Precast Construction

GTU Subject Code: 3170622

Notes prepared by: Dr. Swaral R. Naik (Assistant Professor)

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

Prepared as per the GTU Syllabus. Elective Subject, offered in 7th Semester of B.E. Civil
Syllabus: https://s3-ap-southeast-1.amazonaws.com/gtusitecirculars/Syallbus/3170622.pdf

PRECAST CONSTRUCTION 3170622 1

2. STRUCTURAL CONCEPTS OF PRECAST CONCRETE
SYSTEMS

2.1 LOADS

• Normally building design loads can be taken from the concerned building code of the
country. (e.g. for India it is IS 875_Part 1-5).
• The vertical load comprises of Dead weight (self weight) of the structure, superimposed
load and live loads.
• In precast construction structural members are considered as simply supported. So,
it is easy to organise and accumulate the loads acting from TOP to BOTTOM.
• The calculation of load can be easily done by preparing a load table for particular

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

building as shown in figure.

PRECAST CONSTRUCTION 3170622 2

 Prepared by Dr. Swaral R. Naik (DRAFT COPY)
• The horizontal loads are either derived from wind forces or notional forces. Notional
force occur due to eccentricity, tremors or subsoil settlements. It is considered normally
1.5% of characteristic dead load (gravity load) of the structure.
• Wind force acts on facades and gable where is no single force acts at the point of
application of vertical force that is C.G. of Structural wall and floor slabs.
• Wind force and notional force act in arbitrary direction. The designer will have to
consider the greater of these two.
• Another load is accidental load that could occur from collisions, explosions or from
vertical loads on air raid shelter (air strikes related safety structures).
• The structure that may be exposed to accidental action, code, suggests that,
1. Design in such a way that the parts of the structure that are subjected to
accidental loads can withstand it without any failure. OR
2. Designing in such a way that if failure occurs then it will not lead to
progressive collapse or toppling of entire structure. (This is often termed
as integrity of structural elements, see next figure)

PRECAST CONSTRUCTION 3170622 3

 Integrity between elements

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

2.2 LOAD PATH

• A building constructed from precast components becomes a so-called "house of cards".

It requires rather simple structural calculations as most of the load-bearing structural
members are considered simply supported.
• Using precast floor slabs, walls , beams and columns, it is hardly possible to achieve
restraint (fixity) in the joints.
• After having made the load calculations, the next and very important step is the load
path description. It should explain in detail a possible load path for a specific load (i.e.
dead, live, wind etc….) from the point of application to where the load is transmitted to
the foundation and the soil.
• By using a detailed load path description for vertical as well as horizontal loads, the
designer is able to calculate all internal forces (moments, shears, axial forces etc…)
acting on components and joints necessary for a proper design.

Lateral Load Transfer Path

To transfer the lateral loads, the building utilises horizontal diaphragms (slabs) and
vertical shear walls or columns (in many cases) or bracings. Figure below illustrates the
basic principle of how lateral loads are transferred throughout the building.

PRECAST CONSTRUCTION 3170622 4

 Prepared by Dr. Swaral R. Naik (DRAFT COPY)
Vertical Load Transfer Path
In order to transfer the vertical loads to the ground, the horizontal "beam" members
transfer the weight laterally to the "beams," which then transfer the forces down into the
foundation, and eventually into the bedrock.

reference: https://sites.google.com/site/ae390papadakis/load-path-diagrams

PRECAST CONSTRUCTION 3170622 5

 Prepared by Dr. Swaral R. Naik (DRAFT COPY)

Load Transfer in a skeletal unbraced frame (a) Gravity Loads (b) Lateral Loads

PRECAST CONSTRUCTION 3170622 6

2.3 LIMIT STATES Strength deformation

• Limit states are the acceptable limits for the safety and serviceability requirements of
the structure before failure occurs. The design of structures by this method will thus
ensure that they will not reach limit states and will not become unfit for the use for
which they are intended. It is worth mentioning that structures will not just fail or
collapse by violating (exceeding) the limit states. Failure, therefore, implies that clearly
defined limit states of structural usefulness has been exceeded.

LIMIT STATE

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

of Collapse of Serviceability

It deals with deflection and

It deals with strength and cracking under service load;
stability of the structure under durability under working
maximum design load environment, stability, fire
resistance etc…

• All relevant limit states have to be considered in the design to ensure adequate degree
of safety and serviceability. The structure shall be designed on the basis of the most
critical limit state and shall be checked for other limit states.

