE, IT MAKES SENSE TO USE IT.

IF A PRECASTING YARD IS TO BE CREATED, SPACE MUST BE LAID OUT FOR THE FOLLOWING
ACTIVITIES:
• STORING THE RAW MATERIALS, SUCH AS CEMENT, AGGREGATE, SAND,
ADMIXTURES, WATER, REINFORCEMENT BARS, AND STEEL OR PLYWOOD SHEETS
FOR FORMWORK.
 • A FORMWORK MAKING AND MAINTENANCE YARD.

• A CONCRETE MIXING PLANT.

• A STEEL REINFORCEMENT YARD TO MAKE REBAR CAGES TO BE PLACED INSIDE THE

CONCRETE.

• A CASTING AREA.

• A CURING AREA.

• A STACKING AREA FOR FINISHED COMPONENTS.

FOR INFRASTRUCTURE PROJECTS, A CASTING YARD IS CREATED ON A PIECE OF OPEN LAND

IN THE CITY. IT IS IMPORTANT THAT THIS IS LOCATED NEAR A MAJOR HIGHWAY, AS THE
PRECAST ELEMENTS CAN BE VERY LARGE OR HEAVY, AND CANNOT BE TAKEN THROUGH
NARROW ROADS.

CONNECTING PRECAST 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.

PANELS BOLTED TOGETHER

GROUTING
 PRECAST CONCRETE - COMPONENTS

PRECAST CONCRETE SLABS

SOLID FLAT SLABS

• THIS TYPE OF SLABS ARE USED FOR SUPPORT CONDITIONS IN BUILDINGS.
• RCC SLABS WHOSE THICKNESS RANGES FROM 10 TO 50 CENTIMETERS ARE
MOST OFTEN USED FOR THE CONSTRUCTION OF FLOORS AND CEILINGS. THIN
RCC SLABS ARE ALSO USED FOR EXTERIOR PAVING PURPOSES.

HOLLOW CORE SLABS

• A HOLLOW CORE SLAB, ALSO KNOWN AS A VOIDED SLAB, HOLLOW CORE
PLANK, OR SIMPLY A CONCRETE PLANK IS A PRECAST SLAB OF
PRESTRESSED CONCRETE TYPICALLY USED IN THE CONSTRUCTION OF
FLOORS IN MULTI-STORY APARTMENT BUILDINGS.

DOUBLE TEE SLABS

• A DOUBLE TEE OR DOUBLE-T BEAM IS A LOAD-BEARING STRUCTURE THAT
RESEMBLES TWO T- BEAMS CONNECTED SIDE BY SIDE.
• THE STRONG BOND OF THE FLANGE (HORIZONTAL SECTION) AND THE TWO
WEBS (VERTICAL MEMBERS, ALSO KNOWN AS STEMS) CREATES A STRUCTURE
THAT IS CAPABLE OF WITHSTANDING HIGH LOADS WHILE HAVING A LONG
SPAN. IT CAN BE APPLIED IN ROOFING, PARKING AND BRIDGES.
PRECAST CONCRETE BEAMS

RCC BEAMS
• PRECAST BEAMS ARE STRUCTURAL ELEMENTS DESIGNED TO CARRY TRANSVERSE
EXTERNAL LOADS THAT CAUSE BENDING MOMENT, SHEAR FORCES, AND IN
SOME CASES TORSION ACROSS THEIR LENGTH.
• THESE BEAMS GENERALLY HAVE CONCRETE RESISTING ON THE COMPRESSION
REGION AND STEEL RESISTING APPLIED LOADS ON THE TENSION REGION. IT
CAN BE CLASSIFIED AS PER SIZE INTO- RECTANGULAR, T-BEAM, I-BEAM,
CIRCULAR BEAM AND L-BEAM. IT IS USED TO SUPPORT THE BUILDING’S FLOORS,
ROOF, WALLS AND CLADDING.

PRESTRESSED BEAMS SHELL BEAMS

PRESTRESSED BEAMS
• IT IS VERY EASY TO INSTALL WITH REDUCED ON-SITE LABOR NEEDS AND
COSTS.
• IT COMES IN A WIDE RANGE OF DEPTHS TO MEET EXACT BUILDING NEEDS IT
PROVIDES MUCH-NEEDED REINFORCEMENT FOR MULTI-STORY BUILDINGS
AND INDUSTRIAL APPLICATIONS.

SHELL BEAMS
• SHELL BEAMS ARE COMMONLY USED WITH PRECAST FLOOR SYSTEMS.
• BAND DEPTHS OF 290MM TO 600MM AND WIDTHS OF 600MM UP TO
2400MM ARE POSSIBLE. REINFORCED ULTRASHELL BEAMS CAN SPAN UP
TO 11M.
PRECAST CONCRETE WALLS

LOAD BEARING EXTERNAL CONCRETE WALLS

• THIS WALL IS CONSTRUCTED TO SUPPORT THE ABOVE SLAB OR OTHER BUILDING
ELEMENTS IN A STRUCTURE. THESE WALLS ARE GENERALLY 125 MM TO 200 MM
THICK.

• THE THICKNESS DEPENDS ON THE LOAD PATTERN.

NON-LOAD BEARING CONCRETE WALLS

• THIS WALL HOLDS UP ONLY ITSELF.
• THIS TYPE OF WALL IS USED TO CLOSE IN A STEEL OR CONCRETE FRAME
BUILDING. IT IS USUALLY CARRIED BY SUPPORTS, NORMALLY STEEL SHELF
ANGLES ON EACH FLOOR. THESE WALLS ARE GENERALLY 50 MM TO 100 MM
THICK.
OTHER PRECAST CONCRETE ELEMENTS

PRECAST STAIRCASE
• PRECASTING STAIRCASE PRODUCES BETTER SURFACE FINISHES, AVOIDS THE
INHERENT PROBLEMS OF CASTING COMPLICATED INCLINED SECTIONS ON-
SITE AND PROVIDES RAPID ACCESS TO SUCCESSIVE FLOORS. THEY ARE COST-
EFFECTIVE. THE STAIRCASE CAN BE DESIGNED WITH LANDING SLABS ALSO.

PRECAST STORM WATER DRAIN

• PRECAST CONCRETE DRAINS ALLOW FOR SPEEDIER CONSTRUCTION OF
DRAINS WITH MINIMUM SITE WORK.
• THESE DRAINS RANGE IN WIDTHS FROM 200 MM TO 855 MM AND THESE CAN
BE CUSTOMIZED AS PER YOUR NEEDS. THEY ARE PRODUCED IN STRICT
FACTORY CONTROLLED CONDITIONS THAT ENSURE HIGH QUALITY. THESE
TYPES OF DRAINS ARE ALSO USED IN RESIDENTIAL LAYOUT AND WATER LINES
IN INDUSTRIES.