Course 2012/13 EIABC

BM+C IV - building material and construction IV 2012/13 addis ababa university

chair building construction

6. PRECAST CONCRETE CONSTRUCTION

SYSTEM

6.1. Definition
6.2. Types of precast system
6.3. Types of precast concrete elements
6.4. Advantages of precast concrete system
6.5. Joining (connection) of precast concrete elements
6.6. Precast concrete cladding

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6. PRE CAST CONCRETE STRUCTURES

6.1. INTRODUCTION
The concept of precast (also known as “prefabricated”) construction includes those buildings, where
the majority of structural components are standardized and produced in plants in a location away from the
building, and then 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 main features of this construction process are as follows:

• The division and specialization of the human workforce

• The use of tools, machinery, and other equipment, usually automated, in the production of
standard, interchangeable parts and products

This type of construction requires a restructuring of the entire conventional construction process to enable
interaction between the design phase and production planning in order to improve and speed up the
construction. One of the key premises for achieving that objective is to design buildings with a regular
configuration in plan and elevation.

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6.2 TYPES OF PRECAST BUILDING SYSTEMS

Depending on the load-bearing structure, precast systems can be divided into the following
categories:

 Large-panel systems
 Frame systems
 Slab-column systems with walls
 Mixed systems

6. 2. 1 LARGE PANEL SYSTEMS

The designation “large-panel system” refers to multistory structures composed of large wall and floor
concrete panels connected in the vertical and horizontal directions so that the wall panels enclose appropriate
spaces for the rooms within a building. These panels form a box-like structure. Both vertical and horizontal panels
resist gravity load. Wall panels are usually one story high. Horizontal floor and roof panels span either as one-
way or two-way slabs. When properly joined together, these horizontal elements
act as diaphragms that transfer the lateral loads to the walls.

A large-panel concrete building under construction

Depending on wall layout, there are three basic configurations of large-panel buildings:
• Cross-wall systems
• Longitudinal wall systems
• Two-way systems

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6. 2. 2 FRAME SYSTEMS

Precast frames can be constructed using either linear elements or spatial beam- column sub-
assemblages. Precast beam-column sub-assemblages have the advantage that the connecting faces between
the sub-assemblages can be placed away from the critical frame regions; however, linear elements are
generally preferred because of the difficulties associated with forming, handling, and erecting spatial
elements. The use of linear elements generally means placing the connecting faces at the beam-column
junctions. The beams can be seated on corbels at the columns, for ease of construction and to aid the shear
transfer from the beam to the column. The beam-column joints accomplished in this way are hinged. However,
rigid beam-column connections are used in some cases, when the continuity of longitudinal reinforcement through
the beam-column joint needs to be ensured. The components of a precast reinforced concrete frame are shown
in Figure

6. 2. 3 SLAB-COLUMN SYSTEMS WITH SHEAR WALLS

These systems rely on shear walls to sustain lateral load effects, whereas the slab-column structure
resists mainly gravity loads. There are two main systems in this category:

• Lift-slab system with walls

• Pre stressed slab-column system

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

In the Lift –slab system, the load-bearing structure consists of precast reinforced concrete columns

and slabs, Precast columns are usually two stories high. All precast structural elements are assembled by

means of special joints. Reinforced concrete slabs are poured on the ground in forms, one on top of the other.

Precast concrete floor slabs are lifted from the ground up to the final height by lifting cranes. The slab panels

are lifted to the top of the column and then moved downwards to the final position. Temporary supports are

used to keep the slabs in the position until the connection with the columns has been achieved.

TENDENCIES IN PRECAST CONCRETE

• structural efficiency
• Flexibility in use
• Optimum use of materials
• Speed of construction
• Quality consciousness
• Adaptability
• Protection of the environment

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Course 2012/13 EIABC
BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6.3. PRECAST CONCRETE STRUCTURAL ELEMENTS

 Precast concrete frame
 Precast concrete wall
 Precast concrete floor
 Precast concrete stair

6.3.1. Precast concrete frame

• Precast concrete frames involve an entire structure being fabricated off-site.

• Structural components can be supplied for incorporation into a structure on-site.
• Frames can simultaneously achieve both structural and decorative design requirements –
• a wide variety of mixes, colors and finishes can be accommodated.
• Architecturally-finished precast structures can be left exposed to exploit concrete's high thermal
capacity in a building's "green" energy management system.

Precast Beam & Girders

Benefits
Precast concrete frames
• Enable faster program times - not affected by weather or labor shortages.
• Improve build-ability - structure is fabricated off-site for rapid erection on-site
• Produce a high standard of workmanship in factory conditions - reduces potential for accidents,
addresses on-site skill shortage.
Have a high quality finish that can be left exposed - concrete's thermal properties can be exploited
in low-energy buildings.