2. The serviceability limit state design is based on satisfying the limits on :

• flexural tensile and compressive stresses in the concrete, and
• camber and deflection
3. The limit state of collapse also known as ultimate limit state can be considered for
following major parameters:
• flexural failure
• shear tension failure
• shear compression failure and,
• bond and anchorage failure.

PRECAST CONSTRUCTION 3170622 7

2.4 PRECAST CONCRETE BUILDING SYSTEMS

(1) Skeletal frame systems: Precast concrete components such as beams, columns, stairs
and hollow core slabs to form the frame of buildings.
✦ They are suitable for low-rise buildings such as commercial buildings, schools,
hospitals, parking structures and sporting facilities, where a high degree of
flexibility in planning of floor areas can be achieved by using large spanning
column-beam layout.

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

(2) System with Load-Bearing walls system: They are suitable for domestic housing,
apartments and hotels. Advantages are high construction speed, ready-to-paint surfaces,
facades as architectural precast, good acoustic insulation and fire resistance.

• This system can be used with cross-wall or spine wall systems.

✦ Cross Wall: Load bearing wall placed perpendicular to the long edge of building.
✦ Spine Wall: Load bearing wall running parallel to the long edge of building
• Common examples of these are staff and worker dormitories as well as normal housing
projects. These systems are particularly beneficial when a large quantity of typical
housing is required, which allows for the greatest standardisation of components.

PRECAST CONSTRUCTION 3170622 8

(3) System with Load-bearing facades are often used in combination with skeletal frames
as internal structure. Such systems are economical, have a high construction speed and
can incorporate architectural finishing.

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

(4) Cell systems are mainly used for parts of a building, for instance, bathrooms or
kitchens. Important elements in the design are manufacturing, assembly, transportation
and erection considerations. Heavy cranage with special lifting devices may be needed.

(5) System with precast Portal

Frame: Used for industrial buildings
and warehouse where clear span of
some 25m to 40m I or T sections
principal rafters are necessary.
Although portal frames are used for
single-storey buildings, they may be
used for a roofing structure for
multi-storey buildings due to its
simplicity.

See more on precast building systems:

• https://www.dubaiprecast.ae/systems
• Researchgate: Material on Precast Building Systems

PRECAST CONSTRUCTION 3170622 9

Applications & Types of Precast Concrete Frames

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

2.5 PRECAST FRAME ANALYSIS

• A pre-cast concrete structure is not a cast in situ Structure cut up into little pieces
making it possible to transport and erect. As it is seen in the Load Path explanation it is
clear that the prefabricated and assembled components in precast structure is quite
different to a monolithic continuous structure.
• Therefore it is good to analyse the global structure and find out the location of the
connections which could be introduced for particular precast structure.
• In following figure 2.5_1, it is shown that the approximate bending moments and
deflected shape in a three storey continuous beam and column frame subjected to
vertical and horizontal loads.
• Looking to the bending moment diagram, there are points of zero moment (contra-
flexure). For gravity load, the beam generates contra-flexure near to the Beam column
joint (approximately 0.1L). For horizontal load the beam generates contra-flexure points
at the mid span (approximately 0.5L).
• In columns the contra-flexure for both the load cases lies at the mid-height of the
column (approximately 0.5H). Hence this could be a good location to introduce a pin
connection (or hinge) between the columns.

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 Prepared by Dr. Swaral R. Naik (DRAFT COPY)
Figure 2.5_1: Deformations and bending moment distribution in a continuous structure due to (a) gravity
loads (b) lateral (sway) loads

• Now, if the strength at the ends of the beam is reduced to zero (i.e. hinge and not fixed)
whilst the columns and foundations untouched, the resulting deformations and
bending moments is as shown in figure 2.5_2.
• The beams will not transfer moments, but only shear forces and axial forces. The
foundation will have to be still rigid (fixed). This mechanism is known as pin jointed
skeletal frame.

PRECAST CONSTRUCTION 3170622 11

 Prepared by Dr. Swaral R. Naik (DRAFT COPY)
Figure 2.5_2: Deformations and bending moment distribution in a pin jointed structure due to (a) gravity
loads (b) lateral (sway) loads

• In taller structures (more than 10m height), columns will have greater loads and
moments resulting into large c/s dimensions leading to impractical and uneconomical
columns.
• Bracing can be a good solution to this. Full height bracing is called ‘Fully Braced’ frame
and bracing ending/starting at certain level is called ‘partially braced’ frames.

PRECAST CONSTRUCTION 3170622 12

 • The bracing could be located in the upper storeys, providing the columns in the
unbraced part below the first floor are sufficiently stable to carry horizontal forces
and any second-order moments resulting from slenderness.

