PRECAST CONCRETE STRUCTURAL MEMBERS &

JOINTS

PRECAST CONCRETE
A precast concrete structure is an assemblage of precast elements which, when
suitably connected together, form a three-dimensional framework capable of
resisting gravitation and wind (or even earthquake) loads.
The quantity of concrete in a precast framework is less than 4% of the gross
volume of the building, and two-thirds of this is in the floors.

FIG 01. PRECAST SKELETAL STRUCTURE :

https://www.routledgehandbooks.com/assets/9781315370705/graphics/fig3_1.jpg

PRECAST FRAMEWORK
The distinguishing feature of the precast framework is that the beam-to-column
connections are rarely fully rigid, known as semi-rigid, and therefore the columns
must also resist horizontal actions.
Rigid connections theoretically allow no relative rotation at beam ends and also
transfer 100% of the moment. Pinned connections are assumed to allow beam end
to substantially rotate freely and offer negligible transfer of moments.
Semi-rigid frames are frames for which the beam-to-column connection whose
resistance to angle change falls somewhere between pinned or rigid.

FIG 02. PRECAST SKELETAL FRAME :

https://constrofacilitator.b-cdn.net/wp-content/uploads/2020/02/Precast-Concrete-
Building-Systems.jpg

TYPES OF PRECAST CONCRETE STRUCTURES

Precast Skeletal Structure
It resembles a skeleton of small but very strong components of columns, beams,
floors, staircases, and sometimes structural (as opposed to partition) walls.

FIG 03. DEFINITION OF PRECAST SKELETAL STRUCTURE :

https://i0.wp.com/theconstructor.org/wp-
content/uploads/2012/03/clip_image00221.jpg?resize=624%2C419&ssl=1

The advantage of a skeletal frame system are as follows:

 There is possibility of large columns - free space
 The visual obstruction due to walls is negligible in an open layout
 There is flexibility in the selection of cladding elements for the façade

The frame system can be designed for resisting lateral loans. However, there may
be a need for supplemental lateral loan resistance through the use of braces or
walls. Hence, core or shear walls are provided.

Wall frame
The walls are all load-bearing, which dispenses with the need for beams, and they
support one-way spanning floor slabs. The load-bearing wall units resist and
transfer loads from other elements and cannot be removed without affecting the
strength or stability of the building. Typical load-bearing wall units include solid
wall panels, and window wall and spandrel panels.

FIG 04. CROSS-WALL SYSTEM IN PRECAST WALL FRAME :

https://www.routledgehandbooks.com/assets/9781315370705/graphics/fig3_6.jpg

The wall frame is ideally suited to multi-storey repetitive cellular structures such as
hotels, custodial, education, student accommodation, private and public housing.
Distances between walls may be around 6 m for hotels, schools, offices and
domestic housing, and 10–15 m in commercial developments. It is economical but
has less architectural freedom compared to the skeletal frame.

FIG 05. PRECAST CONCRETE WALL FRAME : https://mmcmag.co.uk/wp-

content/uploads/2019/11/KERKSTEOL.jpg

Portal Frame
Precast Concrete Portal Frames are a combination of two columns and a normal
beam with additional bending strength, to form a U shape; the result is wide spans
and open floors. This is commonly used for industrial buildings and warehouses
where clear spans of some 25–40 m are necessary.

FIG 06. PRECAST CONCRETE PORTAL FRAME :

https://img.archiexpo.com/images_ae/photo-g/124637-10964574.jpg

Although portal frames are nearly always used for single-storey buildings, they
may actually be used to form the roof structure to a skeletal frame.

FIG 07. PRECAST CONCRETE PORTAL FRAME WITH FOLDED

PLATE ROOF UNITS :
https://www.routledgehandbooks.com/assets/9781315370705/graphics/fig3_10.jpg

TABLE 01. APPLICATION AND TYPES OF PRECAST CONCRETE

FRAMES
PRECAST CONCRETE STRUCTURAL MEMBERS
PRECAST COLUMNS
Precast columns are the main vertical-load-carrying members in skeletal frames.
Typically, a precast column is manufactured in grey concrete and is square or
rectangular in cross sections. However, there are many instances where columns of
other shapes are used as part of the external architecture.