Precast columns Inverted Tee beams supported on precast columns

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction
6.3.2. Precast concrete wall

• Precast wall are used for internal & external walls, lift shafts, central cores etc.
• Precast wall system is mostly used in domestic construction, both for individual housing & for
apartments.
• The solution can be considered as the industrialized form of cast in-situ walls or classical brick or
block masonry walls.
• The precast walls can be load bearing or only partition walls.
• The surface of the elements is smooth on both sides & ready for painting or wall papering.
• Precast walls offer the advantage of speed of construction, smooth surface finishing, acoustic
insulation & fire resistance.

6.3.3. Precast concrete floor

• Hollow core floors

• Ribbed floors
• Concrete roof elements
• Massive slab floors

The principal advantages of precast floors are speed of construction, absence of scaffolding, large variety
of types, large span capacity, & economy. Totally precast floors are composed of units, which are totally
cast at the plant. After erection, the units are connected to the structure & the longitudinal joints are
grouted. In some cases a cast in-situ structural topping screed is added.

Partially precast floors are composed of a precast part & a cast in-situ part. Both parts are working
together at the final stage to achieve the composite structural capacity. The main totally precast floor &
roof types are described hereafter.

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

Hollow core slabs are precast, pre stressed concrete elements that are generally used for flooring
Some of their advantages are:
• Long spans, no propping (prop)
• Flexible in design
• Fast construction
• Light weight structures
• Trimmer Beams can also be used
• The slabs have between four and six longitudinal cores running through them, the primary purpose of the
cores being to decrease the weight, and material within the floor, yet maintain maximal strength.
• To further increase the strength, the slabs are reinforced with 12 mm diameter steel strand, running
longitudinally.

6.3.4. Precast concrete Stair

There are many advantages with the use of precast stairs, over in-situ stairs, :
• Stairs provide immediate access to working levels as construction proceeds
 Quick erection, therefore earlier project completion.

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Course 2012/13 EIABC
BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6.4 Advantage of precast concrete system

The key advantages of precast concrete are

 speed,
 economy and
 Quality.

Total precast concrete building systems are becoming a popular choice for many construction projects. Architectural
and structural precast, prestressed concrete components can be combined to create the entire building.
Possible solution lie not only within the classical advantages related to working conditions, technology & speed of
construction, but also in new developments of materials such as high performances & self-compacting concrete,
buildings system such as mixed structures, manufacturing technology, automation, service integrated products

This design approach can take several forms, including precast columns and beams with panelized cladding or load-
bearing precast walls and double tee or hollow core flooring.

These advantages benefit every member of the construction team - specially the owner, whose goals are always
paramount.
ARCHITECT: In addition to helping to meet all of the building owner's goals precast concrete
systems provide specific advantages to architects that can make the design process smoother.

CONTRACTOR: General contractors find the use of precast concrete components make their job
easier at the site, ensuring a smooth process for the owner and designer in both the short and long
terms. There are fewer trades to coordinate with precast construction.

ENGINEER: Structural engineers report no difficulty in learning to design with precast concrete systems. They
also benefit from the material's ease of use and efficiency

The three main advantages of using precast as against in situ concrete are:

• Speed of erection;
• Freedom from shuttering support on site;
• Better quality and variety of surface finish, because panels are manufactured in controlled factory
situations

Disadvantage of precast concrete

• System building is less flexible in its design concept than purpose-mode structures,
• Structural connection between the precast concrete units can present both design & contractual problems

07 BM+C IV 2013 Precast concrete system handout

Course 2012/13 EIABC
BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

10 reasons for choosing precast concrete

1. Precast concrete is COMFORTABLE

The material has intrinsic properties of thermal inertia (allowing a more

constant temperature both in cold and hot regions) and acoustic insulation

2. Precast concrete is SAFE

Concrete does not burn!
Not only is the structural stability maintained for longer periods, but concrete
construction
Prevents the spread of the fire from one building to another.
It is sufficiently strong to resist impacts, blasts and natural catastrophes like
earthquakes, tornadoes and floods.

3. Precast concrete is VERSATILE

Factory production allows a wide choice of surface finishing, color range and special
shapes. Precast concrete has another advantage: its mould ability which entails
designers to copy classical details like keystones and capitals or match the finish of
materials like weathered stones. The precast concrete industry can source a wide
range of aggregates locally and offer a tremendous variety of colors and visual
effects.

4. Precast concrete is HEALTHY

Indoor air quality is a concern for all of us.

Precast concrete is stable throughout its life and does not need
Chemical treatment to protect it against rot and insect attack: this means
that there are no emissions in the internal environment.

5. Precast concrete is OPTIMISED

Advanced technologies used in the pre casting plants create an

improved quality product (i.e. reduced tolerances, thinner sections,
engineered solutions) compared with cast-on-site concrete. Additionally
this quality can be checked before a unit is inserted into the structure or
site work!

07 BM+C IV 2013 Precast concrete system handout

Course 2012/13 EIABC
BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6. Precast concrete is DURABLE

Concrete lasts for years.

Egyptian and Chinese people used an ancient form of concrete for
buildings and structures that still exist today. Concrete is used where the
structural stability has to be maintained for long periods. Effective design
detailing helps to lengthen the life of a concrete building; precast
manufacturers can offer guidance on designing for durability.

