VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY, NAGPUR

DEPARTMENT OF ARCHITECTURE AND PLANNING

PRECAST CONCRETE
CONSTRUCTION - V

SEC. B - GROUP 2
ANSHIKA KHANDELWAL BA19ARC076

SOMANATH BA19ARC054 AASTHA DESHBHRATAR BA19ARC072

HIMALEE SHENDE BA19ARC066 MEGHANA SAVARKAR BA19ARC075

MANI KUMAR BA19ARC067 VANSHIKA RAJPUT BA19ARC079

MAHIMA JADHAV BA19ARC071 LEENA KHANDAIT BA19ARC084

1
 TABLE OF CONTENTS
ADVANTAGES AND DESIGN
01 INTRODUCTION 02 DISADVANTAGES 03 CONSIDERATIONS

TYPES OF PRECAST
04 FUNCTIONS 05 TYPES OF PROJECTS 06 SYSTEMS

07 ELEMENTS
PRECAST
OF
08 CONSTRUCTION 09 ONSITE ERECTION

10 BRANDS 11 CHALLENGES

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 2

 01 INTRODUCTION
● Concrete casted in a reusable mould and then cured in a controlled
environment (precast plant)

● Precast Structural members - concrete frame, walls, floors etc

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 3

 02 ADVANTAGES OF PRECAST CONCRETE
● Saves Construction Time
● Quality Assurance and high standard of workmanship
● Usage of Prestressed Concrete
● Cost-effective and efficient
● Durability and low maintenance
● Aesthetics
● Safe Construction Platform
● Versatile
● Sustainable
● Thermal efficiency

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 4

 DISADVANTAGES OF PRECAST CONCRETE
● High Initial Investment

● Transportation Issue

● Handling Difficulties

● Modification

● Sensitive Connection Works

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 5

 03 CONSIDERATIONS OF PRECAST CONSTRUCTION
● Erection sequence

● Erection safety

● Erection tolerances

● Rigging

● Temporary bracing

● Levelling shims

● propping

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 6

 04 FUNCTIONS OF PRECAST CONCRETE
PRIMARY FUNCTIONS SECONDARY FUNCTIONS
● Keep water out ● Resist wind forces
● Prevent air leakage ● Control water vapour
● Control light ● Adjust to movement
● Control radiance of heat ● Thermal contraction and expansion
● Control conduction of heat ● Structural movements
● Control sound ● Resist fire
● Weather gracefully
● Easy to install

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 7

 PRECAST CONCRETE PROVIDES
● Complete thermal protection

● Continuous air/vapour barrier

● Effective rain screens

● Superior lifespan

● Reduced construction schedule and on-site labour

● High quality control standards

● Numerous finish options and colours

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 8

 05 TYPES OF PROJECTS
● Parking structures

● Foundations

● Bridges

● Culverts

● Curb inlets and catch basins

● Sound walls

● Retaining walls

● Precast concrete buildings

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 9

 PARKING STRUCTURES
● Design, durability, economy and
installation = precast concrete
● Columns, traffic barriers, stairs, paving
slabs, architectural veneer and more
● Single-level + mid-rise structures

FOUNDATIONS
● Provides a moisture-free, and
energy-efficient basement

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 10

 BRIDGES
● Beams, arches, girders, deck slabs, caps
and more.
● Blends in with the environment +
compatible with any historical
surroundings

CULVERTS
● Box and three-sided culverts - in
different shapes and sizes
● Aids in stormwater and wastewater
drainage, create short bridges, retain
rainwater etc.
● High-quality and durable with easy
installation

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 11

 CURB INLETS AND CATCH
BASINS
● Underground infrastructure -
wastewater management
● Local standards - decides the design
● Helps stormwater runoff drain

SOUND WALLS
● Noise barrier between highways and
communities - can cut noise pollution up
to 50%
● The versatility of design - blends into
their surroundings

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 12

 RETAINING WALLS
● Retaining systems include-
○ Segmental retaining wall (SRW)
products
○ Large precast modular blocks
(PMB)
○ Mechanically stabilized earth (MSE)
face panels
○ Crib walls
○ Cantilever walls
○ Post-and-panel systems.

