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D Hussam
Dr. H M h d
Ali Mohammed
PhD Structural Engineering
Building & Construction
Department
P
Precast
t Concrete
C t Homes
H
D Hussam
Dr. H M h d
Ali Mohammed
PhD Structural Engineering
precast concrete homes may not yet be mainstream,
mainstream
but every day more residential architects, builders and
h
homeowners are discovering what precasters
di i h and their
d h i
customers have long known – building with precast
concrete offers advantages during all stages of the
project and
p j beyond
y [[1].
] Precast played a starring role
p y g
in two custom‐built homes that represent very
different styles in markets thousands of miles apart.
apart
The common tie is how using precast simplified the
process and created a beautiful and durable home.
d t d b tif l d d bl h
DESIGNING A DREAM HOME WITH PRECAST
The
h time between
b a homeowner’s
h ’ vision and
d the
h
completed home is filled with hundreds of decisions
p
and details. But it all begins with the design.
Within the first
first‐time
time homeowners, wanted their
dream home to have an open, unobstructed feel but
they were concerned about the home
home’s
s structural
integrity and sound transmission.
The Architect satisfied both concerns by designing
the home with precast concrete supplied by Northeast
Precast in Millville The precast floor planks used on
Precast in Millville. The precast floor planks, used on
the first and second floors, cover a continuous 28 feet
– the
th entire
ti width
idth of
f the
th h
home. Th
That
t wouldn’t
ld ’t h
have
been possible with wood floor joists.
“Normally in a home of this width, you’d have a center
Normally in a home of this width, you d have a center
beam on every floor or walls that support the floors,”
said the engineering consultant for Northeast
Precast. “But prestressing this precast floor system
enables
bl you tto create
t llong spans with
ith li
light
ht section
ti
weights and not have problems with cracking. And
since the planks are insulated, there’s very little sound
transmission between levels.”
The precast floor system eliminated the need for
typical
i l lload‐bearing
d b i walls, ll making
ki it
i easier
i for
f
Architect to design the open concept, and its precision
aided in the design process.
Additionally, if the homeowners want to remodel in
the future,
future the walls can be reconfigured to
accommodate a new design.
Precast is manufactured in the factory, as compared
“Precast is manufactured in the factory as compared
to cast‐inplace concrete, so there’s high quality
control,” Architect said.
l ” A hi id
High quality control and attention to detail helped
Northeast Precast fabricate the most challenging
piece – a gable wall with windows [1].
p g []
Gabled walls are not typically made from precast,
even in structures built primarily with precast.
precast
Northeast Precast had to build a custom form to
accommodate the heavily reinforced wall.
accommodate the heavily reinforced wall
“We make
“W k 1,000 linear
li ffeet
t of
f
walls every day, but they don’t
look like that,” said the general
manager
g of the Superior
p Wall
Division for Northeast. “It was a
bit of a design challenge for us
but we deliver a finished design
product before we build
anything. We work out the
ki k to come up with
kinks i h
something that’s workable
within the parameters of the
realities of precast.”
p
The gable wall was a pivotal structural piece since it
had to resist strong New Jersey lateral wind loads. In
g J y
the future, the consultant anticipates windows will be
installed during the fabrication phase, which would
fabrication phase which would
enable the contractor to close in the building as they
erect the walls.
erect the walls
FASTER CONSTRUCTION AND MORE
Within a matter of days, Northeast Precast fabricated
y
the 11 floor planks – 28 feet long by an average of 8
feet wide – and 36 wall panels
feet wide and 36 wall panels – ranging from 9 to 13
feet in height and 10 to 14 feet in width – to create the
precast structure.
precast structure
“With all the forethought put into the design during
the design phase, prior to production, the installation
went off without a hitch,” General Manager said.
, g
Using precast also helped reduce the number of on‐
site trades people during the construction phase –
something g the homeowner appreciated.
pp That was
especially evident in the decision to precast the gable
wall.
wall
But that was just the beginning of the advantages of
j g g g
using precast. The precast walls feature built‐in
chases in each galvanized metal stud, making them
instantly ready for wiring and plumbing. In addition,
each stud includes a facer so workers could easily and
quickly attach drywall panels [1].
Less insulation is needed to meet code requirements
in a total precast home as well. Expanded polystyrene
foam is integrated into the precast floor system
during the fabrication process and the wall system
f
features uninterrupted, continuous insulation.
i d i i l i
The vertical light broom finishing on the walls also
helped fast track the application of the home’s stucco
exterior. The wall finish served as an excellent
substrate, making wall preparation unnecessary.