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

Figure 2.5_3: Partially braced structures

• U-frame: Another option could be a portal frame (inverted-U frame) where beam-
column connections are kept rigid (similar to the frame shown in fig 2.5_1) but, the
lower ends of the columns can be kept with zero flexural rigidity (i.e. hinge). Moment
diagrams and deflections for this frame analysis is shown in fig 2.5_4. But, this is not a
good practical solution for factory casted large span frames, so better for in-situ
constructions.
• L-frame: A better alternative to this is L-frame. Especially, for long span beams and low
storey heights, like parking structures. In this, one end of the beam is rigid whereas the
other one hinge. All the lower ends of the columns can be kept as hinge, accept for the
foundation columns. Refer fig 2.5_5.
• H-frame: If pinned connections can be incorporated at the point of contra-flexures of the
columns (around mid-height), the structural behaviour of the frame is somewhat
similar to a rigid frame. The beam end can either be both rigid or one pin and one rigid.
• Connections between frames are made at mid-storey height positions.

PRECAST CONSTRUCTION 3170622 13

 Prepared by Dr. Swaral R. Naik (DRAFT COPY)
Figure 2.5_4: Structural system for portal U-frames

Figure 2.5_5: Structural system for portal L-frames

• The foundation to half-storey height ground floor columns must be rigid. The
connection at the upper end of the column may be pinned if it is located at a point
of contra-flexure. If not the connection must possess flexural strength as shown in
fig 2.5_6, where the H-frame has been used in a number of multi-storey
grandstands.

PRECAST CONSTRUCTION 3170622 14

 Prepared by Dr. Swaral R. Naik (DRAFT COPY)

Figure 2.5_6: H-frames (a) structural system (b) deformations & moment diagrams

PRECAST CONSTRUCTION 3170622 15

 3. DESIGN OF PRECAST REINFORCED
CONCRETE COMPONENTS

3.1 PRECAST CONCRETE FLOOR

3.1.1 Precast Concrete Flooring options

• Worldwide, approximately half of the floors used in commercial and domestic

buildings, and more than three-fourths in car parks, are of precast concrete
• There are a wide range of flooring types available to give the most economic solution
for all loading and spans.

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

• Precast concrete floors offer the twin advantages of
• Off-site production of high-strength, highly durable units
• Fast erection of long-span floors
Precaston sitefloors
concrete 127

HOLLOW CORE FLOOR UNITS

• The self-weight of a hollow core unit is about one-half of a solid section of the same
depth. It is said to have a ‘void ratio’ of 50%.
• The most common depths range from 150mm to 400mm. Most units are 1200 mm wide.
• Fig. 3.1.1_1 shows a very efficient profile comprising seven cores that are stacked in
huge quantities in many countries
Figure 4.3 A 1000 mm deep hollow core unit developed by Nordimpianti of Italy, at Sao Paulo exhibition in 2014.
• A 1200 mm section can be split into 400
128 or 600
Precast mm Structures
Concrete wide units as shown in Fig 3.1.1_2.

(a)‘pear’ shaped cores, narrowing

Figure 4.4 Slipformed hollow core units with efficient Figure 4.5 Stacking
to allow additional (b)
1200 mm wide hollow core floor units awaiting delivery within seven days after casting.
prestress where splitting might otherwise occur.

Figure
The height 3.1.1_1:
of voids should not(a) A typical
exceed most
h − 50 mm, common
where Hollow
h is the overall core
depth floor
of the unit.unit (b) stacking of 1200 mm wide floor units
The diameter of circular voids is usually h − 75 mm. The minimum flange thickness depends
waiting for delivery within 7 days after casting
on the overall depth of the unit h, given by 1.6 h. However, because of cover requirements
it is usually necessary for the bottom flange to be at least 30 mm thick. The minimum width
of a web should not be less than 30 mm.
Hollow core units were developed in the 1950s when the dual techniques of long-line
prestressing and concrete production through machines were being developed by companies
such as Spiroll in the United States and Roth in Europe. Precast concrete engineers contin-
PRECAST CONSTRUCTION 3170622 16
ued to optimise the cross section of the units leading to the so-called double-tee unit, shown
in Figure 4.8, achieving even greater spans and reduced mass compared with hollow core
units. Although the finer points of detail of double-tees vary in many different countries, the
 Figure 4.5 Stacking 1200 mm wide hollow core floor units awaiting delivery within seven days after casting.