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 13

 PRECAST BUILDINGS
● Fire-resistant and sound-attenuating,
moisture resistant and create an
energy efficient environment
● Office buildings
● Multi-unit housing
● Hospital and medical centers
● Schools
● Retail shopping centers

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 14

 06 TYPES OF PRECAST SYSTEMS

LARGE PANEL FRAME

SYSTEM SYSTEM

SLAB COLUMN MODULAR

SYSTEM SYSTEM

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 15

 LARGE PANEL SYSTEM
● Multi-storey structure

● Large wall and floor panels connected in

the vertical and horizontal directions

● Can withstand gravity loads

● Based on wall layouts -

○ cross-wall system
○ longitudinal-wall system
○ two-way system.

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 16

 FRAME SYSTEM
● For parks, stadiums, and offices.

● Constructed using either

○ linear elements or

○ spatial beam-column sub

assemblages.

● Linear elements preferred because of

the difficulties associated with forming,
handling and erecting spatial elements

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 17

 SLAB COLUMN SYSTEM
WITH SHEAR WALLS
● Gravity loads - supported by
slab-column structure

● Lateral loads - shear walls

● Two types -

○ lift slab system with walls

○ prestressed slab-column system.

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 18

 MODULAR SYSTEM
● Smaller single units

● Entire unit is cast in a factory and

installed at site

● Suitable for toilet blocks and individual

rooms - guarantees waterproofing at
junctions.

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 19

 07 ELEMENTS OF PRECAST CONSTRUCTION
PRECAST PRECAST
CONCRETE WALLS PRECAST BEAMS AND
(PANELS) SLABS GIRDERS

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 20

 PRECAST PRECAST
COLUMNS STAIRS

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 21

 08 CONSTRUCTION PROCEDURE
Step 1 - After preparation, layout of the structure is set

Step 2 - Foundations of columns are set

Step 3 - Final adjustment of columns, frames and precast panels are installed

Step 4 - Beams and precast floors (in case of large panel and column-slab systems)
are placed

Step 5 - Precast floors (in case of precast frames)

Step 6 - Certain types of connections used during connection

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 22

 STEP

01
LAYOUT OF
STRUCTURE

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 23

 STEP

02
CONSTRUCTION
OF
FOUNDATION

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 24

 STEP

03
COLUMNS AND
PRECAST PANELS
ARE INSTALLED

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 25

 STEP

04
PLACEMENT OF
BEAMS
(FRAME SYSTEM)

AND FLOORS
(LARGE PANEL SYSTEMS AND COLUMN-SLAB
SYSTEMS)

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 26

 STEP

05
PLACEMENT OF
SLAB
(IN PRECAST FRAME)

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 27

 STEP

06
CONSTRUCTION
IS FINALIZED

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 28

 CONSTRUCTION TYPES OF CONNECTORS

BEAM TO COLUMN
CONNECTION
SAFE CLEATED CONNECTION SLIDING PLATE CONNECTION SEATING CONNECTION

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 29

 COLUMN TO FLOOR PANEL TO PANEL
CONNECTION CONNECTION

SEATED CONNECTION DEEP NIB CONNECTION

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 30

 09 PRECAST ERECTION ON SITE
1. START-UP PHASE
GENERAL

● Kick-off meetings for decisions and agreements

WRITTEN INSTRUCTIONS

● Information on components and structures

● Assembly order to assure the building stability
● Curing times (eg indication of when temporary shoring can be removed)
● Various manuals.

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 31

 SPECIAL ELEMENTS
● Special items require special precautions and extra attention.
Clear labelling of -
○ Information on temporary stabilization - stiffening and anchorages
○ Information on the lift bracket and hooking

CONTROL POINTS
● Procedure - hierarchy of control when a default in the element is discovered