FIG 08. PRECAST CONCRETE COLUMNS :

https://i.pinimg.com/originals/11/31/39/11313961e1b2d8186156a2f6188b852f.jpg

FIG 09. PRECAST CONCRETE CIRCULAR COLUMNS :

https://www.jekseng.com/wp
-content/uploads/2015/10/Circular_Precast_Columns.jpg

Generally, columns are manufactured in the largest length possible to erect on site.
If a column is joined on site, the connection is called a ‘splice’. For structures
greater than five storeys two or more columns are spliced together.
Foundation connection may be via a base plate connected to the column or by
reinforcing bars projecting from the end of the column passing into sleeves that are
subsequently filled with grout. Alternatively, a column may be set into a preformed
hole in a foundation block and grouted into position.
Precast column design is no different to the design of ordinary reinforced concrete
columns once all the aspects of manufacture, different types of structural
connections, and temporary stability have been resolved.

PRECAST BEAMS
Beams are the main horizontal load-carrying members in skeletal structures. In a
precast concrete structure, they must at some point in time support the self-weight
of the floor slabs alone and should therefore be capable of resisting all of the
possible load combinations that precast construction brings.
Beams fall into two distinct categories: internal and external.
Internal Beams
Internal beams are usually symmetrically loaded, that is floor slabs are on
both sides of the beam, and therefore the beam is symmetrical in cross
section.

FIG 10. INTERNAL BEAM : https://i2.wp.com/theconstructor.org/wp-

content/uploads/2012/03/clip_image00416.jpg?resize=246%2C225&ssl=1

FIG 11. INTERNAL BEAM (INVERTED TEE)

External Beams
External (edge) beams are where the floor loading is predominantly
asymmetrical.

FIG 12. EXTERNAL BEAM : https://i0.wp.com/theconstructor.org/wp-

content/uploads/2012/03/clip_image00614.jpg?resize=192%2C288&ssl=1

FIG 13. EXTERNAL BEAM (L-SHAPE)

Precast Deep Beam Walls

Deep beam walls (DBWs) are structural beam elements that are sufficiently deep,
typically one-storey height of about 2.8–3.5 m, to behave both as a deep beam in
bending and strut-and-tie action as well as a wall panel, particularly if multiple
DBWs are built one on top of another in a multistorey arrangement.

FIG 14. LOWER STOREY DEEP BEAM WALL

They are increasingly being used in precast frames as transfer elements between
lower floor beam–column to wall panel construction, such that the lowest floor
level DBW is supported on columns.

FIG 15. DEEP BEAM WALL ELEVATION

In figure 15, Cantilevers may result at one or both ends if the columns are moved
off grid. Upper level DBW elements are continuously supported on the lower level
elements, vertically dowelled to provide structural ties throughout.

RCC Beams
Reinforced cement concrete (RCC) beams are structural elements designed to carry
transverse external loads that cause bending moment, shear forces, and in some
cases torsion across their length.
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.

FIG 16. RCC BEAMS : https://constrofacilitator.b-cdn.net/wp-

content/uploads/2020/08/RCC-beams.jpg

Prestressed Beams
This system became known as “prestressed” concrete, because tension or stress
was applied to the concrete beam before it was placed in position.
Fiber-reinforced polymer-prestressed beams are greater than those of steel-
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.

FIG 17. PRESTRESSED BEAMS : https://constrofacilitator.b-cdn.net/wp-

content/uploads/2020/08/Prestressed-beams.jpg
Shell Beams
Shell beams are commonly used with precast floor systems to streamline building
programs and reduce on-site labour. Shell beams are suitable for movement
resisting frames in seismic regions. The units are pre- stressed in conjunction with
conventional reinforcing for maximum efficiency of the shell beam units.