Figure 4.6 Two 600 mm wide hollow core floor units made from 1200 mm wide casting bed, 400 mm wide
Figure 3.1.1_2: Two 600 units
mmarewide hollow core floor units made from 1200 mm wide casting bed, 400 mm
also possible.
wide units are also possible Precast concrete floors 129
unit comprises two deep webs, reinforced for strength, joined together by a relatively thin

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

flange, for stability. Two major drawbacks with double-tees are

1. Not being able to provide sufficient pretensioning force to satisfy the available section
as strands can only be placed in pairs at the bottom of the webs, forcing more strands
to be positioned higher in the web-reducing eccentricity.

Figure 3.1.1_3:
FigureThe 2.42.4mmwide
4.7 The hollow
wide hollow corecore floormanufactured
floor units units manufactured
by Preconco Ltd.,by Preconco Ltd., Barbados.
Barbados.

Table 4.1 Structural propertiesof

of prestressed hollow core floor units units, manufactured in Barbados,
• Fig. 3.1.1_3 shows the storage some 2400 mm wide
Depth Number and breadth Self-weight Service moment of Ultimate moment of Ultimate shear
sometimes used
(mm) in large/regular
(mm) of cores floor
(kN/m ) areas Min(kNm)
resistance North America.
resistance
2 M (kNm) The solid
capacity
sR cores locate the
V (kN) Rd Rd,c

150 11 × 60 2.69 67.5 100.1 120.5

lifting points in which a transverse reinforcement is laid across the unit to facilitate
200 6 × 140 3.33 123.7 179.0 101.1
11 × 60 3.33 120.8 175.7 158.5
lifting from the
250
manufacturing bed. 6 × 140 3.71 183.9 258.1 131.1
11 × 60 4.03 180.9 256.8 200.1
• Table 3.1.1_1300
lists a range of hollow core units from 150 to 500 mm depth based on units
6 × 135 4.22 249.0 342.3 174.0
11 × 60 4.75 246.8 341.7 238.2
containing a 350
smaller number of larger cores, for example 4 to 6 no. per 1200 mm width,
6 × 135 4.62 326.9 448.0 212.0
400 6 × 135 5.03 407.9 551.2 247.0
and a larger number
450
of oval-shaped cores, for example 9–11.
6 × 135 5.43 507.6 677.8 283.0
• The height of500voids should not exceed h − 50 mm, where h is the overall depth of the
6 × 135 5.84 598.7 792.7 317.1
Note: Exposure = XC1 and fire resistance = R60 minutes.
unit. The diameter
Cover or averageofcovercircular
to pretensioning voids
strands = 30 is usually
mm (9.3 mm dia.) and h
35 mm− (12.5
75mmmm. The atminimum
dia.). Final prestress bot-
tom (excluding self-weight), σ = 12.5–13.0 N/mm depending on the availability of the positions of tendons. Self-weight
2
flange
b
includes infilled joints between units. Exposure = XC1, fck = 45 N/mm2, fctm = 3.80 N/mm2.
thickness depends on the overall depth of the unit h, given by 1.6√h. However, because
of cover requirements it is axis
2. The centroidal usually
is high innecessary for the
the section, typically yb =bottom flange
0.7h × depth from theto be at least 30 mm
bottom,
resulting in a low value of the section modulus at the bottom Z relative to the cross-
b
thick. The minimum
sectionalwidth of a web
area, for example Zb /Ac hshould not be
≈ 0.12 compared less
with 0.24 than 30core
for hollow mm. units.The minimum
This offers the potential for composite action with a structural topping.
width of a web should not be less than 30 mm.
Deflected or debonded tendons are used in some cases to overcome transfer stress problems
in long-span units. The cross-sectional profile and end detail at the half-joint is shown in
Figure 4.9. Typical widths are 2.4–3.0 m, and depths range from 400 to 1200 mm. The void

PRECAST CONSTRUCTION 3170622 17

 Figure 4.7 The 2.4 m wide hollow core floor units manufactured by Preconco Ltd., Barbados.

Table 3.1.1_1: Structural properties of hollow core prestressed floor units

Table 4.1 Structural properties of prestressed hollow core floor units
Depth Number and breadth Self-weight Service moment of Ultimate moment of Ultimate shear
(mm) (mm) of cores (kN/m2) resistance MsR (kNm) resistance MRd (kNm) capacity VRd,c (kN)
150 11 × 60 2.69 67.5 100.1 120.5
200 6 × 140 3.33 123.7 179.0 101.1
11 × 60 3.33 120.8 175.7 158.5
250 6 × 140 3.71 183.9 258.1 131.1
11 × 60 4.03 180.9 256.8 200.1
300 6 × 135 4.22 249.0 342.3 174.0
11 × 60 4.75 246.8 341.7 238.2
350 6 × 135 4.62 326.9 448.0 212.0
400 6 × 135 5.03 407.9 551.2 247.0
450 6 × 135 5.43 507.6 677.8 283.0
500 6 × 135 5.84 598.7 792.7 317.1
Note: Exposure = XC1 and fire resistance = R60 minutes.
Cover or average cover to pretensioning strands = 30 mm (9.3 mm dia.) fandck = 3545
mmN/mm
2 & fctm = 3.80 N/mm2
(12.5 mm dia.). Final prestress at bot-

