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PRECAST CONCRETE STRUCTURES

1. INTRODUCTION

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.

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The main features of this construction process are as follows:

? The division and specialization of the human workforce

? The use of tools, machinery, and other equipment, usually automated, in the
production of standard, interchangeable parts and products

? Compared to site-cast concrete, precast concrete erection is faster and less

affected by adverse weather conditions.

? Plant casting allows increased efficiency, high quality control and greater
control

on finishes..

This type of construction requires a restructuring of entire conventional

construction process to enable interaction between design phase and production
planning in order to improve and speed up construction.

1.1 TYPES OF PRECAST SYSTEMS

Depending on the load-bearing structure, precast systems can be divided into

the following categories:

? Large-panel systems

? Frame systems
? Slab-column systems with walls

? Mixed systems

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1. 1. 1 LARGE PANEL SYSTEMS

The designation �large-panel system� refers to multistory structures composed

of large wall and floor concrete panels connected in the vertical and horizontal
directions so that the wall panels enclose appropriate spaces for the rooms within
a building. These panels form a box-like structure. Both vertical and horizontal
panels resist gravity load. Wall panels are usually one story high. Horizontal
floor and roof panels span either as one-way or two-way slabs. When properly joined
together, these horizontal elements act as diaphragms that transfer the lateral
loads to the walls.

A large-panel concrete building under construction

Depending on wall layout , there are three basic configurations of large-panel

buildings:

? Cross-wall systems

? Longitudinal wall systems

? Two-way systems
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1. 1. 2 FRAME SYSTEMS

Precast frames can be constructed using either linear elements or spatial

beam-column sub-assemblages. Precast beam-column sub-assemblages have the advantage
that the connecting faces between the sub-assemblages can be placed away from the
critical frame regions; however, linear elements are generally preferred because of
the difficulties associated with forming, handling, and erecting spatial elements.
The use of linear elements generally means placing the connecting faces at the
beam-column junctions. The beams can be seated on corbels at the columns, for ease
of construction and to aid the shear transfer from the beam to the column. The
beam-column joints accomplished in this way are hinged. However, rigid beam-column
connections are used in some cases, when the continuity of longitudinal
reinforcement through the beam-column joint needs to be ensured. The components of
a precast reinforced concrete frame are shown in Figure

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1. 1. 3 SLAB-COLUMN SYSTEMS WITH SHEAR WALLS

These systems rely on shear walls to sustain lateral load effects, whereas
the slab-column

structure resists mainly gravity loads. There are two main systems in this
category:

� Lift-slab system with walls

� Prestressed slab-column system

In the Lift �slab system, the load-bearing structure consists of precast

reinforced concrete columns and slabs,. Precast columns are usually two stories
high. All precast structural elements are assembled by means of special joints.
Reinforced concrete slabs are poured on the ground in forms, one on top of the
other. Precast concrete floor slabs are lifted from the ground up to the final
height by lifting cranes. The slab panels are lifted to the top of the column and
then moved downwards to the final position. Temporary supports are used to keep the
slabs in the position until the connection with the columns has been achieved.
A lift-slab building

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The prestressed slab-column system uses horizontal prestressing in two

orthogonal directions to achieve continuity. The precast concrete column elements
are 1 to 3 stories high. The reinforced concrete floor slabs fit the clear span
between columns. After erecting the slabs and columns of a story, the columns and
floor slabs are prestressed by means of prestressing tendons that pass through
ducts in the columns at the floor level and along the gaps left between adjacent
slabs. After prestressing, the gaps between the slabs are filled with in situ
concrete and the tendons then become bonded with the spans. Seismic loads are
resisted mainly by the shear walls (precast or cast-in-place) positioned between
the columns at appropriate locations.

Post-tensioned slab-column connection

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2. PRECAST CONCRETE STRUCTURAL ELEMENTS

1.1 Precast Slabs

Hollow core slabs

1.2 Precast Beam & Girders

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1.3 Precast Columns

Precast columns Inverted Tee beams supported on precast columns

1.4 Precast Walls

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1.5 Other Elements

2.

