Project Report Corrected

STUDY OF PRECAST BUILDING AND ITS FEASIBILITY IN RURAL AREAS
CHAPTER-1
INTRODUCTION
GENERAL
India is the world‟s fastest developing country with an economic growth rate averaging
7.5% for last 5 years. We are currently on the verge of large-scale urbanization hence facing a
huge demand for building houses. The construction industry contributes to about 10% of Gross
Domestic Production (GDP) of the nation, registering an annual growth of about 9 To cope up
with this housing necessity, the country needs to build 30 to 35 thousand units of houses per day
at least for the next 8 years. Housing is the primary need of every human being. With the rapidly
growing population, and to fulfill the aforementioned housing demand, a more reliable, faster,
sustainable method of construction is deemed necessary by the construction industry. The
concept of “built it fast” in the most economical way has not changed since the beginning;
however, new technologies have been developed to suit the modern world construction. One
such solution is precast concrete construction technology. Precast technologies is not only
helping contractors and builders get their buildings faster and more economically but it also
helps to reduce construction waste and produce high quality, energy efficient buildings which
results in long term benefits to projects.
Precast constructions has been a common construction method in United States of
America and many European countries. On the other hand Precast for residential construction
has been used in India for only less than a decade, but it has been growing very fast in the past 5
years. Recently, there have been any new developers and contractors who have switched from
traditional construction to precast to keep up with this new trend in the Indian residential market.
Construction is creation of housing or housing units utilizing manufacturing plant motorization
the industrial facility setting improve reasonableness through a mix mass by of materials large
scale manufacturing get together produces and utilization of less talented work construction can
take one of three structures preassamble parts secluded housing the construction of lodging
segments for e.g. window entryways and expenses nearby high cost work proceeding with
advancement in this future of construction gives a developing scope of development items that
J.J.M.C.O.E Jaysingpur Page 1

may additionally decrease development cost particular lodging includes construction of areas of
lodging that are then amassed nearby in this way decreasing nearby work cost.
BACKGROUND & PRESENT SCENARIO
Precast play an important role in the modern world construction of every building today,
it refers to the making of parts in an offsite workshop or factory prior to the installation at the
site. “The primary purpose of precast construction is to produce building components in an
efficient work environment with accesses to specialized skills and equipment in order to reduce
cost and time expenditures on the site while enhancing quality and consistency” [Anderson and
Anderson 2007]. It is clear that most new construction will have to use more and more precast.
From primary structures to small architectural ornaments, precast has become a major part of
building construction. In the near future, precast is expected to play a vital role in Indian
construction, especially, in the residential building construction.
Over the past 15 years, India has experienced the huge increase in housing demand in a
very short period of time, requiring a massive production of residential buildings with the
changing face of realty market. The large projects comprising of townships, mass housing,
commercial mall, IT parks, SEZ‟s etc. are common now a days and will grow exponentially.
Most of these projects are still being constructed using conventional technologies. Due to this,
the inherent benefit these projects offers in terms of repetition and huge volume turnover
remains unexploited and it also makes the project management complicated in terms of speed
and quality of construction. This fast growing economy forced builders to build faster and
affordable with high quality. To meet high demand, some builders tried to innovate and bring
about transition from the conventional cast-in-situ (CIS) construction and move to precast
construction by making building components off-site, and then install them on site. Precast
technology, the so called unconventional method in Indian arena can facilitate both speed and
quality and exploit the advantages that projects offer in terms of repetitions and volume. Today,
the world agrees that precast/prefab construction makes significant impact on both time and
budget.

CONCEPT OF PRECAST
Concrete material is the most widely used construction material on earth which comprises
about 60% of the built environment in many developed countries .Concrete has shaped
civilization from as far back as the ancient Egypt and the Roman Empires and it is indispensable
in the development of infrastructure, industry, and housing. Without concrete the built
environment would fail to accommodate our modern and demanding lifestyle. For concrete the
basic building materials provide strength, durability, and even elegance far in excess of many of
its manufactured competitors. Concrete has a wider range of uses in the construction of
commercial buildings, roads, harbours, dams, bridges, electric poles, residential buildings,
retaining walls, reservoirs, septic tanks, canals, and a whole lot more .The durability of concrete
is of vital importance regarding the life cycle cost of the structure, which includes not only the
initial cost of the material and labour but also the cost of maintenance and repair. The durability
of concrete is therefore defined as its ability to resist weathering action, chemical attack,
abrasion, and other forms of deterioration. Concrete has much higher level of fire resistance than
other building materials. It is not combustible and would not produce smoke or fuel the fire [6].
Concrete product can be either precast or in situ concrete. This study seeks to analyze the
elemental cost comparison of precast and cast-in-place slabs and columns of some selected
public projects in Ghana. The construction industry in Ghana is not familiar to the use of precast
technology for beams, walls, foundations, and so forth and the precast columns and slabs are the
most common in the Ghanaian construction industry.

OBJECTIVE OF PROJECT
 Study of precast construction technique.
 To check possibilities of precast housing feasibility in rural areas.
 Cost comparison between precast and conventional building construction.

PROPOSED WORK
 Collection of data about precast from industry ,journal papers, reference books .
 Study and analysis of precast construction techniques
 Comparison of precast and RCC (conventional) building
 Developing simple house plan as a case study after visiting precast plants at industry.
 Cost estimation of case study from conventional and Precast construction point of view.
 Finding out limitations and opportunities of precast construction in rural areas.

CHAPTER-2
LITERATURE REVIEW
1) Study of comparison between prefabricated and conventional structures.

V.Karthikeyan, E Vinodhini Assistant Professor, Department of Civil Engineering,
Hindustan Institute of Technology and Science, Padur, Chennai, Tamil Nadu, India.
This paper deals with fundamental objectives of the work have been accomplished. The
aggregate cost and length have been resolved for both prefab and ordinary development. And
additionally we had thought about the focal points and detriments of both construction and
traditional development by the overview directed. The examination shows there isn7t a colossal
cost contrast between the techniques (6%), prefab being more temperate in tall structures when
contrasted with regular. In the meantime the prefab development diminishes the undertaking
length, lessened by 335 days when contrasted with the ordinary. Because of overview we had
realized that the prefab development have more points of interest and obtainment in
industrialized, substantial frameworks. Materials that have turned out to be profoundly particular,
with specialist vacillations in cost and accessibility, can be accumulated at construction shops or
processing plants. Moreover, the institutionalization of building segments makes it workable for
development to occur where the crude material is minimum costly. To decide if construction is a
decent choice you have to consider.
1) It can also change the conventional mindset of people and accept to try modern
construction methods. Use of standardized elements from companies that have variety of options
to choose from can help make structure unique.
2) One time investment in good quality lifting machines and proper maintenance can help
in further savings.

