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
into place. In contrast, standard concrete is poured into site-specific forms and cured on site.

Full Definition of PRECAST

1.

: being concrete that is cast in the form of a structural

element (as a panel or beam) before being placed in fi nal
position

ADVANTAGES OF PRECAST CONCRETE

Following are the advantages of precast concrete:
1.

The concrete of superior quality is produced as it is possible to have better technical control
on the production of concrete in factory.

2.

It is not necessary to provide joints in the precast construction.

3.

The labour required in the manufacturing process of the precast units can easily be trained.

4.

The moulds employed for preparing the precast units are of steel with exact dimension in all
directions. These moulds are more durable and they can be used several times.

5.

The precast articles may be given the desired shape and finish with accuracy.

6.

The precast structures can be dismantled, when required and they can then be suitably used
elsewhere.

7.

The transport and storage of various components of concrete for cast in situ work are
eliminated when precast members are adopted.

8.
9.

The work can be completed in a short time, when precast units are adopted.
When precast structures are to be installed, it is evident that the amount of scaffolding and
formwork is considerably reduced

DISADVANTAGES OF PRECAST CONCRETE

Following are the disadvantages of precast concrete:
1.

If not properly handled, the precast units may be damaged during transport.

2.

It becomes difficult to produce satisfactory connections between the precast members.

3.

It is necessary to arrange for special equipment for lifting and moving of the precast units.

4.

The economy achieved in precast construction is partially balanced by the amount to be

spent in transport and handling of precast members. It becomes therefore necessary to locate
the precast factory at such a place that transport and handling charges are brought down to the
minimum possible extent.

TYPES OF PRECAST COMPONENTS IN A BUILDING:

The figure below shows the basic precast structure. The numbers of different
types of components in these structures over the years have become very
large. But following figure shows the major types of precast components in a
building.

Precast Beams:
There are two main categories of beams:
1.
2.

Internal beams where floor loading is approximately symmetrical

External beams where floor loading is predominantly non-symmetrical.

Fig: Internal beams

Fig: External beams

Precast Columns:
For structures of five storeys or less, each column will normally be
continuous to the full height of the building. For structures greater than five
storeys two or more columns are spliced together.
The main types of precast columns are:
1.
Edge columns symmetrical in one direction.
2.
Internal columns symmetrical in all directions.
3.
Corner columns not symmetrical at all.

Precast floor slabs:

The main types of slabs are used in the precast frames are:
1.

Hollow cored slab

1.

Double tee slab

Precast walls:
Precast concrete walls serve two functions:

Stability

As walls or boxes surrounding staircases and lift shafts.

Walls may be classified as infill or cantilever:

Infill walls rely on contiguous composite action with the beam and column
frame.

Cantilever walls or boxes act as deep beams to which the frame is attached.

Precast staircases:
Three options are available for precast staircases:

A single precast unit containing all the flights and landings

Separate precast flights and landings

Parts of the flights and landings are made in one piece.

CONSTRUCTION PRINCIPLES

Precast concrete construction has many advantages over cast-in-situ

concrete structures as well as steel, wood, & masonry structures. Precast
concrete construction provides faster and more efficient construction
process.
Precast concrete construction system has its own characteristics which
influence the layout, span length, construction depth, stability system, etc.
to a greater or less extend.
Theoretically, all joints between the precast concrete units can be made in
such a way that the completed precast structure has the same monolithic
concept as a cast-in-situ structures.
However, precast concrete construction is very labour intensive and costly. If
the full advantages of precast concrete are to be realized, the structure
should be conceived according to its specific design philosophy.
Long spans, appropriate stability concept, simple details, etc. Designers
should from the very outset of the project consider the possibilities,
restrictions & advantages of precast concrete, its detailing, manufacturer,
transport, erection & serviceability stages before completing a design in
precast concrete.

Following are the few Properties of Precast Concrete

Construction Process:

Enables faster programmed times not affected by weather or labour

shortages.

Improves buildability early enclosure of dry envelope enables follow-on

trades to start sooner.