PRECAST FOR LONG SPAN
Many literatures were considered a lot of researches
studying how to cover long span and achieve wide hall
d i h l d hi id h ll
area. From these researches that deal with double tee
beam as a roofing technique [2], and further of the
using
g double tee beam, , all flanged
g beams were
studied [3], on which analysis by using finite element
modeling was carried out to predict a powerful
method to study such precast elements.
An experimental programs were arranged to testing
full‐scale double tee beam [4], and all result compared
with numerical finite element model, , looking
g for
matching between the experimental and the
numerical testing method
numerical testing method.
After that another programs
were
ere done to study
stud non
non‐
prismatic double tee roofing
system [5],
[ ] in order
d to achieve
h
longer span.
g p
Over 54ft safe span could be
obtained by prismatic double
tee beam, and more than 75 ft
by using non‐prismatic
non prismatic double
tee beam [6].
Another study was done to investigate the behavior of
Another stud as done to in estigate the beha ior of
precast flanged beam with existing opening [7], at
d ff
different size and location. Also, precast units provide
dl l d
high
g response
p and could withstand the required
q
loading.
PRECAST FOR WORRY-FREE LIVING
While a home constructed from precast typically costs
Whil h t t d f t t i ll t
more up front, the savings over time more than make
up for it.
f
The owner of the precast home is virtually fireproof
and
d moisture‐
i and
d vermin‐resistant.
i i That
Th means
potentially lower insurance and no regularly
scheduled pest control visits. In addition, continuous
insulation on the wall and floor systems
y minimizes
sound transmission and increases thermal
efficiencies.
efficiencies
“The
The HVAC system can be downsized because the
home is that much more air‐tight and highly
insulated ” General Manager said.
insulated, said “The
The air condition
system was reduced from two units to one unit on a
split system.”
li ”
Finally, the home is built to last with minimal
maintenance required over the years [2].
p
“That house will probably y be around 200 years
y from
now,” Architect said. “If you can build a home out of
concrete and do it right – pay attention to the details
concrete and do it right
– precast is the perfect material.”
PRECAST: A NATURAL FOR TINY HOMES
Precast is making big inroads in the tiny home market
P i ki bi i d i h i h k
as well – a niche product that’s attractive to people
who favor a simpler, downsized lifestyle.
Tiny homes are also popular with people who no
longer want the house payments, insurance
requirements, taxes and upkeep of a larger home. In
i d k f l h I
addition, a tiny house can be used for other
applications such as a side business, an in‐law suite
or a space for animals.
Todd Sternfeld, CEO of
Superior Concrete Products,
based in Euless,
Euless Texas
Texas,
began watching the tiny
h
home trend
t d years ago. IIn
2016, after winning a
Creative Use of Precast
award from NPCA for its
Cleburne Ranchette model,
the company began
marketing a line of tiny
homes.
homes
“Sometimes you just have to go for it,” Sternfeld said.
You have to learn as you go and make adjustments
“You
and changes and raise the bar as you go through the
process That
process. That’s s what we’ve
we ve done
done.” The phone has
been ringing off the hook ever since.
A PLETHORA OF DESIGN OPTIONS
References:
1. Precast Solution, Volume 16, Number 2, Spring 2018
2 Hussam
2. H Ali M
Mohammed,
h d "E
"Experimental
i t l and
dNNonlinear
li A
Analysis
l i off N Non-
Prismatic Double Tee Prestressed Concrete Beams", PhD Thesis, Baghdad
University, 2005.
3 Hussam Ali Mohammed,
3. Mohammed "Nonlinear
Nonlinear Analysis of Flanged Reinforced Concrete
Beams Using Three-Dimensional Finite Element Model", MSc Thesis, Saddam
University, 2000.
4 Hussam Ali Mohammed,
4. Mohammed Ihsan A. A Shaarbaf,
Shaarbaf Khild S. S Mahmod,
Mahmod " Finite Element
Analysis of Prestressed Concrete Double Tee Beams", Journal of Babylon
University for Engineering Science, Vol.12, No.5, 2006.
5 Hussam Ali Mohammed,
5. Mohammed "Behavior
Behavior of Prestressed Concrete Non-Prismatic
Non Prismatic
Double Tee Beams", Journal of kerbala University, Vol.8, No.1, 2010.
6. Hussam Ali Mohammed, "Finite Element Analysis of Non-Prismatic Prestressed
Concrete Double Tee Beams" Journal of Kerbala University, y, Vol.8,, No.1,, 2010.
7. Hussam Ali Mohammed, "The Effect of Web Opening on Prestressed Concrete
Double Tee Beams under Flexure", The Second Annual Scientific Conference
g of Engineering
of the College g g /Babylon
y University
y 24-25, Iraq,
q March 2010