2) A Study of Cost Comparison of Precast Concrete Vs Cast-In-Place Concrete

Vaishali Turai1 & Ashish Waghmare Department of Civil Engineering, S.P.P. University,
Pune, India.
This paper deals with precast industry is booming. Due to its many advantages, such as
reduction of building time, product selection, enhanced quality with certified performance levels,
cost optimization and so on, it currently represents 20% of concrete production worldwide. In the
precast industry, the use of SCC is increasing and it is expected to replace vibrated concrete in
many applications because of its various advantages, including the reduction of harmful effects
of noise in urban environments, the possibility of pouring in congested reinforced areas or
Complex geometry, and a reduction in industrial process costs . The use of cast-in-place columns
in bridge construction requires long on-site construction times and large labor requirements in
the field. Cast-in-place construction is particularly disruptive in situation in which it exacerbates
traffic congestion. Using precast bridge elements is one solution for reducing on-site
construction time, field labor requirements, and traffic delays. This strategy is widely applied for
bridge girders. Although full bridges can be constructed off site, precasting is usually limited to
the columns to make fabrication and transportation easier. However, achieving good connections
between precast column and footing, particularly column-to-drilled shaft connections, is
challenging in seismically hazardous areas. This paper describes the concept, and seismic
performance of the connection between a precast column and drilled shaft, and provides
recommendations to ensure desirable performance.
3) Comparative Study on Prefabrication Construction with Cast In-Situ

Construction of Residential Buildings N.Dineshkumar1 , P.Kathirvel2 1 PG Scholar,
Department of Civil Engineering, Mahendra Institute of Engineering and Technology,
Namakkal, Tamil Nadu, India.
The main goals of the work have been achieved. The total cost and total duration for the
double storey residential building have been determined for both prefab and conventional
construction. And also we had known about the advantages and disadvantages of both
prefabrication and conventional construction by the survey conducted in similar companies. The
comparison showed there is enormous cost difference between the methods, which the prefab is
very high when compared to conventional on this type of individual houses. The prefab

construction for individual double storey residential building cost is 13% more than the
conventional construction. This is main drawback for prefab construction which is not
economical to construct in this case. At the same time the prefab construction is easy to work and
reduces the project duration, is reduced by 63 days when compared to the conventional. It‟s the
main advantages for prefab construction and also it helps when there is labour shortage. As a
result of survey we had known that the prefab construction have more advantages and
procurement in industrialized, heavy infrastructures. But in individual houses there are lot of
constraints and lack of knowledge its get struggling to implement in our country. At this stage
conventional.
4) A Comparison of Construction Cost and Technology Choice Toong Khuan Chan,
Faculty of Architecture Building and Planning, The University of Melbourne Faculty of
Architecture Building and Planning, The University of Melbourne.
This paper deals with indicated that in some developing countries, the construction
industry is very dependent on the importation of construction components and materials
combined with issues of high unemployment leading to high construction costs from imported
materials, inflation and an unstable economy. Thus policies put forward by various countries to
improve the economic performance of their respective construction industries need to be
informed by a precise economic model that illustrates the link between the cost of inputs to the
construction industry to the price of its outputs and its follow-on benefits to the national
economy. Recent work by construction economists (Stapel 2002, Walsh and Sawhney 2004,
Best et.al 2010, McCarthy 2011) are focused mainly on gathering data on construction costs in
major cities around the globe and conducting research to explain observed differences in these
indices based on the type of building; whether the building is to be used as a hotel, premium
office tower, or an industrial or manufacturing facility. The demand for these indices are driven
mainly by investors from developed countries looking to invest in major growth areas, or by
manufacturers seeking to relocate their operations to less expensive locations. On the other
hand, local construction activities are organised by managers sourcing building materials
locally, employing local or migrant labour, and selecting a method of construction that reflects
the ability of the local industry aim to achieve a lowest cost solution.

5) Cost Analysis of Precast and Cast-in-Place Concrete Construction for Selected

Public Buildings in Ghana, Richard Oduro Asamoah, John Solomon Ankrah, Kofi Offei-
Nyako, and Ernest Osei Tutu.
Concrete is a mixture of cement, fine aggregate, coarse aggregate, and water. Concrete
must meet the required standard of strength and durability. In Ghana, the use of concrete and
reinforced concrete for construction purposes is very common. There are many types of concrete
designed to suit a variety of purposes coupled with a range of compositions, finishes, and
performance characteristics .This study focuses on the precast and in situ concrete. Precast is
defined as a concept that uses standardized structural components produced away from the
construction site and the components are transported to the site for assembly. These components
are manufactured by industrial methods based on mass production in order to build a large
number of buildings in a short time at low cost. The use of precast concrete has various
advantages which include the reduction of the site labours, less wastage, less volume of building
materials, and increased environmental and construction site cleanliness. The use of precast
products also provides safety at construction site and reduces time of completion in construction.
Figure 1 shows how easy it is to fix fun hock and steel ceiling noggins. All these indirectly
signify that the precast concrete is much more economical, though the construction cost involves
all matters either initially or throughout the building‟s life. Most concrete buildings are cast-in-
place; the wet mix is deposited and formed at the place where the finished concrete is desired,
generally referred to as site cast concrete, since the location is usually at a building site. Precast
concrete is defined as the process of casting of concrete elements offsite and move them to the
actual building site. Concrete for site cast construction is typically brought to the site by
concrete, transporting mixer trucks with the large rotating barrels. The mix is prepared at a
central batching plant, where controls of the materials may be carefully monitored. However, the
transporting to the site, proper mixing in truck, discharging from the truck and depositing in the
forms, and handling for placement, finishing, and curing are all subject to the level of
responsibility and craft exercised by the people involved. Site conditions in terms of accessibility
and weather can be highly critical to the work, requiring extreme measure in some situations to
control all the stages in the production process. An element is defined as a part of the building or
service which performs the same function in its purest form. One of the most effective tools that

Quantity Surveyors use in the planning and design process is the elemental cost plan. Cost of any
project is influenced by project location, type of design, size of the building, date of tender and
prevailing market conditions. Elemental cost analysis is the study of costs to client which is
given to tenders to determine the probable cost of each element.
6) Comparitive analysis and design for precast and rcc ews buildings, Mohini V.
Patel M.E Structures, Civil Department, KJ College of Engineering & Management
Research Kondhwa Saswad Road, Near Bopdeo Ghat, Pune.
This paper investigates that how the precast technology will be helpful for the country
like India where the more population is present. For this situation providing the shelter to all
economical weaker section people the precast technology will be helpful. To Indian government
to provide the shelter to all people and with optimum cost of construction the precast will be
preferable. With the help of etabs software we analyzed the both rcc and precast structure for
structural stability and have checked for all the different conditions and which gave the
satisfactory results for the structures.
Urbanization in India has generated huge demand for housing which neither the cities nor
the housing sector is prepared for. The number of urban agglomerations has increased from 384
in 2001 to 475 in 2011, a decadal increase of 23.7%. As per the twelfth five-year plan (2012-17)
the total housing shortage in rural areas is 43.66 million units. In order to cater the issue
surrounds the shortage of affordable and low cost mass housing at a much competitive cost and
on time schedule, it is imperative to adopt alternative construction system. The Indian
construction industry led by traditional mode of construction as characterized by challenges such
as low productivity, lack of skilled labor, time and cost overruns etc. Precast Concrete
Construction, the so called unconventional method in Indian Construction Industry can cater the
above needs by offering both speed and quality of the construction.

