PRECAST

PRECAST
CONCRETE
CONCRETE
GROUP 1

GROUP MEMBERS: RIYA

PRANAV SATHE
SHREYA KUMBHAR
SAMRUDDHI SASANE
SNEHA KOTHARI

CLASS : S.Y.B.ARCH ( C )

SUBJECT : BUILDING CONSTRUCTION & MATERIAL-III

FACULTY : AR.SNEHA SHARMA

AR.PURNIMA CHITALE
AR.SUNITA KOTHARI
 content
HISTORY OF PRECAST CONCRETE
WHAT IS PRECAST CONCRETE?
WHY IT IS CALLED SO?
WHY PRECAST CONCRETE?
PROPERTIES OF PRECAST CONCRETE
FEATURES OF PRECAST CONCRETE
PRECAST CONCRETE STRUCTURAL ELEMENTS
TYPES OF PRECAST SYSTEMS
PRECAST CONCRETE V/S SITE CAST CONCRETE
ADVANTAGES OF PRECAST CONCRETE
DISADVANTAGES OF PRECAST CONCRETE
why the precast concrete is used
Market survey

Different agencies supplying precast construction in india

 HISTORY OF PRECAST CONCRETE
Ancient Roman builders made use of concrete and
soon poured the material into moulds to build their
complex network of aqueducts, culverts, and tunnels.
Modern uses for pre-cast technology include a variety
of architectural and structural applications — including
individual parts, or even entire building systems. In
the modern world, precast panelled buildings were
pioneered in Liverpool, England, in 1905. The process
was invented by city engineer John Alexander Brodie,
a creative genius who also invented the idea of the
football goal net. The tram stables at Walton in
Liverpool followed in 1906. The idea was not taken
up extensively in Britain. However, it was adopted all
over the world, particularly in Eastern Europe[4] and
Scandinavia. In the US, precast concrete has evolved
as two subindustries, each represented by a major
association.
The precast concrete products industry focuses
on utility, underground and other non-
prestressed products, and is represented
primarily by the National Precast Concrete
Association (NPCA). The precast concrete
structures industry focuses on prestressed
concrete elements and on other precast
concrete elements used in above-ground
structures such as buildings, parking structures,
and bridges. This industry is represented
primarily by of the Precast/Prestressed
Concrete Institute (PCI).
 WHAT IS PRECAST CONCRETE?
• Precast concrete is a construction product produced by
casting concrete in a reusable mold or "form" which is
then cured in a controlled environment, transported
to the construction site and lifted and set into place

• Precast concrete is made up of coarse and fine

aggregates, cement, water, and admixtures. It is
mixed in the factory’s batch plant according to the
concrete mix design specified by the engineer.

WHY IT IS CALLED SO?

• These concrete structures are
casted off-site much before
they are put into actual use
and thus are known as precast
(pre-casted) concrete.

WHY PRECAST CONCRETE?

• Precast concrete structures provide
superior resistance to fires, natural
disasters, insects and mold.
 PROPERTIES OF PRECAST CONCRETE
1.Great dimensional accuracy and finishes
Precast concrete construction provides superior dimensional
accuracies and finished concrete surfaces in comparison with cast
in-situ concrete

2. Better quality critical elements

Using pre-cast elements can reduces grout loss, inconsistent
joints, surface damages and imperfections .

3. Design flexibility
Precast concrete elements can be constructed to be meet
requirements of the design. Complex shapes, sizes and
specific technical requirements can be easily fabricated in
precast plant.
4. No on-site space for moulds and reinforcement storage 
Precast components are made in a factory and delivered to
site where they are lifted straight from the lorry onto the
building.
5. Faster erection at site
Precast concrete
components arrive at the
job site ready to install,
which can save weeks over
cast-in-place construction.
weather conditions at the
job site will not
significantly affect the
construction schedule.
 FEATURES OF PRECAST CONCRETE

• 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.

• Compared to site-cast concrete , precast concrete erection is faster and less affected by
adverse weather conditions.

• Plant casting allows increased efficiency, high quality control and greater control on
finishes.