Produces a high standard of workmanship in factory conditions reduces

potential for accidents, addresses on-site skill shortage.

Has a high quality finish that can be left exposed concretes thermal
properties can be exploited in low-energy buildings.

Primary Functions of Precast Concrete

Construction

Keep water out

Prevent air leakage

Control light

Control radiation of heat

Control conduction of heat

Control sound

Secondary Functions:

Resist wind forces

Control water vapor

Adjust to movement

Thermal & moisture expansion/contraction

Structural movements

Resist fire

Weather gracefully

Easy to install

Architectural precast concrete provides architects with an exciting medium

when designing facades for a wide range of buildings, from healthcare
facilities to shopping malls, commercial office buildings to sports stadiums.

Precast concrete provides:

Complete thermal protection

Continuous air/vapour barrier

Effective rain screens

Superior lifespan

Reduced construction schedule and on-site labour

High quality control standards

Numerous finish options and colours

Elements in Precast Concrete Building Systems:

Following are the elements generally constructed in precast concrete building
construction:

Precast concrete frame

Precast concrete wall

Precast concrete floor

1. Precast Concrete Frame Construction

Precast concrete frames involve an entire structure being fabricated off-site.
In addition, 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, colours and
finishes can be accommodated. Architecturally-finished precast structures
can be left exposed to exploit concretes high thermal capacity in a buildings
green energy management system.

Construction Process
Precast concrete frames are cast in the same way as precast concrete
cladding, but as they are designed as structural elements have heavier
reinforcement than is required for non-structural cladding. Elegant
connections are required between columns and beams to transfer
considerable forces without adversely affecting the visual appearance of the
frame.

MANUFACTURE OF PREFABRICATED COMPONENTS

Presentation on Prefabricated Structures & Prefabrication

Concept, Components & Advantages
by Priyaranjan Behera
Concept of prefabrication?
Prefabrication is the method of construction which includes assembling components of a structure in
a manufacturing or production site, transporting complete assemblies or partial assemblies

Pre-fabricated Structures Animation

to the site where the structure is to be located. It is combination of good design with modern high
performance components and quality controlled manufacturing procedures. This work is carried out
in two stages, manufacturing of components in a place other than final location and their erection in
position.
Prefabricated sections are produced in large quantities in a factory and then shipped to various
construction sites. This procedure may allow work to continue despite poor weather conditions and
should reduce any waste in time and material at the site. Precast concrete units are cast and
hardened before being used for construction. Sometimes builders cast components at the building
site and hoist them into place after they harden. This technique permits the speedy erection of
structures.

PreFabrication
The Prefabrication as defined will be done in two stages
1.

Manufacturing at factory condition and erection of

2.

components at the required location.

casted with controlled cement concrete in moulds

This requires certain stages of preparation. They are Casting, Curing, Transportation and
erection.
Casting: Precast components are casted with controlled cement concrete in moulds of required
shape and sizes. The vibrator is used to vibrate concrete and this removes any honeycombing inside
the components.
Curing: After 24 hours of casting, the casted components are released from the mould and
transported to curing tanks. Certain special components like railway sleepers where high strength is
required are steam cured.
Transportation and erection: After complete curing is done the components are transported to
the site with heavy trucks and erection will be done using cranes with skilled labour force.

Prefab Building Components

Some of the prefabricated components are as explained below

Prefab Column to Column Connection

Columns: A column is a vertical member carrying the beam and floor loadings to the foundation. It
is a compression member and therefore the column connection is required to be proper. The main
principle involved in making column connections is to ensure continuity and this can be achieved by
a variety of methods.
Beams: Beams can vary in their complexity of design and reinforcement from the very simple
beam formed over an isolated opening to the more common encountered in frames where the beams
transfer their loadings to the column. Methods of connecting beams and columns are

A precasting concrete haunch is cast on to the column with a locating dowel or stud bolt to fix
the beam.

A projecting metal corbel is fixed to the column and the beam is bolted to the corbel.