7) Comparative Study on Prefabrication Construction with Cast In-Situ

Construction of Residential Building N.Dineshkumar, P.Kathirvel
The main objective of the present work is to study the present situation of the precast
construction industry in India. Suggestions for improvement of the industry and study on cost
effectiveness of precast concrete construction for single and multi-story residential buildings are
to be given. A literature survey was carried out in order to obtain the comparison between the
conventional buildings with precast concrete buildings in India and some field visits are
conducted to collect data to investigate the current situation regarding precast industry in India.
In order to compare the cost of precast and in-situ construction, double storey residential
buildings is considered.
8) Building cost comparision of pre cast concrete construction with conventional

construction. C.Shivapriya and S.Senthemikumar asst. proff. school of architechture and
planning Periyar Maniammai University tamilnadu, india.
This paper deals with Construction Practices in Developing Countries” reviews some of
the more significant differences in construction practices in developing countries and Five
primary factors are discussed 1. Cost of labor 2. Cost of money. 3. Technology and methods 4.
Infrastructure 5.Role of the design professional (Randolph Thomas.2002) The article,
“Documenting and Analysing Construction Failures”, by Yates K.J., et.al., provides description
of the methods used for the research, results obtained from the industry survey, summary of the
results of an investigation into case studies on construction failures, analysis of the results,
discussion on construction failure investigative techniques, guidelines developed during the
research project for investigating and documenting failures, recommended format for reporting
the findings of failure investigations. Four stages are necessary to produce improvements and
changes diagnosis/evaluation, changes implementation, control and standardization.
9) Time, Cost, Productivity and Quality analysis of Precast Concrete System B.

Raghavendra K. Holla P, Siddhant Anant P, Muzzammil Ali Mohammad
Out of the various determinants that lead to the success of a project, construction
management plays a vital role among them. Delay in a construction project would cause wastage
of resources and money that needs to be analysed. The construction methodology adopted has a
direct impact on the strength and the quality of the structure. In this aspect, precast concrete

construction is considered to produce better productivity and reduce completion time, cost and
dependency on work force. This paper reviews and summarizes the role of time, cost, quality and
productivity of the precast system in order to compare with the conventional.
10) Design, Cost & Time analysis of Precast & RCC building, Akash Lanke, Dr. D.
Venkateswarlu
Precast concrete is well known technology in which some standardized units which are
manufactured in factories are used for fast construction. Though the technology is developed
many years ago but the implementation is not up the mark in our country. In this study we have
carried out detailed study of various concepts of precast, go through number of literature &
found the facts associated with it. We have taken one building as a case & Design the same
building as a precast building & Traditional Cast in-situ building. Here we have made cost
analysis as well as feasibility check on basis of costing & Duration. For more practical study we
have visited the two ongoing construction sites of Precast & cast in-situ & gathered required
information, From this analysis It is remarkably seen that the cost of precast building is
significantly reduces & duration of construction is also much lesser than traditional method.
From all this study we can be conclude that the precast concrete system is economical than
conventional cast in place method but still there are some conditions which we have to take care
of while using precast, those are quantity of construction, Distance of site from manufacturing
unit, Type of building etc.

CHAPTER-3
PRECAST COSTRUCTION
Precast Concrete is the concrete which has been prepared for Casting, Cast & Cured at a
location which is not it‟s final destination. The art of successful precast construction involves
various activities like Architecture, Design, Detailing. Precast concrete consists of concrete (a
mixture of cement, water, aggregates and admixtures) that is cast into a specific shape at a
location other than its in service position. The concrete is placed into a form, typically wood
or steel, and cured before being stripped from the form, usually the following day. These
components are then transported to the construction site for erection into place. Precast concrete
can be plant-cast or site-cast, but this book deals specifically with plant-cast concrete.
BENEFITS OFFERED BY PRECAST

There are many benefits associated with the use of precast concrete components. Of
course these require proper design, use of the correct materials and manufacturing processes with
skilled and knowledgeable personnel. Properly designed and specified precast concrete go a long
way toward reducing and eliminating many common utility construction problems, while the
economics of precast translate into faster, more cost-effective projects. Benefits available
include.
Speed-To-Market
Precast structural components are fabricated in a controlled plant environment and can be
erected in weather conditions that would delay the full erection of steel components or CIS
concrete. In general, the advantage of precast is that faster erection reduces the overall
construction schedule and overhead costs. Compressed schedules, fewer on-site trades, and
eliminating weather delays add up to reduced project costs.
Quality & Durability

Precast, prestressed products provide a long service life that far exceeds field-placed
concrete partly because members are manufactured in plants under strictly controlled conditions.
The controlled plant environment has offers easy verification of quality and a dedicated

workforce. This means high-quality product can be manufactured every day, regardless of
weather. The low water-cement ratio used in precast concrete creates a denser product that does
not allow penetration of chlorides and other harmful elements as easily as field-placed concrete.
Integrated Project Delivery

Structural precast components can be erected in a relatively short period of time because
they interlock to support one another. Simpler installation requires fewer crew members, which
means which means fewer personnel to manage, fewer trades to pay and fewer trade-related
delays. Precast advantage is a cleaner and safer job site with less risk and more assurance of a
smooth and successful project flow.
Enhances Safety
Precast products eliminate many of the dangers associated with on-site construction by
providing a controlled, off-site fabrication environment. Precast reduces the amount of wet trade
work on site, making them cleaner, tidier and safer.
Sustainability
Precast is perfect for today‟s focus on preserving resources and protecting the
environment though sustainable building practices. It‟s a perfect Green Building product. Precast
reduces overall life cycle impact on environment compared to other methods as it has lower
wastage and high potential to recycle waste.
Optimization & Flexibility
Advanced automation and technologies used in precast plants optimizes the resource
utilization, and produces an improved quality product with reduced tolerances, thinner sections,
and engineered solutions. Also, it offers flexibility of space planning by allowing for longer
spans which create larger open floor plans and increased flexibility in design. For architects, it
can offer variety of different profiles. It is possible to cast the member of very complex design
and shapes.

Innumerable other advantages like high dimension accuracy, tight tolerances, minimal
maintenance, acoustic insulation, thermal inertia, various surface finishes, colours, etc. can also
be availed as desired.
BASIC PRECAST SYSTEM
Precast concrete building structures are composed of some basic types of structural
systems. These systems can be combined in different ways to obtain an appropriate and effective
structural concept that fulfils the needs of specific buildings. The most common systems are:
− beam and column systems (beam elements, column elements, connections)
− floor and roof systems (floor elements, roof elements, connections)
− bearing wall systems (wall elements, connections)
− façade systems (façade wall elements, connections)
The above list is not unique as there are many variations possible to achieve the same objectives
that architects and engineers are now successfully exploring, such as the use of arches and rigid
portal frames. Façades are sometimes load-bearing, providing also the lateral stability, but they
can also be used without a load-bearing function. Other less common precast systems are:
− frame systems (frame elements, connections)
− cell systems (cell elements, connections)
beam Column System
Beam and column systems are composed of columns and beams, although the beams are more
like rafters where the column height may correspond to more than one storey. The system in
forms the basis of the skeletal frame. The connections in these systems are:
− beam to column
− beam to beam
− column to column
− column to base

