4

Precast Concrete

Precasting means casting a concrete member at a place other than where it will be
used and then moving it to the place where it will be installed.
1.

Precast yard

Most precast units are produced in factories or casting yards. Fundamental factors
that contribute to the success of a factory/casting yard for the precasting include:

proximity to the place where the precast unit will be installed

sufficient area for the storage of materials, bending and fabrication of steel
reinforcement, casting, curing and storage of finished products

land price or rent

good access such as road, rail or pier

availability and cost of materials and labour supply

availability plants such as batching plants and lifting facilities

2. Techniques to improve the production

2.1 Fabrication of reinforcement
Reinforcement fixing is labour intensive on site.

For precasting, mechanization is

possible for the fabrication of reinforcement because of mass production.

Cutting, bending and fixing the
reinforcement
degree

of

can

have

automation.

high
The

reinforcement can also be fixed by

spot

welding.

(Normally,

welding for T-bars is not permitted

on site as poor temperature control
on welding lowers the strength of

Automatic rebar fabrication machine

high tensile steel.)

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2.2 Prestressing
The technique prestressing greatly improve the strength of precast units.
pre-tensioning is used for precasting.

Usually,

Sometimes, post-tensioning is also used for

non-standard units or where curved tendons are required.

2.3 Concrete moulds
Steel moulds are usually used for precasting which have the following advantages:

easy assembling and demoulding

durable - can be reused up to a thousand times for percasting works

hard and smooth surfaces of

the moulds can be cleaned
easily and give good
concrete finishes

Steel Mould for Precast Staircase

2.4 Compaction of concrete

2.4.1

External vibrators - which mounted on the moulds reduce the labour works
for compacting the concrete.

2.4.2

Hydraulic pressing - which can be employed to compact low slump concrete

of small precast units, such as paving blocks and concrete drainage pipes.
The units can also be demoulded immediately without breaking.

Hydraulic pressing

Centrifugal Spinning
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2.4.3

Centrifugal spinning - In the production of some precast concrete pipes and

prestressed tubular pile (e.g. Daido Pile), the centrifugal spinning process
effectively compacts the zero slump concrete.

It produces a uniform hollow

tube without the need of a void former.

2.4 Accelerated curing

An increase in the curing temperature of concrete increases its rate of development of
strength. It reduces the curing time hence reduces the cycling times of concrete
moulds and prestressing bed.
2.4.1

Steam curing (at atmospheric pressure and below 100C)

Steam curing is normally applied in special chambers or in tunnels through which

the concrete members are transported on a conveyor belt.

Alternatively, portable boxes or plastic sheet covers can be placed over precast
members; steam is supplied through the connections of flexible hose.

Plastic sheet cover for steam curing

2.4.2

Autoclaving

Autoclaving (high pressure steam curing)

Precast units are placed into an autoclave (a pressure vessel) and steam of high
pressure and temperature (about 170 - 200C and 8 - 10 atmospheric pressure) are
applied.

Usually the concrete can become fully matured in one day.

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Handling of precast units

Since precast concrete unites are bulk and heavy, lifting equipments are required for
the lifting. Lifting fittings should also be cast into units for easy handling.
3.1 Fittings for lifting
lifting hook

lifting hooks

threaded sockets

lifting plates
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3.2 Lifting devices

Mobile crane

Tower crane

4.

Derrick arm

Launching Girder

Application and installation of precast units

There are various applications of precast concrete, and the precast units can be
installed by different methods.

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4.1 Column to foundation connection

1.1 Pocket connection
A pocket is reserved in the
foundation.
the

The column is set into

reserved

pocket

in

the

foundation and the spaces between

the column and the socket is filled
with cement grout.
Pocket connection

1.2 Bolting connection

The main bars of the precast column are connected to the steel base plate / channels
by welding.

The precast column can then be connected to the foundation by bolting.

Precast column

Column
reinforcement

Steel channel
welded to
main bars

Grout or
dry pack

Holding
down bolt

Foundation

Column-foundation bolting connection

Column-foundation bolting connection

(Source: R. Chudley)

1.3 Dowel and sleeve connection

Grout-sleeves are cast into a precast unit.

The sleeves fit over reinforcement projecting from the mating part.

The sleeves are grouted and the gap between the units is filled with dry-pack or
non-shrink grout
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precast column
sleeve (to be filled
with cement grout)
grout hole
dowel
shim packing
joint filled with
dry pack or
groutand sleeve connection
cement
Dowel
Sleeve
foundation

Column - foundation connection with dowel and sleeve method

4.2 Beam to column connection

2.1 Simply supported joint and hinge joint
he beam usually sits on a corbel or the column head. For a heavy structure, it is
important to place a resilient pad, which is commonly called a bearing, between the
two structural components to transfer the load uniformly so as to prevent localized
stress. If the horizontal translation is restrained, say by a dowel, it becomes a hinge
joint.

Hinge joint

Simply
supported joint

Beam to Column connection by Bolts and Brackets

(Source: R. Chudley)

2.2 Bolting Connection

For bolting connection, steel brackets have to be shop welded to the main bars of the
precast units.

The precast units can then be connected to the main structure on site

rapidly by bolting.
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2.3 Exposed reinforcement connection

The exposed reinforcements of the precast column and the precast beam are
lapped together.

The joint is then completed with insitu concrete.