CRANE HAND
● Control points for crane signallers and riggers

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 32

 2. INTERIM STORAGE
● Temporary storage should be avoided
● Elements temporarily stored - protected

FRAME TRANSPORT AND A-RACKS INLOADERS

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 33

 3. LIFTING OF ELEMENTS
● Only unsecured elements should be lifted

● Lifting must be done vertically

● Exclusion zone - lifting and assembly of the element

● Elements should be directly assembled from the frame transporter, A-frame

or internal loader

● Information such as weight, lifting points, loop angles etc must be provided

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 34

 LIFTING EQUIPMENT
SHACKLES LIFT MANDRELS EYE BOLTS

LIFTING YOKE ASSEMBLY WINCH CLAMPING BRACKETS

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 35

 Possible rigging configurations
Non-equalised loads

Equalised loads

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 36

 4. ASSEMBLY EQUIPMENT
● Right crane choice - as per the weight
tolerances

● Proper communication between crane hand

and crane operators

● Common lifting - with two cranes

● Safe working at heights, can be done by -

○ MEWP’s

○ Personnel transport with crane

○ Ladders

○ scaffolding

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 37

 5. SUPPORT EQUIPMENT
● Support Devices
● Handling Support Devices
● Fastening Sleeves and Screws

6. RAILS, COVERINGS AND BARRIERS

● Important safety precautions
● Fall protection - max. Height of 2.5 meters
● Rails properly adjusted
● Barrier - two guard rails and a toe board
must be installed.

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 38

 7. PERSONAL SAFETY
● Personnel Protection Equipment
● Fall Protection
● Safety Lines
● Retractable Belts and Tackles
● Fall Absorber Security Slings

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 39

 8. ASSEMBLY
● Fastening and hoisting
○ Pillars and columns
○ Beams and support
○ Facade and walls
● Assembly of rails holders, rails, coverings etc
● Support equipment
● Ceiling elements
● Other construction activities during construction
● Dismantling of elements

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 40

 10 BRANDS
ULTRACORE SOLUTIONS
PVT.LTD

BRHC CONCRETE
INDUSTRIES

KKSPUN INDIA
LTD.

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 41

 ULTRACORE PVT.LTD
● Wide range expertise in the fields of
structural design, redesign for
conventional to Precast structures,
manufacturing of components and
transportation and erection of concrete
panels.

● Products they offer -

○ Precast boundary walls
○ Precast wall panels
○ Precast beams and columns
○ Hollow core slabs

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 42

 BRHC CONCRETE
INDUSTRIES
● Supreme manufacturer of concrete pipes
and precast concrete products

● Products they offer -

○ Concrete drains
○ Concrete benches
○ Rcc pipes
○ Concrete road barriers
○ Kerb stone
○ And customized products

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 43

 KKSPUN INDIA LTD.
● India's largest provider of precast concrete
solutions for the Infrastructure Industry.

● Products they offer -

○ Precast stormwater drains
○ Sewer pipelines
○ Tunnel and shafts
○ Box culverts
○ Precast kerbs and road barriers

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 44

 11 CHALLENGES
● Sealing the Joints - cleaning and using sealants

● Shipping the Product - size and weight specifications

● Offloading & Rigging Concerns - correct rigging structure

● Preparation of Subgrade - level and firm subgrade

● Lack of Flexibility - built as per drawings

● Repairing Spalls or Cracks - structural and cosmetic repairs

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 45

 REFERENCES
● https://civiltoday.com/civil-engineering-materials/concrete/232-advantages-and-disadvantag
es-of-precast-concrete
● https://nitterhouseconcrete.com/guide-to-precast-concrete/
● https://theconstructor.org/concrete/precast-concrete-floor-wall-frame-construction/273/
● https://theconstructor.org/concrete/precast-concrete-floor-wall-frame-construction/273/
● https://lockesolutions.com/common-problems-with-precast/
● https://www.civilclick.com/precast-concrete/
● https://www.worksafe.govt.nz/topic-and-industry/concrete/safe-work-with-precast-concrete/
● https://www.rakennusteollisuus.fi/globalassets/tyoturvallisuus/turvallisuusryhma/aineistot_
muu/turvaohje-crh-elementtien-asennus.pdf
● https://www.brhcpipes.com/products.php
● https://ultracoresolutions.com/products/
● https://kkspunpipes.com/precast-concrete-product-manufacturers.html

SEC. B-GROUP 2 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY 46

THANK YOU
PRESENTATION BY
SEC. B - GROUP 2
47