Topics

 Precast concrete structures (PCS)

 including columns, beams, floor slabs, wall panels and

stairs

 Precast concrete connections

PCS: Characteristics
 THESE ARE FORMS/STRUCTURE/STRUCTURAL COMPONENTS
& ELEMENTS MADE OFF-SITE.

 ALSO KNOWN AS “PREFABRICATED STRUCTURES”

 Majority of the structural components are standardised and produced in

plants in a location away from the building, and then transported to the site
for assembly.

 The more the components the easier the coordination and with a better
possibility of cutting down time & cost ie economies of scale.
PCS: Advantages
 Standardisation Units-Speed

 1 person/group does 1 element of the work thus specialising in that

particular expertise always with the intention of attaining speed, less
error.

 This will cut down the cost of production by mere simplification of

works, enhanced by, in a controlled environment eg work/production
can proceed in all weathers!

 Plant casting allows increased efficiency and high quality control.

 Compared to in-situ cast concrete, precast concrete erection is faster and

less affected by adverse weather conditions.
PCS: Advantages
 Ease of Transportation

 As these can be produced elsewhere and transported to any

site required. Hence improve the space of a construction
site.

 As the time for completion for a or any fixing/installation is

cut short or made faster with modules & the like.
PCS: Advantages
 Components are manufactured by industrial methods

 It is being carried out with high/great attention given to

quality assurance & control, using the best available
technology, if not the latest.

 Works are made manageable & easier by being assisted with

the use of equipments & specific tools and guided by
computer.

 Provides same quality and sizes of the PC units.

PCS: Advantages
 MASS PRODUCTION

 Mass production in order to build a large number of

buildings in a short time and spreading the overhead, thus
reduce per unit cost.

 PCS, is not suitable for small projects.

 Brainstorm: What are the disadvantages of PCS?

Main Features of PCS
 The main features of this construction method(precast)

 Division and specialisation of workforce.


 Use of tools, machinery and special equipment, usually automated in the
production of standard, interchangeable parts/components.

 Precast concrete erection is faster and less affected by weather
conditions.

 Factory casting allows increased efficiency, better quality control and
finishes.

TYPES OF PCS
 PCS can be identified & generalised into 4 systems:-
 (easily identified as their name implies!)

 1. Large Panel Systems

 2. Frame Systems

 3. Slab-Column Systems (with shear walls)

 4. Mixed Systems
1. Large Panel Systems
1. Large Panel Systems
 Visually ~ this method of construction appears to be like the staking of
cardboards, or playing cards, or even, toy blocks.

 Its Characteristics.

 Multi-storey structures composed of large walls and floor panels connected

in the vertical and horizontal positions. Wall panels are usually ONE
STOREY high.

 These panels form a box like structure enclose designated spaces for the
rooms within a building. When joined together, these horizontal panels act
as diaphragms, transferring lateral & vertical forces loads via the other panel
components down to the ground.

 Horizontal floor and roof panels either one-way or two-way slabs.

2. Frame Systems
 As the name implies, its basic requirement for installation is the need to
have a Frame, of which, it itself is formed by precast components, namely,
columns & beams.

 The frame forms the superstructure for all other structural components to be
fixed to.
 Characterised by...

 Linear elements (connected on the same plane of installation). The use of

linear elements 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 loading & shear forces transfer from beam to the
column.
2. Frame Systems
The beams can be seated on corbels at the columns.
2. Frame Systems
The column-beam joints are hinged.

Several Methods of Beam to Column connections (hinged/pin jointed).

Rigid column-beam joints are used in some cases(seldom), only if &

when the need to ensure the continuity of longitudinal reinforcement
through the column-beam.
3. Slab-Column Systems (with shear walls)
 Again, as the term/name implies, this involves 2 elements
of construction, namely slab & column.

 The 2 categories on this system are:-

 A. Lift-Slab System

 B. Pre-Stressed Slab-Column System

3A. Lift-Slab System with walls
 Load-bearing structure consists of precast reinforced concrete
columns and slabs.

 Precast column are usually TWO STOREYS high or in sets of 2

storey height elements i.e. for purpose of ease of installation.


 All precast structural elements are assembled by special

detailed connectors/joints.

Lift-Slab System
2 common methods used, depending on the construction situation,
limits, targets etc...

Working up… Stacking then working down…

Lift-Slab System
Lift-Slab System
 The slab panels cast-insitu on the ground then lifted UP the
column via jacks(most often hydraulic i.e. strength+slowly).
The consecutive slabs are separated by a medium eg wax
&/@ polythene sheets which dissolves in volatile spirits.

 Alternatively, the slab(prefabricated) are installed from the top
then slowly lowered to their respective levels.

 Temporary supports are used to keep the slab in place until the
permanent connection with the column has been achieved.

Lift slab animation
3B. Pre-Stressed Slab-Column System
 This system uses horizontal pre-stressing (strengthening) on
two orthogonal directions to achieve continuity.