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

tom (excluding self-weight), σb = 12.5–13.0 N/mm depending on the availability of the positions of tendons. Self-weight
2

includes infilled joints between units. Exposure = XC1, fck = 45 N/mm2, fctm = 3.80 N/mm2.

DOUBLE -TEE UNITS

2. The centroidal axis is high in the section, typically yb = 0.7h × depth from the bottom,
resulting in
• Precast concrete a low value
engineers of the section
continued modulus the
to optimise at the bottom
cross Zb relative
section of thetounits
the cross-
leading to
sectional area, for example Zb /Ac h ≈ 0.12 compared with 0.24 for hollow core units.
the so-called double-tee unit, shown in Fig. 3.1.1_4, achieving even greater spans and
This offers the potential for composite action with a structural topping.
reduced mass compared with hollow core units.
Deflected or debonded tendons are used in some cases to overcome transfer stress problems
• Thein unit comprises
long-span two
units. The deep webs,profile
cross-sectional reinforced
and end for strength,
detail joinedistogether
at the half-joint shown in by a
130 Precast Concrete Structures
Figure 4.9.
relatively thinTypical
flange,widths are 2.4–3.0 m, and depths range from 400 to 1200 mm. The void
for stability.

Figure 3.1.1_4: Double-tee floor units

Figure 4.8 Prestressed double-tee floor units.

• Typical widths are 2.4 m – 3.0 m, and depths range from 400 mm to 1200 mm. The void
ratio is about 70%, allowing the unit to span over longer spans and with less weight per
area than the hollow core unit.

PRECAST CONSTRUCTION 3170622 18

• Most double-tee floors require a structural topping to be site cast, together with a
reinforcing mesh, thus reducing the overall benefit gained by the greater spans and
reduced weight.
• Fig. 3.1.1_5 shows a variation of the double-tee in that the keyed end section is made
solid to facilitate continuous and composite action between spans, the splayed end is
reinforced to resist large negative bending moments on either side of the interior
Precast concrete floors 131
beam(s).

Precast concrete floors 131

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

Figure 3.1.1_5: Multi-rib units with tapered half joint and special end detail suitable for continuous design,
Figure 4.10 Multi-rib units with tapered half joint and special end detail suitable for continuous design, at
Samsung, South Korea. at Samsung, South Korea.

• Table Figure
3.1.1_24.10 lists some
Multi-rib unitstypes of prestressed
with tapered double-tee
half joint and special end detailunits having
suitable 2 no. design,
for continuous websat160 mm
Samsung, South Korea.
Structural properties
wide Table
at the4.2bottom, togetherofwith
double-tee
theirfloor units (without
moments structural toppings)
of resistance and shear capacity.
Overall Flange Web breadtha Self-weight MsR (kNm/m MRd (kNm/m VRd,c (kN/m
Depth (mm) depth (mm) (mm) (kN/m2) width) width) width)
Table 3.1.1_2: Structural properties of prestressed double-tee floor units
300
Table 4.2 Structural75 180
properties of double-tee floor 2.60 69.8
units (without structural 116.4
toppings) 68.0
400 75 180 2.96 124.1 201.2 89.6
Overall Flange Web breadth a Self-weight MsR (kNm/m MRd (kNm/m VRd,c (kN/m
500
Depth (mm) 75(mm)
depth 180
(mm) 3.32 2)
(kN/m 190.4
width) 303.0
width) 106.5
width)
600 75 180 3.68 271.2 427.6 120.5
300
700 75
75 180
180 2.60
4.04 69.8
362.3 116.4
566.4 68.0
133.2
400
800 75
75 180
180 2.96
4.40 124.1
471.0 201.2
733.8 89.6
144.9
500 75 180 3.32 190.4 303.0 106.5
a Web breath refers to the breadth of each web near the centroidal axis.
600 75 180 3.68 271.2 427.6 120.5
Axis distance to pretensioning strands = 50, 100, 150 and 200 mm (12.5 mm dia.). Final prestress at bottom σpo (excluding
700
self-weight) = 18.0 – 75 180 on the availability
19.0 N/mm2 depending 4.04 of positions362.3
of tendons. Some566.4
tendons debonded 133.2
at the
support.
800 Exposure = XC1,
75 data based on180fck = 45 N/mm2, f4.40
ck(t) = 30 N/mm 471.0
2, 25% final losses of pretensiong force.
733.8 144.9
a Web breath refers to the breadth of each web
a Web breath nearto
refers thethe
centroidal
breadthaxis.of each web near the centroidal axis.
Axis distance to pretensioning strands = 50, 100, 150 and 200 mm (12.5 mm dia.). Final prestress at bottom σpo (excluding
Comparison
self-weight) = with
18.0 –Table 4.1 2isdepending
19.0 N/mm interesting,
on thefor example
availability serviceofmoment
of positions of resistance
tendons. Some M sR foratthe
tendons debonded the
400 mm Exposure
support. deep hollow
= XC1,core and double-tee
data based units
on fck = 45 N/mm fck2, 25%
ckas follows (see
2, f (t) = 30 N/mm = Section
45 N/mm
final
2 , fck(t) = 30 N/mm2
4.3.3
losses for terminology):
of pretensiong force.