DESIGN CONSIDERATIONS
• Final position and loads

• transportation requirements – self load and position during transportation

• storing requirements – self load and position during storing – (avoid or store in the same
position as it transported / built in)

• lifting loads – distribution of lifting points – optimal way of lifting (selection of lifting
and rigging tools)

• vulnerable points (e.g. edges) – reduction of risk (e.g. rounded edges)

PRECAST CONCRETE STRUCTURAL ELEMENTS

A precast building is constructed by assembling and connecting

various prefabricated elements required in the building
structure. These elements are:

1. Precast slabs

2. Precast beams

3. Precast columns

4. Precast walls

5. Precast foundation

6. Precast stairs
 PRECAST SLABS
• Precast slabs are cast in a factory environment and include the following
prestressed concrete options:
 Hollow core units:
o A Hollow core slab offers the ideal structural
section by reducing deadweight while providing the
maximum structural efficiency within the slab
depth.
o Precast floors are available with a variety of
factory-formed notches, slots and reinforcement
arrangements which offer various design
approaches.
 Double-tee units:
o Double Tee (TT) slabs are two
symmetrically placed beams interacting with a
slab forming in one section with a “double
tee” shape made in precast, prestressed
concrete.
o Resistant to moisture and corrosion. Parking
garages, office buildings, commercial buildings,
factories, industrial buildings, etc., are all
ideal applications.
o Made with G50 concrete and ½” strands
ASTM A416 as standard, each double Tee
slab is normally 2400mm wide
 PRECAST BEAMS

 Beams and beam shells are both used for suspended flooring.

 Beams are typically used as ledges for other forms of precast flooring
to sit on, but can also be used as a flooring option in their own
right. They are generally manufactured to suit each particular
situation and profiles can include :
• Tee-beams
• L-beams
• Rectangular beams
• U-beams
• Beamshells.

 Beams can be either

reinforced or prestressed
TEE-BEAMS
 Tee-beams (either single or double) cover
the span range beyond slab-type members
such as hollowcore planks.
 Tee-beams are a very efficient structural
shape.
 The units are generally cast with straight
strands or deflected strands, depending on
design considerations.
 The Tee-beams are the basis for the design
of economical, fire rated structures where
construction time, long spans or heavy
loadings are important cost influences

L-Beam (Spandrel)

 L-beams have an 'L' shape profile

which provides a ledge for a precast
flooring system to sit on.
 These beams are generally used to
span clear sections and are reinforced
and/or prestressed
 Rectangular Beams

• Rectangular beams get their name from the end

profile.
• These beams are generally used to span clear
sections and are reinforced and/or prestressed.

U-Beams
• U-beams as the name suggests have a 'U'
shaped profile.
• These beams are generally used to span clear
sections and are reinforced and/or pretensioned.
• They are more commonly used for single-unit
pedestrian bridges than with composite flooring
systems
Beam Shells
• This is a complimentary composite system
of precast elemnts that contain all the
positive main beam reinforcement and
most/all of the stirrups in a minimum
volume of concrete for economy and ease of
handling.
 PRECAST COLUMNS

 Precast concrete columns are modular in design in

order to be made into different heights. Widths are
12", 18" and 24 ".

 Columns are not structural, but can be used as

such only after a structural engineer has adapted
them to a building.

 Precast column can be produced as either single

storey corbel column or multi storey corbel column.

 Columns can either be rectangular or circular in

section.

 Projecting rebar can be provided for tying

in to in-situ floors.

 Options for foundation connections include

cast in base plates, dowel tubes or
projections.Beam support is achieved
by either flared heads, corbels or
bolt-on brackets
 Precast walls
Wall panels available in standard 8’-0" widths. A wall system
can be comprised of :

2.Mullion panel

1. Flat , 3.Ribbed panel

hollow core
or insulated
panel

4.Spandrel
5.Double tee Panel
 PRECAST FOUNDATION

• Precast footings are a recent

innovation.
• No holes need to be dug for footings,
as the precast blocks are set on grade,
and the posts, columns or beams fit
in pockets cast in the concrete block.
• Precast concrete foundations are pre-
engineered systems manufactured in a
controlled environment

PRECAST FOOTINGS CAST IN-SITU FOOTINGS

Built off site Formed and cast on site

Lowest site impact (0.5-1.0 High site impact (5-8 days)

days)
Negligible impact by weather
Panelized = joints for expansion
and contraction
Construction impacted by
weather
Monolithically cast = cracks
 PRECAST STAIRS

Precast stairs are designed and

manufactured to any specific
floor height and application.
These are durable and
maintenance free. Eliminates the
need for temporary stairs during
construction. Safety rails and
handrail can be pre-installed prior
to installation.