FIG 18. SHELL BEAMS : https://constrofacilitator.b-cdn.net/wp-

content/uploads/2020/08/Shell-beams.jpg

PRECAST WALLS
Precast concrete walls serve two functions: stability; and to enclose staircases and
carry shafts. They can be classified into load-bearing and non-load-bearing walls.

Load bearing walls are 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.

A Non-load-bearing wall holds up only itself. It is usually carried by supports,

normally steel shelf angles on each floor. These walls are generally 50 mm to 100
mm thick.

Walls can also be classified as infill or cantilever.

Infill Walls
Infill panels, otherwise called infill walls, are non-load-bearing. They are installed
between floors on the primary structural frame of a building to support the
structure's cladding system. They consider contiguous composite action with the
beam and column frame.
FIG 19. INFILL PANEL WALLS :
https://www.designingbuildings.co.uk/w/images/9/96/Infillpanelwalls.jpg

Cantilever Walls
Cantilever walls are walls that do not have any supports and thus lead to an open
unobstructed excavation. A vertical cantilever retaining wall panel is ideal for both
above and below ground applications.

FIG 20. VERTICAL CANTILEVER RETAINING WALL :

https://www.thomasarmstrongacpconcrete.co.uk/images/installation-cantilever-
vertical-prestressed-precast-concrete-wall.jpg?crc=4010141603

PRECAST CONCRETE FLOORING OPTIONS

Precast concrete flooring offers an economic and versatile solution to ground and
suspended floors in any type of building construction.
Precast concrete floors offer the twin advantages of:
1. Off-site production of high-strength, highly durable units
2. Fast erection of long-span floors on site

FIG 21. T-SLAB : https://www.constructionspecifier.com/wp-

content/uploads/2020/09/T-SLAB-install.jpg

Flooring Arrangements
A floor slab may comprise of a large number of individual units, each designed to
cater for specified loads, moments etc., or it may comprise a complete slab field
where the loads are shared between the precast units according to the structural
response of each component. It is necessary to define:
Floor unit - a discrete element designed in isolation of other units.
 FIG 22. CONCRETE HOLLOW CORE FLOOR UNITS

Floor slab - several floor units structurally tied together to form a floor area,
with each unit designed in isolation usually for uniformly distributed
loading.

FIG 23. CONCRETE HOLLOW CORE FLOOR SLABS :

https://upload.wikimedia.org/wikipedia/commons/7/78/Hollow_core_slab.JP
G

Floor field - a floor slab where each floor unit is designed as part of the
whole floor, allowing lateral spreading of isolated point or wall loads, and
spreading of section properties due to the loss of a hole.

FIG 24. FLOOR FIELD

RCC slabs
RCC 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.
In many domestic and industrial buildings a thick concrete slab, supported on
foundations or directly on the subsoil, is used to construct the ground floor of a
building.
In high rises buildings and skyscrapers, thinner, precast concrete slabs are slung
between the steel frames to form the floors and ceilings on each level.

FIG 25. RCC SLAB : https://constrofacilitator.b-cdn.net/wp-

content/uploads/2020/08/RCC-slabs-1.jpg
Prestressed 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.

FIG 26. PRESTRESSED HOLLOWCORE SLABS : https://www.mct-

usa.com/wp-content/uploads/2019/11/Prestressed-hollowcore-slabs-1-
1000x500.jpg

Prestressed solid slabs

The solid slab is a customized, loosely reinforced, full concrete slab that is used in
residential and industrial construction. Mounting parts, such as electrical outlets,
wiring, openings, etc. or even heating conduits can be previously installed in the
solid slab in the precasting plant.

FIG 27. PRECAST CONCRETE SOLID SLAB :

https://5.imimg.com/data5/PV/LD/MY-3108035/precast-concrete-slab-
500x500.jpg

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.

