PRE-CAST AND PRE-STRESSED CONCRETE

Submitted by – Ashutosh Kamal Arya

Submitted to – Ar Aditi kapoor Enrollment No. – 040115017
Batch – 2015-20
Semester – VI
Subject – Construction Materials
 P RECAST C ONCRETE F RAMING S YSTE

Pla nt-C a st Prec a st C o ncrete

• C oncrete elements, c ast and cured in a manufa cturing
plant, then transported to the construction site.
• Plant casting allows increased efficiency and higher quality
control.
• Durable, permanent steel forms are reused many times,
reduc ing formwork c osts compared to siteca st conc rete.
• 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 c ontrol of surfa ce finishes.
 P RECAST C ONCRETE F RAMING S YSTE

Plant-C ast Precast Concrete

• Struc tural elements
are commonly
reinforced with tightly
stretched
pretensioned steel
strands, which
provide increased
struc tural effic ienc y.
• Conventional steel
reinforcing is added
for resistance to
thermal and other
secondary stresses.
 P RECAST C ONCRETE F RAMING S YSTE

Plant-C ast Precast Concrete

• On the c onstruc tion site,
precast concrete
elements are lifted into
place and assembled
into struc tural assemblies
in a process similar to
that used for struc tural
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.
P RECAST C ONCRETE F RAMING S YSTEMS

PREC AST,
PRESTRESSED
CONCRETE
STRUCTURAL
ELEMENTS
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEM

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 c ore slabs stac ked
at the precasting plant.
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEM

Precast C oncrete 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 LEM

Precast Concrete
C olumns and Wall
Panels
• Provide support for
beam and slab
elements.
• Sinc e these elements
c arry mainly axial
loads with little
bending force, they
may be
c onventionally
reinforc ed without
prestressing.
• Or, long, slender
multistory elements
may be prestressed
to provide resistance
to bending forces
during handling and
erec tion (columns at
right).
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEM

and Wall Panels Precast Concrete Columns

• Prec ast c oncrete wall
panels may be solid (right),
hollow, or sandwic hed
(with an insulating c ore).
• Wall panels c an be ribbed,
to inc rease their vertic al
span c apac ity while
minimizing weight, or
formed into other spec ial
shapes (below).
 P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEM

Other Prec a st C oncrete Elements

• Precast concrete stairs (below)
• Uniquely shaped structural elements for a sports
stadium (right)

Etc.
 P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEM

Assembly Concepts for

Precast Concrete Buildings
• Vertic al support c an be
provided by precast
c olumns and beams
(above), wall panels
(below), or a
c ombination of all three.
• The c hoice of roof and
floor slab elements
depends mainly on span
requirements.
• Precast slab elements
are frequently also used
with other vertic al
loadbearing systems
suc h as sitec ast
concrete, reinforced
masonry, or steel.
P RECAST, P RESTRESSED C ONCRETE S TRUCTURAL E LEM

Assembly C onc epts for

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

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

M ANUFACTURING OF
PREC AST C ONCRETE
STRUCTURAL
ELEMENTS
 M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LE

C asting Hollow C ore

Planks
• Precast elements are
manufac tured in c asting
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,
lifting loops, and other
embedded items are Untensioned prestressing strands can be seen in the
added as needed. left-most c asting bed. In the bed sec ond from the
right, low-slump concrete for hollow core slabs is
• C onc rete is plac ed. being formed over tensioned strands using an
extrusion process. A completed hollow core casting
is visible at the far right.
 M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LE

Prestressing and
Reinforcing Steel

• Many precast elements

c ontain 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 LE

C asting Hollow C ore

Planks
• Onc e the c onc rete has
c ured to sufficient strength,
the c astings are c ut into
sec tions of desired length
(above).
• In some c ases, transverse
bulkheads are inserted to
divide the c asting bed into
sec tions before c onc rete is
plac ed. In this c ase, only the
prestressing strands need to
be cut to separate the
sec tions (below).
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LE

C asting Hollow C ore

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

C asting Hollow C ore

Planks
• Precast concrete
elements are
shipped to the
c onstruc tion site by
truc k and erected
on site by c rane.
M ANUFACTURING OF P RECAST C ONCRETE S TRUCTURAL E LE

C asting Hollow
Core Planks
• Sample hollow
core slab
sec tions of
varying
depths.
• At bottom left,
note the
insulated
sandwic h floor
panel.
P RECAST C ONCRETE F RAMING S YSTEMS

JOINING PREC AST

C ONCRETE
ELMENTS
 J OINING P RECAST C ONCRETE E LEMEN

Example Column-to-Column Connection

• Metal bearing plates and embedded anchor bolts are cast into
the ends of the c olumns.
• 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 LEMEN