Area M
• Comparison onwith
Comparison Tab. 3.3.1_2
Table
Self-weight withPrestress
4.1tendons Tab.
is interesting, for at 3.1.1_1
example is interesting,
bottom service for example,
moment of resistance for the service
sR
MsR(kNm/m
400 of
mmresistance
deep hollow
(kN/m )core Aand σb units
double-tee (N/mmas follows (see mm
Section
p (mm )
mm )deep Ic (×10
coreZ4.3.3
) b (×10for
and mm terminology):
) width)
2 2 2 6 4 6 3
moment MsR for the 400 hollow double-tee units as
Hollow core 5.03 1266 12.86 4646 24.44 339.9
follows:
Double-tee 3.32 Area
1116 18.70 3776 13.24 MsR
124.1
Self-weight tendons Prestress at bottom (kNm/m
(kN/m2) Ap (mm2) σb (N/mm2 )
2 I (×106mm4) Z (×106 mm3) width)
M sR = (σb + fctm) Zb /b, where fctm = 3.8 N/mm , b = 1.2 cm and 2.4 m for
b
hollow core units
and double-tee units.
Hollow core 5.03 1266 12.86 4646 24.44 339.9
Double-tee
PRECAST CONSTRUCTION 3.32 1116 18.70
3170622 3776 13.24 124.1 19

M sR = (σb + fctm) Zb /b, where fctm = 3.8 N/mm 2 , b = 1.2 m and 2.4 m for hollow core units
and double-tee units.
 support. Exposure = XC1, data based on fck = 45 N/mm2, fck(t) = 30 N/mm2, 25% final losses of pretensiong force.

132 Comparison with Table

Precast Concrete 4.1 is interesting, for example service moment of resistance MsR for the
Structures
400 mm deep hollow core and double-tee units as follows (see Section 4.3.3 for terminology):
This comparison highlights the issue of low values of Zb for double-tee units, even though
Area MsR
the unit can be prestressed
Self-weight
totendons
a higherPrestress
level at mid-span (18.7 N/mm 2) thanks to debonding
at bottom (kNm/m
at the support. If this (kN/msame
2) Adouble-tee
p (mm )
2 unit is designed
σb (N/mm 2) compositely
Ic (×10 6mm4) Zwith 6a 75
b (×10 mm )
3 mmwidth)
topping
increases
M sRHollow core
to 170 kNm/m
5.03
width,
1266
closing
12.86
the gap with the
4646
hollow core
24.44
unit relative
339.9
to
theirDouble-tee
self-weight. 3.32 1116 18.70 3776 13.24 124.1
Both hollow core unit and double-tee floors are restricted, certainly in economical terms,
to aM rectangular plan
sR = (σb + fctm shape.
) Zb /b, whereIt is
fctmpossible to make
= 3.8 N/mm 2, b =trapezoidal
1.2 m and or 2.4splayed endedcore
m for hollow unitsunits
to suit
non-rectangular
and double-teebuilding
units. grids, but the detailing of these units would be difficult and not
economical.
• If this same Some companies
double-tee unit isquote 20%–50%
designed surcharges
compositely withfor manufacturing
a 75 mm toppingnonstandard
MsR increases
to 170 kNm/m width, closing the gap with the hollow core unit relative ‘composite
units. A precast flooring method which enables non-rectangular layouts is the to their self-
beam and plank floor’. This is a tertiary system in which a composite floor is produced as
weight.
shown in Figure 4.11; primary beams (r.c., precast, steel etc.) support long span beams,
reinforced
• Both theseortypes
prestressed depending
of flooring areonmost
structural
commonlyrequirements and manufacturing
rectangular in plan, though capabil-it is
ity. These carry precast concrete planks that may be shaped to suit non-rectangular, even
possible to manufacture
curved, building layouts. The some planksunitsaretorelatively
suit non-rectangular
inexpensive tobuilding
produce grids.
in a range But,ofthe
moulds of will
detailing different sizes. It and
be complex is usual
wouldfor alead
structural topping to be applied
to an uneconomical design.toSomethe floor, and
companies
this is reinforced using a mesh. The final constructed floor resembles a double-tee floor in