The joint provides good moment resistance.

It is also called composite moment connection.

Precast column
Exposed
reinforcements
of beam and
column

Joint completed
with insitu concrete

Precast beam

Beam column connection with exposed reinforcement method

3. Column Splicing
3.1 Welding connection
A steel plate is fixed to the end of

Upper column

each precast column by welding to

its main reinforcements.

Column
main bar
shop welded
to base plate

The

columns are butted against each

other and the joint is completed by

Insitu
butt weld

butt welding.
Lower column

steel base
plates

Column splicing with welding method

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3.2 Dowel and sleeve connection

Grout-sleeves can be cast into a precast unit, then the sleeves fit over reinforcement
projecting from the mating part.

The sleeves are grouted and the gap between the

units is filled with dry-pack or non-shrink grout.

Grouted sleeve connection

3.3 Insitu concrete connection

The exposed reinforcements of the

columns are lapped together.
main bar

The joint is completed with insitu

binder

concrete.

upper
precast
column

insitu
concrete

It provides good moment resistance.

main bar
of lower
column

main bar
of upper
column

dry joint
insitu
concrete
precast
column

binder
B

Section A-A

lower
precast
column

Section B-B

Column Splicing with insitu concrete

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4. Precast Slab
4.1 Planks and blocks

A precast slab can be formed by placing long planks at suitable centres

supported on main beams or loading bearing walls

The intermediate spaces are then filled with smaller block units to complete the
slab.

Normally, a structural topping is not required but the upper surfaces of the units
are usually screeded to provide the correct surface for the floor finishes.

This method eliminates the requirement of falsework during the construction

period.

Planks and blocks

4.2 Hollow core slab

Prestressed tendon

Assimilated I-beam

Hollow core slabs can be used for most

building floor or roof systems.

The voids greatly reduce the dead load of

the slab and the material cost.

The web resembles closely spaced I-beams

that provide efficient moment resistance.

Prestressed hollow core slabs are available.

Hollow core slab

This means long spans, shallow

depth and the ability to carry heavy loads are easily accommodated.

Hollow core slabs may be simply supported on beams or load bearing wall.
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To resist hogging moment at the support, steel dowel are can be provided.
Filled with cement grout
Dowel
Min. 75mm

Hollow floor installation

4.2 Double Tee Slabs

Double tee slabs are prestressed.

Double tee slabs can be used for most applications requiring a long span floor or
roof system (10m to 30+ m) and/or additional load carrying capability.

They may be supported on beams or load bearing walls.

Steel bracket welded to

the main reinforcements
Steel bracket welded to
the main reinforcements

Min. support
width 150 mm

Double Tee Slabs on beams

Double Tee s slab on wall

(Source: CPCI)

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External Wall

Faade Panel is the most widely used precast concrete wall in Hong Kong.

Various installed methods had been used.

Building
structural
frame

Joint filled
with cement
grout

Fixing of Facade Panel

Cast with
insitu
concrete

(Source: City University)

The prevailing installation method:

Erection of the faade panel with temporary plumbing guide

Fixing of reinforcement of adjoining walls lapping with the dowel of the faade
panel

Shuttering of wall formwork and casting of concrete

Fabric reinforcement for wall construction after installing precast faade

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Composite Construction / Permanent Formwork

Precast units are placed underside to serve as formwork for concreting.

They also

become integral parts of the permanent structure. The major advantage of using
permanent formwork is that it eliminates or minimizes the temporary works such as
formwork and falsework. In addition, there is no need for stripping.
Composite Floor Slab
Insitu concrete

top reinforcement

binder

precast slab
Solid Planks for Composite Slab

Composite Slab

Composite Beam

Precast shell beam for composite construction

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6. Advantages and disadvantages of Precast Concrete

6.1 Advantages of precast concrete

The units can be mass-produced and are therefore cheaper.

Cost of formwork can be reduced.

Easier to fix reinforcement and place concrete which to be done on ground and
under cover.

Units can be cured by accelerated techniques.

The quality of units can be strictly controlled.

Units can be cast before the site becomes available hence the construction time
can be reduced.

Temporary supports such as falsework and scaffolding are reduced to minimum.

Precast units can be structurally load tested if required.

Precast units can be pre-tensioned.

Precasting produces less construction waste than insitu works and therefore more
environmental friendly.

6.2 Disadvantages of precast concrete

Uneconomical if only a small number of units are required.

Waterproofing of joints may be expensive.

The transportation of long units may be difficult.

Cranes may be required to load and unload the units on site.

Reference:

Construction of Prestressed Concretes 2nd Edt., Ben C. Gerwick, Jr. (1993), Wiley Inter.
Science.

Modern Prestressed Concrete Design Principles and Construction Methods 4th Edt., James R.
Libby (1990), Van Nostrand Reinhold.

Post-tensioning in Building, VSL

Construction Technology Vol. 3 2nd Edt., R. Chudley (1991), Longman.

Civil Engineering Construction IV Vol. 4, S.A.R Jufri & R.J. Wellman (1992), Hong Kong
Polytechnic.

Precast Concrete Material, manufacture, properties and usage, M. Levitt (1982), Applied
Science Publishers

Recommended Practice for Erection of Precast Concrete, PCI Erectors Committee (1983), PCI

http://www.cpci.ca/
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