FIG 28. DOUBLE TEE :

https://upload.wikimedia.org/wikipedia/commons/thumb/8/80/Diagram_of_double
_tee.svg/1200px-Diagram_of_double_tee.svg.png
Waffle slabs
A waffle slab or two-way joist slab is a concrete slab made of reinforced concrete
with concrete ribs running in two directions on its underside. The name waffle
comes from the grid pattern created by the reinforcing ribs.
Waffle slabs are preferred for spans greater than 40 feet (12 m), as they are much
stronger than flat slabs, flat slabs with drop panels, two-way slabs, one-way slabs,
and one-way joist slabs.
Waffle slab can be used as both ceiling and floor slab. They are used in the areas
where less number of columns are provided, such as areas which have huge spans.

FIG 29. WAFFLE SLAB :

https://www.treehugger.com/thmb/Ri230Mw11_3hNUD-
641Llci1kwo=/627x627/smart/filters:no_upscale()/__opt__aboutcom__coeus__res
ources__content_migration__treehugger__images__2012__10__FileItem-150605-
forjadotoweb-0c521aefb4a641fc8250fd9727af02e9.jpeg

PRECAST FOUNDATION
Isolated footings
Isolated footings (also known as Pad or Spread footings) are commonly used for
shallow foundations to carry and spread concentrated loads, caused for example by
columns or pillars.
Isolated footings can consist either of reinforced or non-reinforced material. These
are used for smaller structures and residential buildings.

FIG 30. PAD FOOTING :

https://www.geoengineer.org/storage/news/2386/featured_image/7965/featured_im
age.jpeg
FIG 31. PAD FOOTING ASSEMBLY :
https://www.monachinotechnology.com/ewExternalFiles/Precast%20Foundations-
6.png

Pocket footings
Pocket footings offer more strength to shallow foundations to carry and spread
concentrated loads. They are used for commercial and industrial buildings.

FIG 32. POCKET FOOTING : https://img.archiexpo.com/images_ae/photo-

m2/105207-4357145.jpg

Combined footings
These concrete footings are usually rectangular and support two or more columns
that are so close to each other their footings would overlap. They are used for
commercial and industrial buildings.

FIG 33. COMBINED FOOTING : http://4.bp.blogspot.com/-

upkWYC8IaVo/UIB9ulHnmDI/AAAAAAAAAjw/2CuyE3c60YE/s1600/1.gif

Precast piles
Precast piles are prefabricated piles made of prestressed concrete that are driven
into the ground using diesel or hydraulic hammer. The piles are made of
prestressed concrete and have fixed dimensions. The main benefit of these concrete
piles is the high vertical pile load and resistance.
*These piles are used for the most conventional foundation method. It’s usually the
quickest and also the cheapest method besides the use of wooden piles.

FIG 34. PRECAST PILES : https://aarsleff.co.uk/wp-

content/uploads/2018/01/solutions-driven-precast-concrete-piling.jpg
PRECAST STAIRCASES
To speed up site production, stair flights can be of precast instead of cast in-situ
concrete. Precast stairs produces better surface finishes, avoids the inherent
problems of casting complicated inclined sections on site and provides rapid access
to successive floors.
They are particularly cost effective when the design of the building requires a
reasonable amount of repetition.

FIG 35. PRE CAST STAIRCASES : https://gharpedia.com/wp-

content/uploads/2018/08/020508010019-01-Precast-Concrete-Stair-600x412.jpg

CONNECTION IN PRECAST STRUCTURE

Connections form the vital part of precast concrete design and construction. They
alone can dictate the type of precast frame, the limitations of that frame, and the
erection progress.
Connection - is the total construction between two (or more) connected
components: it includes a part of the precast component itself and may
comprise several joints.
Joint - is the part of a connection at individual boundaries between two
elements (the elements can be precast components, in situ concrete, mortar
bedding, mastic sealant, etc.).
Structurally, joints are required to transfer all types of forces – the most
common of these being not only compression and shear, but also tension,
bending and occasionally torsion.

FIG 36. TYPES OF CONNECTIONS IN PRECAST STRUCTURE :

https://www.routledgehandbooks.com/assets/9781315370705/graphics/fig3_32.jpg