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

Example Slab-to- Beam Connection

• Hollow c ore
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 inc hes of
c ast in plac e
concrete.
 J OINING P RECAST C ONCRETE E LEMEN

Sitecast Concrete Toppings over Precast

Slabs

• G rea ter floor strength

and stiffness
• Greater fire
resistance
• Greater ac oustic
isolation
• Allow easy integration
of electrical services
into floor system
• Create a smoother,
flatter floor
thank you !
FERRO-CEMENT

Submitted by – Ashutosh Kamal Arya

Submitted to – Ar Aditi kapoor Enrollment No. – 040115017
Batch – 2015-20
Semester – VI
Subject – Construction Materials
 Contents
• Introduction
• What Is Ferro-cement?
• Materials Used In Ferro-cement
• Properties Of Ferro-cement
• Behaviour Of Ferro-cement
• Process Of Ferro-cement
• Cost Effectiveness Of Ferro-cement
• Applications
• Advantages
• Disadvantages
• Conclusion
4/26/2015 2
 Definition

Ferro cement is a form of reinforced

concrete using closely spaced multiple
layers of mesh and/or small diameter rods
completely infiltrated with, or encapsulated
inmotor

3
Typical Cross Section Of Ferro cement

4
Materials Used In Ferro Cement
• Cement mortar mix

• Skeleton steel

• Steel mesh reinforcement or Fibre-reinforced

polymeric meshes

5
6
 Cement Mortar Mix

• OPC and fine aggregate

matrix is used
• sand occupies 60 to 75%
of the volume of the
mortar
• Plasticizers and other
admixtures are used
7
 Skeleton Steel

• Used to impart
structural strength in
case of boats, barges
etc.
• Reinforcement should
be free from dust, rust
& other impurities

8
 Steel M esh Reinforcement
• Available as
woven/interlocking
mesh and welded mesh
• Expanded-metal lath is
also used
• Made from carbon,
glass etc.

9
Commonly used reinforcing mesh
10
 Chemical Admixtures in Ferro cement
•water reduction, with strength and
reduces permeability.
•Air entrainment, which increases
resistance to freezing and thawing;
•suppression of reaction between
galvanized reinforcement and
cement .
 Water
• Water should be portable.
• clean, and free from organic matter - silt, oil,
sugar, chloride and acidic material
• pH equal or greater than 7 .
Mix Proportions
•Sand: cement ratio (by mass) 1.5 to 2.5
•Water: cement ratio (by mass) 0.35 to 0.60
12
 Properties Of Ferro Cement
• It is a very durable, cheap and versatile material.
• Low w/c ratio produces an impermeable structures
• less shrinkage, and low weight.
• high tensile strength and stiffness
• better impact and punching shear resistance
• undergo large deformations before cracking or high
deflections

13
Behavior of Ferro-cement in tension
RC in tension Ferro cement in tension

14
 Process Of Ferro-cemen t Construction

• Fabricating the skeletal framing system

• Applying rods and meshes

• Plastering

• Curing

15
 Cost Effectiveness

• Depends on type economic system and applications.

• Relative cost of labor.
• Doesn’t need heavy plant or machinery.
• Low cost construction materials are used.

16
 Applications

• Floors And Roofs

• Waterproofing

17
• Rural Applications

• Marine Applications

18
• Transport System

• Agriculture Structures

19
4/26/2015
• Fire resistant structures
• Soil stabilization
• Man hole covers
• Wall cupboards
• pipes

20
 Advantages Of Ferro -Cement:
• 20% savings on materials and cost
• Suitability for pre-casting
• Flexibility in cutting, drilling and jointing
• Very appropriate for developing countries, labor
intensive
• Good impermeability
• Fabricated into any desired shape.
• Ease of construction, low weight and long
lifetime.
• Better resistance against earthquake.
21
 Disadvantages of Ferro-Cement:
• Corrosion of the reinforcing materials due to the
incomplete coverage of metal by mortar.
• It is difficult to fasten to Ferro-cement with bolts, screws,
welding and nail etc.
• Large no of labors required.
• Cost of semi-skilled and unskilled labors is high.
• Tying rods and mesh together is especially tedious and
time consuming.
• Low ductility
• Susceptibility to stress rupture failure
• It can be punctured by collision with pointed objects.
22
 Conclusion
In India, Ferro-cement is used often because the
constructions made from it are more resistant to
earthquakes. It has a wide range of other uses
including sculpture and prefabricated building
components.