Beam column system
Floor And Roof System
The main purpose of floor and roof systems is to carry vertical load to the vertical load-
resisting structural elements. Besides, precast floors and roofs are often used as essential parts of
the estabilishing system to transfer horizontal loads by diaphragm action to the stabilising units,
andThe most common floor systems are hollow-core floors and double-tee floors, Double-tee
units are also used in roof systems. The connections of these systems are
− slab to slab at longitudinal interior joints
− slab to edge element at longitudinal edge
− slab to slab at interior support
− slab to end support
The elements in a floor system will not resist loads separately from each other, but a
degree of interaction between adjacent elements is desired. To obtain a transverse distribution of
load effects in case of concentrated loads and prevent uneven vertical displacements at the
longitudinal joints, the floor connections must be designed to develop shear key action that
ensures the interaction between adjacent elements. In composite floor plate floors (also known as
half-slab), precast concrete floor plates are used as formwork for the cast insitu part and remain
integrated in the composite floor section, Composite action depends on the shear transfer in the
horizontal joint between the precast plate and the cast insitu concrete part, There is no
requirement for design of longitudinal joint between the plates as the topping is continuous over
the precast joint lines.

Wall systems
The main types of precast concrete wall systems are shown in as façades and interior
cross-walls. Walls can be classified as bearing and non-bearing walls. Bearing walls are used to
support bridging components like floors, roofs or beams, Examples of non-bearing walls The
connections of these systems are:
− wall to wall at interior and exterior vertical joints
− wall to wall at interior and exterior horizontal joints
− wall to base/foundation
The connections of non-bearing wall systems are mainly façade to beam – rarely are they
connected to columns.Non-bearing walls are normally designed to carry their dead weight, which
means that the connections at horizontal joints need to resist the weight of the wall elements
above this level of the wall. However, as an alternative, non-bearing façade walls might be fixed
to the adjacent load bearing system in such a way that the dead weight of each wall element is
supported by the main system. Prefabricated walls can be used as part of the stabilising system to
resist horizontal loads in its own plane. In that case the prefabricated wall should behave as one
structural unit composed of interacting wall elements. This structural interaction within the wall
needs to be secured by structural connections that resist the required shear forces, tensile forces
and compressive forces.
Moment resisting frame systems
Precast concrete moment-resisting frame systems are found in skeletal or portal systems
where „frame action‟ is used for the stabilisation. This is obtained by combining spatial H-shaped
elements, L-shape elements, or portal frames, etc. with monolithic connections at the
intersections between beams and columns within the element. The elements are connected in
locations where flexural resistance is not required at points at contra flexure. Alternatively the
connections between beam and column elements may be designed and detailed to obtain the
required continuity and moment resisting capacity. However, this often makes the connections
complicated and costly, and such solutions seldom appear in practice.

Cell systems
Precast concrete cell systems are composed of closed cell elements or open cell elements
with U or L-section. Complete structures can be made by combining cell elements. However, it
is more common to use cell elements for specific parts of a structure, for instance wet areas, and
combine these with ordinary walls and floor systems.

ASPECTS ON CONNECTION METHODS
There are several ways to obtain tensile capacity in connections. Considering the safety
aspect only, the order of preference is as follows:
1) Bolting
2) Grouting reinforcing bars at the site
3) Embedding reinforcing bars in epoxy or polyester at the site
4) Welding
The use of bolts is a simple way to establish a safe connection, but it generally puts strict
requirements on the tolerances. The bolts can be threaded rods or regular bolts. Grouting at the
site will to some extent depend upon the weather to be successful. Generally the requirements on
tolerances are not severe. When the result from a casting operation is successful, a very sound
connection is established. It also provides fire and corrosion protection for the steel details. Mix
proportions, aggregate size and casting procedures will vary with the size, location and
orientation of the operation. Patches permanently exposed will often not be acceptable.
Anchoring the grout to relatively large steel surfaces is a problem that is often overlooked. Large
elements such as steel haunches can be wrapped with mesh or wire. For recessed plates and
similar elements headed studs or wiggled refractory anchors can be welded to plate to provide
anchorage for the grout. Gluing with epoxy or polyester is very dependent upon weather
conditions to be successful, especially temperature. Also the workmanship is of great importance
to secure a satisfactory result, like the mixing of the ingredients and the preparatory cleaning and
drying of the contact surfaces. Some types of glued connections also put some requirements on
tolerances. Most types of glue loose most of their strength when heated to about 80oC. Welded
connections will in most cases fit without any problems, but the quality of the weld is totally

dependent upon the skill of the welder. When welding outdoors the welder must have extensive
knowledge about what kind of electrodes to use under different weather conditions on different
material qualities, and of treatment of the electrodes and materials prior to welding. Also the
actual work may be difficult and laborious to perform; like when fixing a small plate with only
ladder access, with heavy cables and no place to put the clamp. The heat generated when welding
may also damage the quality of the concrete close to the weld. Welded connections will in many
cases have to be fire protected.
FORCE TRANSFER MECHANISM

Force transfer types
The connection characteristics can be categorised by the type of action it is designed to resist:
− shear
− tension
− compression
− flexure
− torsion
For many structural connections the behaviour is dominated by one of the actions above.
Sometimes connections are classified by this dominating action as „shear connections‟,
„compression connections‟ etc. However, very often the structural connections should be capable
to transfer a combination of these basic actions. Shear transfer is required at joints between
precast wall elements and between floor elements. At longitudinal joints between hollow core
units shear transfer is required horizontally as well as vertically. Connections between precast
beam elements or floor elements and a cast insitu topping may require shear resistance to obtain
an adequate behaviour in the final state. The ability to transfer tensile forces is normally secured
by means of various types of tie bar, anchor bars and other connecting devices of steel. Tensile
capacity is often required between wall elements used for stabilisation, between floor elements
and between precast floors and their supports. Depending on the position of the ties these
connections can be more or less capable of transferring bending moments, even if this was not
intended by the design. Unintended tensile resistance can sometimes appear in connections, for
instance due to bond between the short end face of a floor element and the joint concrete in the
support joint near by. Unintended tensile or flexural resistance may result in undesirable

restraints that must be considered in the design, Transfer of compressive forces is an important
function of connections at horizontal joints in precast walls, in connections between precast
column elements, and at support connections of precast beams. Flexural resistance is required for
instance when a precast column is fixed at the base, or when continuity is needed at interior
supports of beams or floors. Also for beam/column connections in moment resisting frames,
flexural resistance may be required. Torsional capacity is needed at support connections of
simply supported beams that are loaded eccentrically with respect to the sectional shear centre.
This may for instance be the case for one-sided ledge beams used for precast floors. Many
structural connections should be able to transfer more than one type of basic action. For instance
connections at the short ends of floor elements may need, besides the primary support action,
both shear resistance along the support and tensile resistance across the joint. In support
connections it may also be necessary to combine the ability to transfer forces with the need for
movement. Design of connections with regard to the ability to transfer forces must be based of
the knowledge and understanding of basic force transfer mechanisms.
3.0: Column beam connection