Precast concrete stair, made up

of reinforced concrete is one of
the best options to eliminate
the trouble of adjusting the
number of steps, rise, run and
width of each stair flight.
 Methods of attachment of precast members

1. Weld plates 2. Rebar and Grout

The most common method of Used typically with slabs, reinforcing bars
attachment of precast members is by are spliced into slabs and grouted in place
use of steel welds plates . Typically , (see below):
the precast members have embedded
plates that can be used as welding
surfaces for loose connecting plates
or angles
 TYPES OF PRECAST SYSTEMS

1. Large-panel systems

2. Frame systems

3. Slab-column systems with walls

 LARGE-PANEL SYSTEMS

• “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 storey high.

• Horizontal floor and roof panels span

either as one-way or two-way slabs.
 FRAME SYSTEMS

 Precast frames can be constructed using either linear elements or spatial beam column sub-
assemblages.
 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
 SLAB-COLUMN SYSTEMS WITH 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

The load-bearing structure
consists of precast reinforced
concrete columns and slabs.
Precast columns are usually
two stories high.

 Prestressed slab-column
system
Horizontal prestressing in
two orthogonal directions
to achieve continuity.
The precast concrete column
elements are 1 to 3 stories
high.
 Construction method for precast concrete system

Construction considerations

 All safety issues on site when handling precast elements,

 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.
Sequence of work
QUICK CHECK
 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 verticality/position is achieved.
 Estimated time to install a typical precast element is ½ to 3/4 hour
 equipments

1. Cranes

Mobile crane
 Tower crane (above 3stories)

2. Lifting tools
 Spreader beams
 Wire rope slings

3. Rigging tools

 Eye bolt
 Shakles
 Hooks
 PRECAST CONCRETE V/S SITE CAST CONCRETE

PRECAST SITE CAST

 Transportation and elevation  No transportation

capacity limits the size-
 The size limitation is depending
 Higher, industrialized quality – on the elevation capacity only
less affected by weather no
 Lower quality because directly
 Space requirement on the site affected by weather
for fabrication
 Proper, large free space
 Unlimited opportunities of required
 ADVANTAGES OF PRECAST CONCRETE
 Very rapid speed of erection

 Good quality control

 Entire building can be precast-walls, floors , beams , etc.

 Rapid construction on site

 High quality because of the controlled conditions in the factory.

 Prestressing is easily done which can reduce the size and number of the
structural members.

 Aesthetic versatility

 Durability

 Security

 Low maintenance

 Economy
 DISADVANTAGES OF PRECAST CONCRETE
 Very heavy members

 Camber in beams and slabs

 Very small margin for error

 Connections may be difficult

 Somewhat limited building design flexibility.

 Because panel size is limited, precast concrete can not be used for two-way
structural systems.

 Economics of scale demand regularly shaped buildings.

 Need for repetition of forms will affect building design.

 Joints between panels are often expensive and complicated.

 Skilled workmanship is required in the application of the panel on site.

 Cranes are required to lift panels.

 why the precast concrete is used
1. comfortable
The material has intrinsic properties of thermal
inertia (allowing a more constant temperature
both in cold and hot regions) and acoustic
insulation

2 . safe
Everybody knows that 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 . optimistic
Advanced technologies used in the precasting 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
 4 . versatile

Factory production allows a wide choice of surface

finishing, colour range and special shapes. Precast
concrete has another advantage: its mouldability
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
colours and visual effects.

5 . 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.
 6 . 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 . ecological
Made of natural raw materials (stones, gravels, sand, cement),
locally available almost everywhere and in an enormous quantity,
precast concrete minimises 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 . 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.
 Market survey
Precast concrete slab : RS 1200/square feet
Precast concrete column and beam:. RS 500/number
Precast concrete staircase : RS 17999/ cubic meter
Precast concrete Foundation : RS 30000/ cubic meter
Precast concrete compound wall : RS 100/square feet
Precast concrete wall: RS 1 Lakh / unit
Precast concrete septic tanks: RS 7000/ piece
Precast concrete toilets : RS 4500 / unit
 Different agencies supplying precast construction in
india

 Arto Precast Concrete , Bengaluru

 India Precast , Gurugram
 Ultracore Solutions Pvt. Ltd. , Hyderabad
 Drsti Precast Pvt. Ltd. , Coimbatore
 MBM Precast India Pvt. Ltd. , Sanand , Gujarat
 Precast Buildcon India Pvt. Ltd. , Hyderabad
Thank you