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

quote 20%–50% surcharges for manufacturing nonstandard units.
structural form and has a similar void ratio of about 70%, but the way in which each of
these has been achieved may be tailored to suit the building requirements.
The precast planks described earlier
COMPOSITE BEAM may& bePLANK
used in isolation
FLOOR of the precast beams, span-
UNITS
ning continuously between brick walls, steel or r.c. beams. The cross section of composite
planks is as shown in Figure 4.12a. To speed erection rates, the planks may be up to 3 m
•Awide (1.2 and
precast 2.4 m method
flooring are common). whichThe lattice non-rectangular
enables floor slab, commonly known
layouts as ‘Omnia’
is the ‘composite is
a semi-precast option of using a lightweight, yet versatile in
beam and plank floor’. This is a tertiary system in which a composite floor is producedterms of shape, precast soffit
strengthened to span up to about 6 m using top reinforcement in compression. Figure 4.12b
as
andshown
c show inthe FIG. 3.1.1_6;
two stages primary
of precast beams (r.c.,
production from precast, steel etc.) and
a UK manufacturer support
Figurelong
4.12dspana
beams, reinforced or prestressed depending on structural requirements and
manufacturing capability.

Nominal mesh
reinforcement In situ concrete
topping

Main beam

Bearing pad
Precast planks

Interface shear links Precast beams (supported

on main beams)

Figure 3.1.1_6: Composite beam and plank flooring comprising precast primary and secondary beams,
Figure 4.11 Composite beam and plank flooring
precast plankscomprising precast
and structural primary and secondary beams, precast
topping.
planks and structural topping.

PRECAST CONSTRUCTION 3170622 20

 Reinforced (rc) In situ topping screed
precast plank shown thus

75–100 mm

• The precast concrete planks that may be shaped to suit non-rectangular, even curved,
Up to 2400 mm
building layouts.
• It is usual for a structural topping to be applied to the floor, and this is reinforced using
a mesh. The final constructed floor resembles a double-tee floor in structuralAlternative
form edge
and
details
Prestressed (psc)
has a similar void ratio of about 70%, but the way in which
Precast concrete floors 133
each of these has been
precast plank

achieved may be tailored to suit the building requirements.

Reinforced (rc) In situ topping screed
precast plank shown thus 134 Precast Concrete Structures rc or psc precast unit.
(a) Min. width 300 mm

75–100 mm

Up to 2400 mm

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

Alternative edge
details
Prestressed (psc)
precast plank

(b)

134 Precast Concrete Structuresrc or psc precast unit. Figure 4.12 (a) Composite plank floor options. (b) Reinforced lattice girder and rebar cage for composite
Min. width 300 mm (c) plank floor. (Continued )
(a)

(c) (d)

(b)
Figure 4.12 (Continued) (c) Precast concrete stage of composite plank lattice floor. (d) Construction
Figure 3.1.1_7 (a): Cross section of composite planks, (b)stage plank with lattice
of composite plank reinforcement, (c)of plank
lattice floor. (Courtesy ready
Pfeifer Seil und Hebetechnik
Figure 4.12 (a) Composite plank floor options. (b) Reinforced lattice girder and rebar cage for composite
for installation, & (d) construction stage of composite Memmingen, Germany.)
plank floor system
plank floor. (Continued )

similar variation ideal for making both floors and beams continuous in Germany. The tops of
• The cross section of composite planks
the beamsis asbeshown
may in interface
provided with Fig. 3.1.1_7 (a).
shear loops To speed
to make erection
a composite beam. Lightweight
infill blocks (e.g. dense polystyrene) are sometimes placed on to the tops of the planks to
rates, the planks may be up to 3 m wide
reduce (but
weight 1.2 and
by about 2.4the
25%, but mweight
are common).
saving blocks may cost more than the displaced
concrete. It isrelatively easy to form large-size voids in this floor and to add site reinforcement
• Fig. 3.1.1_7 (b & c) show the twotostages of precast
cater for stress production
raisers at corners etc. from a UK manufacturer
and Fig. 3.1.1_7 (d) a similar variation ideal for making both floors and beams
continuous in Germany. In this type the beam and the planks are filled with the in-situ
(d)
concrete together for better integrity and bonding.
Figure 4.12 (Continued) (c) Precast concrete stage of composite plank lattice floor. (d) Construction
stage of composite plank lattice floor. (Courtesy of Pfeifer Seil und Hebetechnik
Memmingen, Germany.)