ELEMENTS OF PRECAST
Precast Slabs
Main types of slabs used in precast frames are: hollow core slab and solid slab. The details
of hollow core slabs are shown in the Figure 5.2. The hollow core slabs are prestressed, precast
concrete slabs, with hollow portions in the zones of zero stresses. They reduces the overall
concrete dead load, concrete requirement and provides for better insulation. It is possible to
achieve larger unsupported spans. Their general thickness used are 150, 200, and 265 mm.
These slabs are casted 140m long at a time, with a fixed width of 1.2m. After steam curing the
slabs are cut into smaller pieces as per site requirement. They are then delivered to site and
installed in position using tower cranes. After installation as per drawings, a thin reinforcement
screeding of 50-75mm is laid on the top, to seal the joints.
Figure 3.2: Precast Concrete Structural Elements for a Typical Residential Unit

Figure 3.3: Precast (a) Hollow Core
Another common type of slab used are solid slab. These slabs are casted on a tilting bad with
lateral and longitudinal reinforcement. These slabs are generally used for long span in the
common areas and toilets where it is required to facilitate for various MEP services. They are
helpful to reduce weight thus easy for site crane handling. It also eliminates the shuttering cost,
and helps to attain a superior slab soffits.
Precast Columns
Columns (Shear walls) in precast construction can either be done in CIS or precast. They
are most suited in commercial, industrial bay buildings where thicker sections are needed.
Precast columns are provided with corbel for simple beam column connections. Precast also
allows for casting of triple height columns, thus faster erection.

Figure 3.4: Typical Precast Column Details
Precast Beams
There are two main categories of beams used in a precast structure. Internal beams are
used where floor loading is approximately symmetrical, and external beams are used where floor
loading is predominantly non-symmetrical. The use of precast beams with proper designed
connections ensure higher structural stability.
Precast Wall Panels
Precast wall panels and claddings are smart substitute for conventional infill block work
or brick walls. These walls offers superior finish surface, eliminates the plaster and touch ups,
facilitate for desired & accurate openings of doors, windows, ventilators etc. These wall panels
also improve the overall lateral stability of the structure.

Figure 3.5: Precast (a) Wall Panels & (b) Claddings
Precast Staircase
Precast staircase eliminates the complicated on site shuttering & reinforcement, and
provides high quality finish. They can either be a single precast unit containing all flights and
landings or separate precast flights & landings. Figure 3.5: Precast Staircase Details Some other
elements are precast balconies, canopies etc. and in common areas boundary walls, kerb stones,
main gate, etc. are shown in. Figure 3.6
Figure 3.6: Precast Staircase Details
Some other elements are precast balconies, canopies etc. and in common areas boundary walls,
kerb stones, main gate, etc. are shown in.

Figure 3.7: Details of (a) Boundary wall, (b) Kerb Stone, & (c) Main Gate
BASIC DESIGN CONCEPTS FOR PRECAST CONCRETE BUILDING
1) In design of precast members and connections, all loading and restraint conditions from
casting to end use of the structure should be considered. The stresses developed in precast
elements during the period from casting to final connection may be more critical than the service
load stresses. Special attention should be given to the methods of stripping, storing, transporting,
and erecting precast elements.
(2) When precast members are incorporated into a structural system, the forces and deformations
occurring in and adjacent to connections (in adjoining members and in the entire structure)
should be considered. The structural behavior of precast elements may differ substantially from
that of similar members that are monolithically cast in place. Design of connections to transmit
forces due to shrinkage, creep, temperature change, elastic deformation, wind forces, and
earthquake forces require special attention. Details of such connections are especially important
to insure adequate performance of precast structures.
(3) Precast members and connections should be designed to meet tolerance requirements. The
behavior of precast members and connections is sensitive to tolerances. Design should provide
for the effects of adverse ccombinations of fabrication and erection tolerances. Tolerance
requirements should be listed on contract documents, and may be specified by reference to
accepted standards. Tolerances that deviate from accepted standards should be so indicated.
(4) All details of reinforcement, connections, bearing elements, inserts, anchors, concrete cover,
openings and lifting devices, and specified strength of concrete at critical stages of fabrication

and construction, should be shown on either the contract documents prepared by the
architect/engineer of record or on the shop drawings furnished by the contractor. Whether this
information is to be shown on the contract documents or shop drawings depends on the
provisions of the contract documents. The shop drawings should show, as a minimum, all details
of the precast concrete members and embedded items. The contract documents may specify that
portions of connections exterior to the member are also to be shown on the shop drawings. The
contract documents may also require the contractor to provide designs for the members and/or
connections. The contract documents should show the loads to be considered in design of the
precast concrete elements of the structure, and they should indicate any special requirements or
functions (for example: seismic loads, allowance for movements, etc.) that should be considered
in design assigned to the contractor. In this case, the shop drawings should include complete
details of the connections involved.
CONSTRUCTION METHOD FOR PRECAST SYSTEM
Construction Considerations
The contractor should consider the following:

• All safety issues on site when handling precast elements, especially so when
working within a tight site
• The lifting capacity of the crane used
• The working boom-radius of the crane
• The suitability of construction materials for the purpose of use, i.e. sealant,
grouting, shim plate, propping etc
• Co-ordination with the precaster and specialist supplier to achieve the best
performance and working method - precaster often provide relevant technical
requirements to the contractor during the design development phase to avoid
discrepancy.
Sequence Of Work
• Ensure the correct panel before hoisting
• Ensure the crane lifting capacity before hoisting the panel

• Ensure the desired crane‟s working radius

• Ensure the anchorage for the propping does not damage cast-in building services
• Ensure the desired Reduced Level (R.L.) of panel-base by adjusting the shim
plate. Shim plate to be at an interval of 500mm c/c
• Ensure the desired verticality/position is achieved
• Estimated time to install a typical precast element is 1/2 to 3/4 hour.
Construction Requirements
Alignment, Verticality and Levels
• Tolerance level
1. For Wall
• Vertical deviation +2 mm, -2 mm
• Horizontal deviation 0 mm
2. For Beam & Slab
• Departure from intended horizontal position, +2 mm or –2 mm
• Departure from intended vertical position, +2 mm or – 2 mm
The diagrams below illustrated the sequence of installation for the precast beam-slab system:
The Procedure:
 Setting out:
1. Surveyor to set cross reference.
2. Transfer grid and mark wall position on slab.
3. Mark 100mm offset line from rear building edge.
4. Offset wall position by 200 mm.
5. Secure 2x2 timber to the floor at wall edge to guide wall

 Wall Positioning
1. The first wall in place has to be the partition wall at the rear.
2. Mark a line parallel to and 100mm from the external edge of the wall.
3. Place shim plate @~500 c/c on the floor and level to wall soffit. Shim plate may also be
placed on Non-shrink mortar bed and allow to set.
4. Adjust position of the dowel bar.