23
Thank you !
LOW COST BUILDING MATERIALS

Submitted by – Ashutosh Kamal Arya

Submitted to – Ar Aditi kapoor Enrollment No. – 040115017
Batch – 2015-20
Semester – VI
Subject – Construction Materials
 Selection Of Low Cost Building Material

○ Manufacturing of Low Cost Building Materials

□ Environmental friendly
□ Improve technologies for production
□ Reduction in waste generation
○ Use of Recycled Waste as Building Materials
□ Waste produced can be used for the production of a material cheaper in cost
○ Use of Natural Low Cost Building Materials

□ Natural materials are sustainable and environmental friendly

□ Materials like stone , wood ,lime ,bamboo ,sand have low embodied energy
○ Use of Local Building Materials

□ Reduces transportation dependence

□ Suitable for local environment
2
 Selection Of Low Cost
Building Material

○ Use of non-toxic Building Materials

□ Materials to be free from any kind of toxins
□ Higher air cycling required if any highly organic volatile compounds are used
○ Longevity, Durability and Maintenance
□ Use of durable construction materials decreases the maintenance cost
□ Low maintenance cost saves a lot of building operating costs

○ Recyclability and Reusability

□ In a form so that it can be recycled or reused. Eg.Plastics
○ Biodegradability
□ Decompose naturally when discarded
□ Not produce toxic gases while decomposition

3
 Building Materials

Natural Man Made

• Random Straw or Coconut Fibres • Fly Ash
Stabilised Soil • Coal Washery Rejects
• Bamboo • Aerocon Panels
• Compressed Earth Block • Ferro Cement
• Non –erodible Mud Plaster
• Straw
• Fibre Cement Composites
• Bagasse Composite boards

4
Building Materials
NATURAL
 Natural
Random straw or Coconut Fibres Stabilised
Soil
• Ancient construction material used in
many countries
• Have both strength and durability
• Compacted material
• 1% of straw increases the strength by
three time as compared to no straw
• Coconut fibres increases the durability
• Sulphur coating enhances the water
resistance

6
 Natural
Bamboo

• India is the largest producer,50% of world

production
• Easily affordable
• Easy assembly and long durability
• High tensile strength, than steel
• Fire resistant unto 4000 deg C
• High elasticity hence used in earthquake
prone areas
• Low weight –easy for transportation and
assembly

7
Natural
Bamboo

8
 Natural
Compressed Earth Block
Natural

• Raw earth stabilised by cement or lime

• Also known as Adobe bricks ,light in
weight
• Non toxic
• Fire resistant ,Sound resistant
• Low transportation cost
• Insect resistant as they are very dense
• Available in customizable sizes
• Used in stucco work for exteriors

9
 Natural
Non-erodible Mud Plaster

• Economical process of preventing mud

walls from erosion
• Mud mixed with bitumen and kerosene
oil
• Resistant to water

10
 Natural
• Fire resistant
Straw
• Thermal insulation
• Soil and Moisture insulation
• Non toxic
Life Extended Thatch Roofing
• Treating with copper sulphate solution
decreases the biodegradability
• Treatment of roof surface with
phosphorylated spray or CNSL oil
imparts-
o Water proofing
o Termite resistance
o Fire resistance
o Weathering resistance
Improved Thatched Roofing
• CBRI a d v i s e t o a d d m u d p l a t e r s i n
between to increase fire and water
resistance

11
 Natural
Fibre Cement Composites
• Natural fibre used with cement as an
alternative building material
• Fibres used like bagasse , cereal straw,
corn and cotton stalk ,kenalf /rice husk
• Imparts o High fracture toughness
o Light weight o High flexibility
o High strength to weight ratio o Resistance to cracking
o Corrosion resistance o Add workability

12
13
 Natural: Cement Composite
Bagasse Cement- Boards
and Panels

• Fibrous matter after sugar is extracted

• Sugarcane bagasse and Portland cement
is mixed
• High density boards

14
 Natural: Cement
Composite
Bagasse PVC Boards

• Sugarcane bagasse and PVC is mixed as a

binder
• Inherent self extinguishing property
• Used in door shutters, sanitary fixtures,
pipes, cable, cabinets

15
 Natural: Bagasse PVC
boards
Jute and Coir
• Widely available in India
 Coir-CNSL Board
o used for window and door shutter,
partitioning, false ceiling, furniture etc.
o Single layer flat pressed medium density
board
o Low water absorption, workable with
wood tools
o Paintable, pre laminable, screw able

 Coir-CNSL Thermal Insulation Board

o Coconut fibres as reinforcing material
o CNSL as natural binder
o Low density for moderate thermal
insulation

16
 Natural: Bagasse PVC
boards
Jute and Coir
 Jute-Coir Composites
o Economic alternative for wood
o Eg- coir ply boards with jute face veneer,
coir plus waste rubber inside