PRECAST CONSTRUCTION 3170622 21

similar variation ideal for making both floors and beams continuous in Germany. The tops of
the beams may be provided with interface shear loops to make a composite beam. Lightweight
infill blocks (e.g. dense polystyrene) are sometimes placed on to the tops of the planks to
reduce weight by about 25%, but the weight saving blocks may cost more than the displaced
• A reinforced concrete (RCC) flexure member (i.e. slabs, beams, etc…) have some limits
in terms of spans & depths mainly because of deflection or crack criteria. But, this limit
can be overcome by using prestressing.
• The other type of half-slab is shown in Fig. 3.1.1_8, a prestressed solid plank, generally
prestressed with 5 mm or 7 mm wires according to the loadingPrecastand
concrete
spanfloors 135
requirements.

Prepared by Dr. Swaral R. Naik (DRAFT COPY)

4.13 Prestressed
FigureFigure concrete composite
3.1.1_8: Prestressed plank,composite
concrete often knownplank,
as ‘half-slab.’
often known as ‘half-slab.’

Statically
• Solid slabs, oftenreinforced
called concrete may be limited
‘solid planks,’ in termsdesigned
are usually of span and depth, mainlywith
compositely due to
an in situ
deflection or crack width criteria which can be overcome by prestressing. The other type of
topping as discussed
half-slab earlier.
is shown in Figure These
4.13, units solid
a prestressed are plank,
majorly used with
reinforced when a 12
up to domestic
no. 5 or sound
7 mm wires, or between 4 and 9 no. 7-wire helical strands, depending on depth and loading
insulation requirement is to be met. The depths vary between 75 mm to 200 mm, a usual
requirements. Solid slabs, ‘often called solid planks,’ are usually designed compositely with
depthanis 100topping
in situ mm.asA limiting
discussed span4.4.1.
in Section of The
4.5m is preferred
precast soffit section by most 100
is typically manufactures
mm
deep, but depths of between 75 and 200 mm are possible. Solid planks are often used in
considering
domesticlifting andwhere
properties handling of the planks.
the requirement for 300 kg/m 2 sound insulation can easily be met
using a 75 mm precast soffit (12 no. 7 mm wires at 20 mm cover) and 50 mm topping, and
for an imposed live load of 1.5 kN/m 2 plus 1.2 + 0.6 kN/m2 for finishes, services and ceiling,
spans of 5.0 m are possible without temporary propping, or 5.5 m with propping. Propping
Each
helps toofoptimise
the flooring systems
the design introduced
where the limiting spanearlier has successively
is controlled almost equallyeroded
by servicethe
major advantages in the and
stress, final deflection usedeflection
of precastafterconcrete floors
finishes (see over
Section competitors
4.6.2). suchspan
In fact, a limiting as timber
of 4.5 m (length/depth
or cast in situ floors. = 4500/75 = 60) due to lifting and handling may be imposed by some
manufacturers.
Each of the flooring systems introduced earlier has successively eroded the major advan-
Since
tages inthethe1960s, the hollow
use of precast core
concrete market
floors in Europe
over competitors recently
such as timber passed
or cast1000M
in situ m
2

(about 300
floors.soccer pitches
Since the perhollow
1960s, the month!) The advantages
core market withpassed
in Europe recently precast1000Mare:m2 – about
300 soccer pitches per month! The advantages with precast are
i. Manufacture of units simply and economically
1. Manufacture of units simply and economically
ii.2. Safe
Safe and
andrapid erection
rapid of floors
erection of floors
3. Possiblity to create a structurally complete precast floor
iii.4. Possibility to create
Use of minimum amountsa of
structurally complete
in situ reinforcement and precast floor
wet concrete

iv. Usethese
However, of minimum amountswith
may be in competition of in situcriteria
other reinforcement and access,
depending on-site wet concrete.
structural
design requirements, interface with other trades, availability of expensive or cheap labour,
services requirements, etc. Specifiers must therefore study all available options.

PRECAST CONSTRUCTION 3170622 22