 The precast concrete column elements are 1-3 STOREYS
high.

 The reinforced concrete floor slabs fits the clear span between
columns

 The columns and floor slabs are pre-stressed by means of pre-

stressing tendons that pass through ducts in the columns at the
floor level and along the gaps left between adjacent slabs.
Pre-Stressed Slab-Column System
Pre-Stressed Slab-Column System
After pre-stressing (strengthening), the gaps between the slabs are filled with
cast in-situ concrete.

The tendons become bonded with the spans

4. Mixed Systems
 This is when several elementary methods of each of the
other systems are combined such as

 Columns / floor use Lift System + Walls use Large Panel

System.

 This is often & normally done to suit the site condition

(restrain/restriction) & also, the situation of use (design)..
PC COMPONENTS/ELEMENTS
PC COMPONENTS
 In the Precast Concrete Industry, the more
components/elements that can be precast &
modulated/standardized (either production or installation),
the better effectiveness of the system.

 Lets look at some of the components of such...

PC SLABS
PC COLUMNS
PC Beam & Girders

Why are the rebars exposed?

Cause these form part of the structures that needs & will be ‘fused’(partial castng)
together with the other components eg columns, slabs & wallls.
PC WALL PANELS
PC STAIRS
Possible Impacts (Precast Methods of Construction)

 With the marvel of Research & Development +

Technology, we may now achive restructuring of entire
conventional construction process to enable interaction
between design and production planning to change,
improve and speed up our Labour-Intensive construction
industry. Among others, methods & systems that are made
available to us in Malaysia are;-
 i. IBS (Industrialised Building Systems)
 Based on the structural aspects of the systems, IBS can be
divided into five common types
Possible Impacts (Precast Methods of Construction)

 I. IBS (Industrialised Building Systems)

 Based on the structural aspects of the systems, IBS can be divided into five common types

 a. Precast Concrete System (which is being deliberated upon, now).

 b. Formwork System.

 d. Steel Frame System.

 c. Blockwork System.

 e. Timber Frame System

 II. Duralite (mineralised wood wool construction panel)

 These are panel boards used for/at walls, roof, floor etc whilst still adopting the conventional superstructures
namely timber, steel & concrete.
Installation/Assembly Of Precast Concrete Elements
 All these components & elements are of not much use if they are not
given due consideration of component/modular connection methods,
as these are essential & vital aspects for all precast constructions as it
determines the performance of the system, among others:-

 a. Fixing
The point of fixing of these panelled parts are its weakest, thus needs
proper & adequate attention for good performance.

Each and every panel has a specific location during installation, thus
during the process of assembly, it needs to be put-in-place. More
importantly, prior to completion, the panels need to be held-in-place.
This is, most often, either done by pre-designing the parts or
providing starter bars or stayers
Fixing
Possible Impacts (Precast Methods of Construction)
 b. Sturdiness

 The entire assembly of walls needs to be sturdy enough to be able to stand on its own. For
the system to ‘work’, each and every connection of the panels is very much dependent
upon each other ie to keep it sturdy.

 c. Strength

 When the panels are fixed, the structure needs to ‘act’ as 1. Commonly, a precast panels
system adopts the concept of Loadbearing! All forces/loads are shared and brought down
to the ground as a whole or partially(portion) of the elements/components.

 d. Weatherproofing...etc

 Because of its characteristics of being in panels and requires to be connected/fixed to each

other their ‘weakest’ points are at the joints. These have to be addressed effectively by
good detailing & the use of appropriate sealing(sealant/grout) agent.
8. Connection Detailing Examples
 a. Column To Column

 The dowels(starter bars) are tired/secured to the rebars(for

rigidity/strength) & to ensure quality of ends(for
connection) a metal plate is used.
Column To Column
The dowels(starter bars) are tired/secured to the rebars(for rigidity/strength) & to ensure
quality of ends(for connection) a metal plate is used.
What is the function of the metal ‘shim’ plate?
These are to allow/facilitate for any required adjustments
‘vertically and/or horizontally!!

Upon locating the starter bars/dowels into the allowed receptors/holes, the
column is then checked for verticality, before fixing (nuts/bolts or weilding).
Slab To Beam Connection
 The slabs are placed at the sides of the beam leaving
the beams top reinforcement bars exposed.
 Note
 The beam sits on the corbel and is held in place by a
web plate (pin jointed)
Slab To Beam Connection

For continuation of the structure, ie securing both elements of structure, starter reinforcement
bars are placed(from 1 slab to the other through the beams rebar.

The gap/exposed reinforcement bars are later grouted.

Beam To Column
As pointed out earlier (refer diagram Item B2) more commonly these are
pin jointed ie allowing a certain degree of movement...

However, due to design(need for better rigidity &/@ strength) these can be
differently detailed allowing fusion of the 2 elements of structure