PRE-CAST

CONTRUCTION
AAYUSH LAKHAWAT
ABHISHEK GUPTA
AYUSHI BANSAL
DEEKSHA MANCHANDA
15 P RECAST C ONCRETE F RAMING S YSTEMS

Plant-Cast Precast Concrete

• Concrete elements, cast and cured in a manufacturing
plant, then transported to the construction site.
• Plant casting allows increased efficiency and higher quality
control.
• Durable, permanent steel forms are reused many times,
reducing formwork costs compared to sitecast concrete.
• Use of Type III, high early strength cement and steam curing
allow concrete members to be cast and cured in as little as
24 hours.
• Controlled casting conditions and high quality forms allow for
greater control of surface finishes.
 15 P RECAST C ONCRETE F RAMING S YSTEMS

Plant-Cast Precast
Concrete
• Structural elements
are commonly
reinforced with tightly
stretched
pretensioned steel
strands, which
provide increased
structural efficiency.
• Conventional steel
reinforcing is added
for resistance to
thermal and other
secondary stresses.
 15 P RECAST C ONCRETE F RAMING S YSTEMS

Plant-Cast Precast
Concrete
• On the construction site,
precast concrete
elements are lifted into
place and assembled
into structural assemblies
in a process similar to
that used for structural
steel.
• Compared to sitecast
concrete, precast
concrete erection is
faster and less affected
by adverse weather
conditions. A vacuum lifting device is used to lift and place precast
concrete pranks.
15 P RECAST C ONCRETE F RAMING S YSTEMS

PRECAST,
PRESTRESSED
CONCRETE
STRUCTURAL
ELEMENTS
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Precast Concrete Slabs

• Used for floor and roof decks.
• Deeper elements (toward the
right below) span further than
those that are shallower (toward
the left).
• Right: Hollow core slabs stacked
at the precasting plant.
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Precast Concrete Beams and Girders

• Provide support for slabs.
• The projecting reinforcing bars will bond with concrete
cast on site.
• Right: Inverted tee beams supported by precast
columns.
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Precast Concrete
Columns and Wall
Panels
• Provide support for
beam and slab
elements.
• Since these elements
carry mainly axial
loads with little
bending force, they
may be
conventionally
reinforced without
prestressing.
• Or, long, slender
multistory elements
may be prestressed
to provide resistance
to bending forces
during handling and
erection (columns at
right).
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Precast Concrete Columns

and Wall Panels
• Precast concrete wall
panels may be solid (right),
hollow, or sandwiched
(with an insulating core).
• Wall panels can be ribbed,
to increase their vertical
span capacity while
minimizing weight, or
formed into other special
shapes (below).
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Other Precast Concrete

Elements
• Precast concrete stairs
(below)
• Uniquely shaped structural
elements for a sports stadium
(right)
• Etc.
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Assembly Concepts for

Precast Concrete
Buildings
• Vertical support can be
provided by precast
columns and beams
(above), wall panels
(below), or a
combination of all three.
• The choice of roof and
floor slab elements
depends mainly on span
requirements.
• Precast slab elements
are frequently also used
with other vertical
loadbearing systems
such as sitecast
concrete, reinforced
masonry, or steel.
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Assembly Concepts for

Precast Concrete
Buildings
• Above: Precast
concrete structure
consisting of solid wall
panels and hollow
core slabs.
• Below: A single story
warehouse consisting
of double tees
supported by
insulated sandwich
wall panels.
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEMENTS

Assembly
Concepts for
Precast Concrete
Buildings
• A parking garage
structure
consisting of
precast double
tees supported
by inverted tee
beams on
haunched
columns.
15 P RECAST C ONCRETE F RAMING S YSTEMS

MANUFACTURING OF
PRECAST CONCRETE
STRUCTURAL
ELEMENTS
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LEMENTS

Casting Hollow Core

Planks
• Precast elements
are manufactured in
casting beds, 800 ft
or more in length.
• High-strength steel
strands are strung
the length of the
bed and tensioned.
• Conventional
reinforcing, weld
plates, blockouts,
Untensioned prestressing strands can be seen in the
lifting loops, and left-most casting bed. In the bed second from the
other embedded right, low-slump concrete for hollow core slabs is
items are added as being formed over tensioned strands using an
extrusion process. A completed hollow core casting
needed. is visible at the far right.
• Concrete is placed.
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LEMENTS

Prestressing and
Reinforcing Steel
• Many precast
elements contain
both prestressing
strands and
conventional
reinforcing.
• Right: The
prestressing strands
for an AASHTO
girder are depressed
into a shallow v-
shape to most
efficiently resist
tensile forces in the
beam. Shear stirrups
are formed from
conventional steel
reinforcing.
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LEMENTS
Casting Hollow Core
Planks
• Once the concrete
has cured to
sufficient strength,
the castings are cut
into sections of
desired length
(above).
• In some cases,
transverse
bulkheads are
inserted to divide
the casting bed into
sections before
concrete is placed.
In this case, only the
prestressing strands
need to be cut to
separate the
sections (below).
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LEMENTS

Casting Hollow Core

Planks
• Individual sections
are lifted from the
casting bed (right)
and stockpiled to
await shipping to
the construction site.
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LEMENTS

Casting Hollow Core

Planks
• Precast concrete
elements are
shipped to the
construction site by
truck and erected
on site by crane.
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LEMENTS

Casting Hollow
Core Planks
• Sample hollow
core slab
sections of
varying
depths.
• At bottom left,
note the
insulated
sandwich floor
panel.
15 P RECAST C ONCRETE F RAMING S YSTEMS

JOINING PRECAST
CONCRETE ELMENTS
J OINING P RECAST C ONCRETE E LEMENTS

Example Column-to-Column Connection

• Metal bearing plates and embedded anchor bolts are cast into
the ends of the columns.
• After the columns are mechanically joined, the connection is
grouted to provide full bearing between elements and protect
the metal components from fire and corrosion.
J OINING P RECAST C ONCRETE E LEMENTS

Example Beam-
to-Column
Connection
• Beams are set
on bearing
pads on the
column
corbels.
• Steel angles
are welded to
metal plates
cast into the
beams and
columns and
the joint is
grouted solid.
J OINING P RECAST C ONCRETE E LEMENTS

Example Slab-to-
Beam
Connection
• Hollow core
slabs are set on
bearing pads on
precast beams.
• Steel reinforcing
bars are in
inserted into the
slab keyways to
span the joint.
• The joint is
grouted solid.
• The slab may
remain
untopped as
shown, or
topped with
several inches of
cast in place
concrete.
J OINING P RECAST C ONCRETE E LEMENTS

Sitecast
Concrete
Toppings over
Precast Slabs
• Greater floor
strength and
stiffness
• Greater fire
resistance
• Greater
acoustic
isolation
• Allow easy
integration of
electrical
services into
floor system
• Create a
smoother,
flatter floor
 J OINING P RECAST C ONCRETE E LEMENTS

Precast Concrete
Construction and
Seismic Design
• 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 A large scale test facility for simulating seismic forces on precast
for use in such areas. concrete structural systems.