 Beam Setting Out

1. Cast wall joint.
2. Mark 1 m reference line.
3. Confirm pocket level. Position shim plate to correct beam soffit level if required.
4. Mark position of beam on floor.
5. Hoist beam in place and check top level.
6. Plumb beam to verify position on floor below.
7. Ensure beam verticality with a spirit level.
8. Wedge beam against pocket and grout the gap between the beam and the wall.
 Slab Setting Out I
1. Position the slab temporary supports and adjust the slab soffit level approximately.
2. Raise the height of the supports about 5 mm above slab soffit level.

 Wall Adjustment
1. Position adjacent walls and plumb wall corners at 200 mm offset

2. Adjust verticality until within +2 or –2 mm
3. Ensure the four faces of every walls are adjusted
4. Position string 250 mm from face of walls
5. Walls within the same line are to be adjusted within same tolerance
6. Ensure air-pocket is fully grouted
 Slab Setting Out II

1. Hoist slab in place on top of beam and support.
2. Verify level of every plank soffit at four corners and center.
3. Adjust level of temporary support accordingly

 Staircase
1. Position landing or slab and verify soffit level at four corners.

2. Adjust level to within tolerance.
3. Position shim plates at staircase support location to correct level.
4. Verify level difference between pegs on top and below.
5. Hoist staircase in place.
6. 10mm gap between precast plank and staircase

Precaution
1. Specify items which cannot be compromised

• Zero tolerance on partition walls.
• Dividing boundary line between units.
• External building lines.
• Staircase dimension.
• HS internal dimensions.
2. Alignment Priority
• Alignment of grooves.
• Uniformity of grooves.
• Horizontality of architectural treatment i.e. Brick Tile.
Post Installation
1. Verify alignment and verticality of every wall.
2. Verify cast slab level at 1m grid.
3. Report deviation and rectify if required.

VISIT TO B.G. SHIRKE COMPANY
3.8: Photo gallery of B.G. Shirke company

PROCEDURE FOR PRECAST COMPONENTS:
1) Reinforcement work:
a) Insure making of true size links so that cage will be corrected size as per drawing and
correct clear cover to the main reinforcement drops and notches will be maintained.
b) Make standard sample of each type of link/ring and keep same at steel yard for
reference of all the time.
1) Mould preparations:
a) Clean the mould surface/end plates/notch boxes using grander equipped with cup
wire brush mould must be absolute clean for every casting.
b) Apply the mould oil over mould surface uniformly then wipeout excess oil if any
using cotton west.
c) Place the reinforcement cage in mould with proper cover.
d) Assemble mould size properly using 2mm thick rubber strap/firm tape glued to
underside of mould from thought the length. Fix end plates notch boxes firmly with
nuts/bolts provided all bolts must be used as per provision made fix rubber bush
around the main bar at end plates to sill the gap.
e) Insure that all gaps are properly silled and absolutely no slurry leakage takes place.
3) Concrete placing/compaction:
a) Insure that concrete is desired mix/quality having slump between specified limit.
b) Pour concrete uniformly throughout the layer uniformly in layers use needle vibrator
for vibration as this added keep to vibrators one with 40mm needle anoter with 25mm
needle. Use 25mm needle for congested areas
c) Insure that concrete get vibrated and compacted all around the notches
d) Level and finish the top surface properly.
e) Tab gently over the notches/size and drops to get entrapped air out.

f) Clean the outer mould surface with wet cloth also clean mould surrounding area.
4) Initial water curing after 3 to 4 hrs of concrete pouring cover the mould top with wet
hessian cloth and spray gentle water periodically.
5) Demoulding/surface hacking/component id marking:
a) Open the mould and plates/sides next day as per production time cycle
b) Carryout the hacking of surface with hacking hammer immediately after sides/end
plate are removed
c) Take at most care while removing end plates/ notch boxes so that no any kind of
damage to beam ends is done.
d) Make the component id marking on surface of the component with oil paint.
6) Curing: Curing is most important activity make arrangement of enough sprinklers/hessian

cloths bundles and continuously pumprd water insure that components r continuously
cured 7x14 days as specified.
7) Checking and approval for each components apart from checking as per QC plan and
checklist QC must check each components visually prior to dispatch then sign on
concrete surface on component with waterproof marker as QC ok.

CHAPTER-4
METHODOLOGY
ECONOMIC STUDY
Transportation and Erection
In precast construction, the rigging of scaffolding, formwork, storage areas etc. is either
not necessary or done only once. Scaffolding is generally not required for precast structures.
Cranes are used to lift precast components into their place in a structure.
Transportation
When a building uses precast elements, large parts of the building can be brought to the site with
each transport. Larger trucks consume less fuel per ton transported. Materials for formwork,
scaffolding etc. are not required at the site and do not need to be transported.
Precast concrete structures are usually lighter than the equivalent area of on-site cast-in-
place concrete. This can represent a significant reduction in the number of truck movements and
reduced consumption of fossil fuels. The amount of energy consumed during the transport of
precast elements is about 0.00114 MJ/kg/km. This represents 5% to 10% of the total energy
consumption during manufacturing of precast concrete elements.
Construction time
Precast concrete construction is nearly always faster when building the main parts of a
structure. Components are manufactured in a precast plant at the same time as the foundations
are being constructed at the site.
Precast units are normally large pieces, so greater parts of a building are completed with
each activity compared to cast-in-place construction (formwork, scaffolding, reinforcement,
concrete etc). Precast erection is fast and efficient, generally carried out using mobile cranes.
Total precast bridge structures (abutments, wingwalls, girders + decks and traffic
barriers) can dramatically speed up construction and reduce inconvenience and detours for
motorists.

Manpower
An erection team will consist of a crane and small crew. Experienced erectors can erect a
whole frame and the floors and roof together with the walls of a building often before any other
trades are engaged at the site.
The following are typical erection times:
 Erection of hollow core floor slabs – 300 m2 per working day
 Grouting of floor joints – 500 m2 per day
 Erection of columns – 8 pieces per day
 Erection of beams – 15 pieces per day
 Erection of double tee slabs – 25 pieces per day
 Erection of walls – 15 pieces per day
 Stair and elevator shafts – 2 floors per day
For commercial buildings (offices, shopping centers, schools etc.) about 100 m2 of a
building can be erected each day, including the erection of all components and all necessary
connections. The corresponding figure for the erection of apartment buildings is about 80 m2 per
day. The difference is generally due to smaller pieces and stricter tolerances.
There is little waste to dispose of at a building site when the structure is precast. This was
documented in a major investigation carried out in Sweden in 1996 where about 400 apartments
were to be built. Ten similar buildings were selected, each containing 11 apartment buildings;
five were precast and five were cast-in-place. Records were kept of the consumption of energy,
materials, productivity, construction time, working environment, sick leaves, accidents, quality
control, installation, waste generation and cost. The final result was the amount of waste at the
building site was 35% less for the precast buildings compared with the cast-in-place buildings.
In 2001, close scrutiny was paid to the waste generation at a major project in Oslo,
Norway. The buildings contain about 150,000 m2 of floor space. The structure was constructed
using steel frames with precast hollow core floor and roof slabs. The delivery and erection of the
steel frame and the slabs were combined in the precast contract. The surplus material generated
at the site during the erection of these components was only about 1 kg per m2 of hollow core
slab. The surplus material consisted mainly of wood, concrete and reinforcing steel from the