7. Precast concrete is ECOLOGICAL

Made of natural raw materials (stones, gravels, sand, cement), locally

available almost everywhere and in an enormous quantity, precast
concrete minimizes the whole life cycle impact on the environment
when compared with other construction materials. Precast concrete units
can entirely be re-used or recycled (almost
100% of a concrete building can be recycled, no matter how heavily
reinforced).

8. Precast concrete is FAST

The top floor of a skyscraper can be cast in the factory when the
foundations have not yet started. But the project requirements of a
modern construction prefer a just-in-time delivery! On-site construction
using precast concrete is not only faster, but also safer as secure
working platforms are quickly established.

9. Precast concrete is AFFORDABLE

Precast concrete combines the excellent quality of factory production with a

relatively inexpensive material. The costs to repair and maintain a concrete
structures are highly limited. There is therefore no need to compromise on quality to
reduce costs, simply choose the best way to use locally available resources.

10. Precast concrete is SUSTAINABLE

07 BM+C IV 2013 Precast concrete system handout

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

DESIGN CONCEPTS FOR PRECAST CONCRETE BUILDINGS

The design concept of the precast buildings is based on the build ability, economy and standardization of
precast components. 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.
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.

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 combinations
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.

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6.5. JOINING (CONNECTION) OF PRECAST CONCRETE ELEMENTS

TYPICAL CONNECTION OF PRECAST CONCRETE ELEMENTS

6.5.1 COLUMN TO FOUNDATION CONNECTION

COLUMN TO COLUMN CONNECTION

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BEAM TO COLUMN CONNECTION

SLAB TO BEAM CONNECTION

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

6.6 PRECAST CONCRETE CLADDING PANELS

The word cladding is used in the sense of clothing or covering the building with a material to provide a

protective or decorative cover. The cladding panels, usually storey (floor) height serve the function of

providing protection against wind and rain and resistance to the transfer of heat from inside to outside,

without providing structural support.

Panels can be either top hung from the structure or supported from their base. Nibs projecting from the back

of the panel transmit the load to the structure by means of a mortar bed. Panels can then be restrained

either by dowel bars or by angle cleats, both of which must be fixed so as to permit vertical movements

arising from the deformation of the structure or movement of the panels. Various combinations of dowel

and cleat.

Fig. Various combinations of dowel and cleat fixings: (a) cleat to

dowel bottom; (b) cleats top and bottom

Two types of fixing are in common use in addition to the fixings for handling listed earlier. These are:

– Angle cleats;
– Dowel fixings

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chair building construction

ANGLE CLEATS;

Although usually used for top restraint panels, angle cleats may also be employed at the base support position. There
should be at least two cleats per panel, irrespective of panel size, and their size should be calculated by a structural
engineer according to the loading for each job. They should be designed to give three-dimensional adjustments by the
use of slotted holes and/or by packing pieces.
Bolts fixing the angle cleats are normally fixed to cast-in sockets or expanding sleeves. Cast-in sockets are used
with precast concrete, as they can be accurately cast in place in the factory. However, with in situ concrete, their
precise location cannot be guaranteed, and channels are used to allow adjustment where channels are not suitable,
the structure is drilled to receive bolts with expanding sleeves, taking care to avoid reinforcement

DOWEL FIXINGS

Dowel bar fixings are a common and simple method of locating and restraining the panel at its
bottomsupport nibs. The main reason for their use is that they are considerably cheaper than non-ferrous angle
cleats and can more easily accommodate dimensional inaccuracies in the structure. Usually, they are set in a
50 mm×50 mm pocket in the in situ floor slab, a 50 mm diameter hole being provided in the panel to receive the
dowel bar. The space around the dowel is grouted with either neat cement or an epoxy resin grout.
Where dowels are used in conjunction with panels supported at their head, some provision for vertical movement
may be required. In this case, the bars can be bound with Sell tape to avoid adhesion of the grout. A resilient pad
between the panel nibs allows movement and prevents grout loss.

a. Dowel fixing system

b. angle cleats connection system

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BM+C IV - building material and construction IV 2012/13 addis ababa university
chair building construction

Although the dimensional inaccuracies in manufacture of medium-sized precast concrete panels are not
likely to be in excess of ±3 mm, the inaccuracies imposed during assembly because of deviations in the frame
and erection deviations on these panels are likely to be much more than this, possibly ±25 mm. Thus
tolerance must be allowed in the method of fixing and in the allowable clearance between the panels and
the structure to take account of such inaccuracies of construction. Allowance must be made in the
design of the fixings for thermal movement of the panel. Avoid three fixings at different levels as shown in
the fig below.

EARTHQUAKE PERFORMANCE

Due to their large wall density and box-like structure, large-panel buildings are very stiff and are
characterized with a rather small fundamental period. However, in areas of high seismic risk, structures
must be designed to respond safely to the dynamic forces imparted into the structure

07 BM+C IV 2013 Precast concrete system handout