 Coconut and Wooden Chips Roofing

Chips
o Coconut fibres and wooden chips soaked
in water for 2 hours and then drained off
o Mixed with cement and layed over
corrugated mould kept under pressure for
8-10 hours
o CNSL oil can also be used as a natural
binder

17
Building Materials

MAN MADE
 Man Made
Fly Ash

• Mineral residue after burning burning

coal and fine glass
• Constitutes of silica, alumina and iron
Fly Ash Bricks
o Class C fly ash and water
o Due to high calcium oxide its self
cementing
o Energy efficient
o Lower water penetration, light weight,
thermal insulation

19
 Man Made
Coal Washery Rejects Bricks

• Left over after fluidised bed combustion

• Uses water and reduces air and land
pollution
• Energy efficient
• Red mud, coal ash, etc from large scale
industries can be used
• These are mixed with lime pozollona and
cement to form bricks

20
 Man Made
Aerocon Panels

• Inorganic bonded sandwich panels

• 2 fibre cement sheets engulfing a
Portland cement mix with fibres of
silica's and micaceous aggregates
• Light weight, thermal insulation, fire and
sound resistant
• Termite and weather resistant
• Suitable for seismic or cyclone prone
zones

21
 Man Made
Ferro Cement

• Thin walled versatile high strength

cement based composite material
• Cement mortar reinforced with 2-3 layers
of wire mesh
• Light weight high strength

22
 Plaster

 Calcium Silicate Plaster  Fibre Reinforced clay plaster

o Derived from Wollanstonite naturally o Natural or artificial fibre(polypropylene)
occurring calcium silicate o Achieve better sticking properties
o Does not emit VOC or any other harmful o Less Brittles
gases
o Gives a smooth finish

23
 Roofing

 Bamboo Matt Roofing Corrugated

Sheets
o Better than clay and Mangalore tiles
o Preferred for semi permanent structures

24
 COB

Mix soil with only a little water - pick

up as much as you can in your two
hands and make a ‘roll’.

Place these rolls closely together

in rows; Then smooth one of the
ends.
Anyone can make this sort of a wall but you
CANNOT MAKE A HIGH WALL.
It is very good for curved or circular walls.
 PRESSED
BRICKS

A hand operated machine

compresses t h e earth into hard,
smooth, strong bricks (the
m a c h i n e c a n b e o w n e d by t h e
c o m m u n i t y or panchayat).

T h e s e can be used for even t h r e e

storey houses, though each
storey must be prot ect ed form
rain by overhanging slabs.
PISE (RAMMED
EARTH)

Wi t h a p r o p e r ly m ade fr a m e
( w h i c h ca n b e t a ke n t o p i e c e s )
r a m m e d e a r t h makes a very
st rong wall.

I t is essentially good for large,

low, s o l i d l o o k i n g b u i l d i n g s o r i t
ca n t a k e t h e w e i g h t o f h e a vy
r o o f i n g s u c h as r e i n f o r c e d
concrete.
WATTLE AND DAUB

Th is syst em o f usin g mud fo r h ou se

buildin g is m o r e usual in india’s e a s t e r n
states.
It is mainly used in bamboo growing
areas.
I t is part icularly go o d and ‘safe’ in areas
p r o n e t o eart h tremors. It is also
adaptable t o any shape of building.
 RAT TRAP BOND
The RAT TRAP BOND is still
mainly unknown in india,
though used in england for the
past several hundred years. It is
as strong as t he other bonds
but uses 25% LESS bricks and
mortar.
Thermal insulation is very much
better.

Bricks are laid on edge, not flat.

This creates a ‘bonded cavity’.
The CAVITY in the RAT TRAP BOND wall ensures
good insulation from heat and cold.
This can be ruined by a poor mason carelessly
slopping mortar into the cavity while he is building.
To avoid this
1. Make sure the mortar is not too wet, and
2.Use a 3” wide strip of wood, laid over the central
cavity and place the mortar on both sided of it.
 BRIC K JALI
‘Jali’ - formerly pierced stone panels – is one
of india’s oldest methods of letting into a
building filteredlightandventilationbut
maintaining privacy and security.

BRICK JALI can function in the same way – either as

panels or as a complete load bearing wall.
T h e r e is t h e old “honey comb” pattern of
‘jali’ brick work.

The holes can be extended vertically.

Or t h e r e c a n be a l t e r n a t i n g s e c t i o n s of
o n e r o w of h o l e s followed by 2 or 3 rows
of holes, t h e n t h e single h o l e rowagain
– And so on.

O n c e t h e s e patterns have b e e n used – a g o o d

m a s o n can devise and enjoy doing many
patterns.
Thank you !