grouting of the joints at the site. All surplus material, except some epoxy resin, was recycled, and
was not considered as waste.
PRODUCTION PLANNING
Generally, the production cycle is one day for a non-complicated precast element. In
planning the production of precast elements, time of construction of each floor is a key factor in
estimating the number of precasting moulds. For example, in a project consisting of 15 precast
façades per storey and a working cycle of 6 days per storey, the number of mould required is
15/6 or 3. A storage area in the precast yard should be sufficient to accommodate precast
elements delivered to the construction site and extra precast elements in case of emergency
delivery. For the production of precast elements, the precast manufacturer requiresabout or at
least 1.5 months for manufacturing the moulds and 0.5 month for production of the precast units.
Therefore, the precast shop drawing (showing geometrical size) should be consolidated at least 2
months in advance of the scheduled date of delivered to site. All the above should be allowed for
in addition to the time required for approval and consent by government or client. Embedded
items including window frames, E/M pipe sleeves and openings in precast elements should be
delivered to the precast yard before production. Unlike traditional in-situ construction, this
requires coordination and approval of embedded items at an early stage. For projects with a large
number of precast elements, time required for the above would be much longer and has to
be taken into account.
MOULDS
Materials
Moulds can be made of any suitable material including steel, timber, glass reinforced
concrete or a combination of these. The selection of the mould materials will depend on the
several factors highlighted in the CoP. Locally, the steel mould is the most common type owing
to its robustness and precision. In general, the steel plate thickness adopted for mould design and

fabrication varies from a minimum of 4.5mm to 6.0mm, which can be used over 100 times with
proper care and maintenance.
Tolerances
To enhance cost competitiveness, adjustable moulds should be adopted where possible,
for greater flexibility and variety in the production of precast
concrete elements.
Recesses, sleeves and box outs

Moulds should be designed to allow for appropriate placing and compaction of the
concrete. Adequate numbers of braces, ties and struts should be provided for proper casting and
hardening of the concrete.

CASE STUDY OF POLICE HEAD-QUARTERS (kARAD)
3.6 Photo gallery of police headquaters karad

ESTIMATATION: CONVENTIONAL V/S PRECAST
SAMPLE PLAN

Calculations of quantities by conventional methods
SR.NO DESCRIPTION NO. LENGTH WIDTH HIEGHT QUANTITY

1. Columns
a) Column A 6 0.30 0.30 3 1.62
b) Column B 6 0.23 0.23 3 0.95
Total 2.57
2. Slabs
a) Slab A 1 6.9 5.4 0.12 4.47
b) Slab B 1 3 1 0.12 0.36
Total 4.83
3. Beams
a) On external 1 32.6 0.23 0.40 2.99
wall
b) On internal 1 3.15 0.23 0.40 0.289
wall
1 3 0.23 0.40 0.276
1 2.3 0.23 0.40 0.211
c) vertical wall 1 1.3 0.23 0.40 0.12
1 3 0.23 0.40 0.276
Total 4.162
4. Brickwork
1. External wall
a) Front side 1 7.05 0.23 3 4.86
b) back side 1 1.5 0.23 3 1.03
c) Side wall left 1 5.02 0.23 3 3.46
d) Side wall 1 5.52 0.23 3 3.81
right

2.Internal wall
a) Horizontal 1 12.5 0.23 3 8.62
b) Vertical 1 9.82 0.23 3 6.77
Total 28.55
Deduction
Door (D1) 1 1 0.23 2.1 0.48
D2 1 1.2 0.23 2.1 0.58
D3 5 0.9 0.15 2.1 1.41
Window 4 1.5 0.23 1.2 1.65

Total 4.12
Total 24.43
Table 4.1-Measurement sheet(conventional method)

Abstract sheet
SR.NO DESCRIPTION QUANTITY UNIT TOTAL

(Cu.m) COST COST
1. Providing and casting in situcement concrete M- 2.57 9500 24236

20 of trap / granite /quartzite/ gneiss metal for
R.C.C. columns as per detailed designs and
drawing or as directed including centering,
formwork, cover blocks compacting and
roughening the surface if special finish is to be
provided and curing complete. (Excluding
reinforcement).With fully automatic micro
processor based PLC with SCADA enabled
reversible drum type concrete mixer.
2. Providing and laying in situ cement concrete M- 4.83 10000 45909

20 ready mix of trap/granite/quartzite/gneiss
metal, natural sand for RCC slab and landings as
per detailed design & drawing or as directed
including centering, curing and roughening the
surface if special if finish is to e provided
(excluding reinforcement & structural steel)
Complete
3. Providing and casting in situ cement concrete M- 4.162 9000 36522

20 of trap /granite/quartzite/gneiss meta, natural
sand for R.C.C beams & lintels as per detailed
design and drawing or as directed including
centering, formwork, cover blocks, compaction,
curing and roughening the surface if special finish

is to be provided (excluding reinforcement &

structural steel)
4. Providing first class burnt brick masonry with 24.43 5500 134365
conventional/I.S. type bricks in cement mortar 1:6
in plinth as backing in composite masonry
including bailing out water, striking joints,
racking out joints and watering complete
Providing cement plastering 12mmthick in two 90.64 400 36256
coats in cement plaster 1.5without neeru finish to
concrete brick surface in all positions including
scaffolding and curing complete
5. Providing structural steel work in column, beam, 1258kg 46/kg 58000

Slab
Total 339044
Table 4.2 Abstract sheet (Conventional method)
Abstract sheet by using precast member
SR.NO DESCRIPTION Quantity UNIT TOTAL

COST COST
1. Slab panels 18 No‟s 2800 50400

Panel size- 0.5m x 0.5m
2. Beams 117.26/feet 350/run.ft 41041

Beam size- 0.23m x 0.40m

3. Columns 118.08 Feet 200/run.ft 23616

Two core column
4. Wall panels
a) 1m x 2.6m 28 no‟s 12000 336000
b) 1.5m x 2.6m 2 no‟s 14000 28000
c) 0.5m x 2.6m 3 no‟s 10000 30000
Total 509057
4.3 Abstract sheet (Precast method)
COST & DURATION COMPARISON:

As the population continuously growing rapidly, so the need of rapid or fast construction
is requirement of future generation. Precast concrete construction methods are become feasible
and alternatives method or solution in such applications Ides buildings and bridges. The primary
benefit of precast construction is reduction in time of construction. Waste management and cost
efficient construction. Precast concrete is the ideal solution for residential because the structure
of residential buildings are somewhat standard so the construction of same type of elements are
easy and result in to cost saving on if its production is in bulk. Precast concrete provides
stability, Flexibility, sound durable and adaptability with cost efficiency. Precast concrete
construction required less construction process which saws money on financing costs. Cost
minimization on labor policies, skills, development of employ, providing training to them is
main factors. Repairs cost also reduces in precast concrete construction.