Precast concrete Stairs Uniquely shaped structural elements for a sports stadium

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DESIGN CONCEPTS FOR PRECAST CONCRETE BUILDINGS

The design concept of the precast buildings is based on the buildability, economy
and standardization of precast components.
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In design of precast members and connections, all loading and restraint

conditions from casting to end use of the structure should be considered. The
stresses developed in precast elements during the period from casting to final
connection may be more critical than the service load stresses. Special attention
should be given to the methods of stripping, storing, transporting, and erecting
precast elements.

When precast members are incorporated into a structural system, the forces
and deformations occurring in and adjacent to connections (in adjoining members and
in the entire structure) should be considered. The structural behavior of precast
elements may differ substantially from that of similar members that are
monolithically cast in place. Design of connections to transmit forces due to
shrinkage, creep, temperature change, elastic deformation, wind forces, and
earthquake forces require special attention. Details of such connections are
especially important to insure adequate performance of precast structures.

Precast members and connections should be designed to meet tolerance

requirements. The behavior of precast members and connections is sensitive to
tolerances. Design should provide for the effects of adverse ccombinations of
fabrication and erection tolerances. Tolerance requirements should be listed on
contract documents, and may be specified by reference to accepted standards.
Tolerances that deviate from accepted standards should be so indicated.

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 All details of reinforcement, connections, bearing elements, inserts,
anchors, concrete cover, openings and lifting devices, and specified strength of
concrete at critical stages of fabrication and construction, should be shown on
either the contract documents prepared by the architect/engineer ofrecord or on the
shop drawings furnished by the contractor. Whether this information is to be shown
on the contract documents or shop drawings depends on the provisions of the
contract documents. The shop drawings should show, as a minimum, all details of the
precast concrete members and embedded items. The contract documents may specify
that portions of connections exterior to the member are also to be shown on the
shop drawings. The contract documents may also require the contractor to provide
designs for the members and/or connections.

The contract documents should show the loads to be considered in design of

the precast concrete elements of the structure, and they should indicate any
special requirements or functions (for example: seismic loads, allowance for
movements, etc.) that should be considered in design assigned to the contractor. In
this case, the shop drawings should include complete details of the connections
involved.

Precast concrete structure consisting of solid wall panels and hollow core slabs.

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A single story warehouse consisting of double tees supported by insulated sandwich
wall panels.

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3. TYPICAL CONNECTION OF PRECAST CONCRETE ELEMENTS

COLUMN TO COLUMN CONNECTION

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BEAM TO COLUMN CONNECTION

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SLAB TO BEAM CONNECTION

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WALLPANEL CONNECTED TO INSITU CONCRETE

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CONNECTION BETWEEN SLABS

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CORNER CONNECTIONS OF WALL PANELS

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CONNECTION OF WALL PANELS TO COLUMNS

4. PRECAST CONCRETE CONSTRUCTION AND SEISMIC DESIGN

There is a general concern regarding the seismic performance of precast

construction.

It is noticed that large panel construction performs better than frame system.

However, in areas of high seismic risk, structures must be designed to respond

safely to the dynamic forces imparted into the structure. Innovations in joint
design are improving the connection systems in precast concrete structures and
making them increasingly suitable for use in such areas.

Information, pictures, photographs etc of the paper have been taken from

www.bca.gov.sg/publications/BuildabilitySeries/others/bsl_cp3.pdf www.cpci.ca
Precast industrial buildings detailing manual by National Precast Concrete
Association Australia

www.world-housing.net/uploads/precast__concrete.pdf

Precast construction by Svetlana Brzev, British Columbia Institute of Technology,

Canada ,Teresa Guevara-Perez, Architect, Venezuela

ACI 550R-96, Design recommendations of precast Concrete Structures.

Precast.ppt by Fundamental of Building construction , Materials & Methods, 5th

Edition