CHAPTER-5
RESULT AND DISCUSSION
As brief review of case study we have observed that cost estimation by precast
method is increased by 33.39% when compared with conventional method. But when we
consider time factor, precast construction method require less time than conventional method.
 For civil work cost per sq.ft
1) By conventional method- 800 Rs. Per sq.ft.
2) By precast method- 1190 Rs. Per sq.ft.
Also we observed that in precast system, skilled labours are required & ultimately high precision
of work is achieved. Hence requirements of owner gets fulfilled. But in conventional
construction method accuracy of work is less & also there is wastage of material
5.1Comparison of precast & Cast in situ
Particular Precast RCC

Construction speed Very rapid speed of Comparatively slow
erection. Rapid construction construction on site casting,
on site. so reinforcement laying &
fixing , formwork, setting of

concrete required time.

Quality control Good quality control. Quality may affect due to
site condition, due to bad
supervision, unskilled
labour.
Environmental conditions Weather is eliminated as a Environmental conditions
factor you can cast in any like temperature, humidity
weather and get the same can affect on performance
results, which allows you to of concrete.
perfect mixes and methods.
Labour requirement Less labours are required More labours required on
and the labour can be less site in case of RCC.
skilled.
Manufacturing conditions High quality can be RCC is casted on site & the
achieved because of the site condtions are not
controlled conditions in the regularized, so it may affect
factory. on strength.
Quantity discount Since a precasters can buy The owner can only buy
materials for multiple small required quantity so
projects quantity discounts quantity discount is not that
can lower costs. much.
Durability With the ability to so tightly RCC is sufficiently durable
control the process from but if required proper quality
materials to consolidation to control.
curing, you can get
extremely durable concrete.
Size & shape Repeatability its easy to In-situ concreting is suitable
make many copies of the where the building is uneven
same precast product, by shape & there are no
maximizing repetition, you repetitive shape, can be
can get plenty of water from possible to modify shape on

a mold & a set- up. This site. More flexibility in

cannot be modified on site. execution.
Connections Connections are simple Connections may be
difficult.
Design flexibility Building, design flexibility Somewhat limited building
is more design flexibility.
Size limitation No limitation for size. Because panel size is
limited, precast concrete
cannot be used for two- way
structural system.
Cost It is comparatively Economics of scale demand
economical when the regularly shaped buildings.
building having no regular
shapes.
Shape Here we need regular shapes It can be casted in any shape
in building to achieve on site.
economy, need for repetition
of forms will affect building
design.
Table 5.1-Comparision of precast and R.C.C

CHAPTER 6
CONCLUSION
As we have seen various methods of precast, Design, case studies of precast & it is found
that, the design comes out as economical if proper care while designing is taken. We have design
the same building by traditional & precast method & Notice the Cost & completion duration It is
remarkably seen that the cost of precast building is significantly reduces & duration of
construction is also much lesser than traditional method. From all this study we can be conclude
that the precast concrete system is economical than conventional cast in place method but still
there are some conditions which we have to take care of while using precast, those are quantity
of construction, Distance of site from manufacturing unit. Type of building etc. we have
identified that for standard & Repetitive work precast is the best option to choose. In observation
the most important thing is to be observed project is in precast construction technique is the time
effective it require less time to construct. It requires skilled worker and qualified contractor,
Lower initial cost especially for large project. We can achieve better concrete quality control and
lighter concrete unite. The main limitation of precast is transportation from place of
manufacturing to place of site where it is to be fixed.

REFERENCES
1) Abubakar, S.Y. (2002) Migrant labour in Malaysia: Impact and implications of the Asian
financial crisis, EADN Regional Project on the Social Impact of the Asian Financial Crisis, East
Asian Development Network.
2) Sultan, B. and Kajewski, S. (2006) Requirements for economic sustaina bility in the Yemen
construction industry, in Serpell, A. Ed., Proceedings International Symposium on Construction
in Developing Economies: New Issues and Challenges, Santiago, Chile
3) Walsh, K. and Sawhney, A. (2004) Process for implementation of the basket of construction
components approach, International Comparison of Cost for the Construction Sector, The World
Bank Group.
4) Yong, T.N. (2010) Feasibility of precast concrete construction system in Malaysia: A

comparative study between Australia and Malaysia, Research project report, The University of
Melbourne, October 2010.
5) Rawlinsons (2010) Rawlinsons Australian Construction Handbook 2010, Rawlhouse

Publishing Pty Ltd, Australia
6) Yong, T. N. (2010), Feasibility of Precast Concrete Construction System in Malaysia: A

Comparative Study between Australia and Malaysia, Research Project Report, The University of
Melbourne, Australia
7) Rawlinsons (2010), Rawlinsons Australian Construction Handbook 2010, Rawlhouse

Publishing Pty Ltd, Australia.
8) Isabelina Nahmens and Michael A. Mullens Lean Homebuilding: Lessons Learned from a
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9) Volume: 03 Issue: 06 | June-2016 www.irjet.net p-ISSN: 2395-0072 by Akash Lanke, Dr.

D. Venkateswarlu - “Design, Cost & Time analysis of Precast & RCC building”

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STUDY OF PRECAST BUILDING AND ITS FEASIBILITY IN RURAL AREAS

J.J.M.C.O.E Jaysingpur Page 1

BACKGROUND & PRESENT SCENARIO

J.J.M.C.O.E Jaysingpur Page 2

J.J.M.C.O.E Jaysingpur Page 3

 Study of precast construction technique.

 To check possibilities of precast housing feasibility in rural areas.

 Cost comparison between precast and conventional building construction.

J.J.M.C.O.E Jaysingpur Page 4

J.J.M.C.O.E Jaysingpur Page 5

1) Study of comparison between prefabricated and conventional structures.

J.J.M.C.O.E Jaysingpur Page 6

2) A Study of Cost Comparison of Precast Concrete Vs Cast-In-Place Concrete

3) Comparative Study on Prefabrication Construction with Cast In-Situ

J.J.M.C.O.E Jaysingpur Page 7

J.J.M.C.O.E Jaysingpur Page 8

5) Cost Analysis of Precast and Cast-in-Place Concrete Construction for Selected

J.J.M.C.O.E Jaysingpur Page 9

J.J.M.C.O.E Jaysingpur Page 10

7) Comparative Study on Prefabrication Construction with Cast In-Situ

8) Building cost comparision of pre cast concrete construction with conventional

9) Time, Cost, Productivity and Quality analysis of Precast Concrete System B.

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BENEFITS OFFERED BY PRECAST

Quality & Durability

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Integrated Project Delivery

Optimization & Flexibility

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BASIC PRECAST SYSTEM

beam Column System

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Beam column system

Floor And Roof System

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Moment resisting frame systems

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ASPECTS ON CONNECTION METHODS

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FORCE TRANSFER MECHANISM

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3.0: Column beam connection

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Figure 3.3: Precast (a) Hollow Core

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Figure 3.4: Typical Precast Column Details

Precast Wall Panels

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Figure 3.5: Precast (a) Wall Panels & (b) Claddings

Figure 3.6: Precast Staircase Details

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BASIC DESIGN CONCEPTS FOR PRECAST CONCRETE BUILDING

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CONSTRUCTION METHOD FOR PRECAST SYSTEM

The contractor should consider the following:

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• Ensure the desired crane‟s working radius

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 Beam Setting Out