Column and beam reinforcement, generally in the form of hooks, are left exposed. The two
members are hooked together and covered with insitu concrete to complete the joint. This is as
shown in the figure.
Waffle unit for flooring / roofing: These are suitable for roofs / floors spanning in two directions.
They are laid in a grid pattern. These units are cast in moulds. The saving achieved is not much.
Also Shuttering are complicated and costly. Time consumption for construction is less

STRENGHT AND SERVICEABILITY REQUIREMENTS

Transverse openings in concrete beams could be different in shapes and

sizes as shown in Figure 1. Even though large number of transverse
openings with various shapes and sizes might employ, but it is better to use
circular shape to make rooms for service pipes, for example electrical supply
and plumping, and using rectangular transverse opening through for
accommodating rectangular ducts of air conditioners.

Figure 1 different shapes and sizes of transverse openings in

concrete beams

In existing structures and buildings, creating transverse openings through

beams for better utilization and services above beam soffit other than dead
spaces could be detrimental potentially.
Problems related to transversal openings through beams can be avoided
provided that placements of utility services is planned and taken into
account previously but this is not the case most of the times.
Generally, there are two most common situations when drilling holes are
required which are during utility installation of recently constructed buildings
and in existing structures.
In the former case because of contractor request who want to save money
by rearrangement of pipe services that is not accounted for carefully in the
design stage.
These types of requests would endanger serviceability and safety of
buildings. The latter is when structural performance of an old building is
needed to be assessed. In this circumstances core sample of concrete is
taken out for testing purposes after that the opening is filled with grouts that
are non-shrinking.
The effects of openings in concrete beams on serviceability and strength of
the structure are discussed in this article.

Effects of Openings in Concrete Beams on

Serviceability
Effects on Cracks and Crack Width
It is demonstrated that beams with opening near center stub showed similar
crack pattern. Generally, flexural cracks are appeared ahead of shear cracks
but this pattern is reversed in beams with openings. If opening size is
increased, Loads that cause diagonal cracks and crack width will decline.
Moreover, it can be claimed that crack width is larger in beams with openings
than solid beams and exceed limitations of crack width irrespective of
location and size of holes. From this it becomes quite clear that serviceability
of cracks could extremely influenced by openings.
Moreover, there are various techniques that are used to repair beams which
are drilled for assessment purposes such as filling holes with unshrinking
grouts and externally bonded fiber reinforced polymer plate. The latter
method proved to be much more effective compare with the former.

Beams improved with externally bonded method provide much higher crack
control compare with grouting and even better than solid beams.
Furthermore, opening locations in beams affect the diagonal cracks and
changing locations could lead to narrowing crack width when openings are
close to center stub.

Effects on Stiffness and Deflection

The stiffness of beams after cracking is considerably affected by openings
and any increase in the size of holes will directly decline beam stiffness. In
contrary, there are no obvious or clear influences of the opening location on
the beams stiffness.
Openings in beams will lead to increase deflection without considering size
and location of openings. Consequently, this could be detrimental for
serviceability of the beams.
It should be said that beam strengthened with externally bonded plate
method entirely remove weaknesses that arise from openings. Additionally,
grouting improvement might make some improvement but it is not near
from the desired result.

Effects of Openings in Concrete Beams on

Strength
Effects on Ultimate Strength
Increasing opening sizes and changing their locations from the center stub of
the beam are obviously decreasing the ultimate strength of the beams.
When the openings are located close to the beam supports to skip failure
plane, the ultimate strength decreases compared with beams without
openings by more than ten percent. This could be resulted from cutting one
or more stirrups which decrease capacity to carry considerable amount of
applied shear.

In circumstances where the openings are drilled for estimating performance

of old buildings, different methods for example externally bonded fiber
reinforced polymer plate, grouting by using non-shrinking cement or any
other way can be employed to regain the ultimate strength of the elements.
Grouting might regain the beam strength to an extent, but it is around
twenty percent less than original strength. Externally bonded FRP plate will
be beneficial to regain the strength that has been lost as a consequent of
openings.
Finally, it is recommended to adopt a considerably large safety factor in the
original design or utilizing a promising technique such as externally bonded
FRP plate for regaining strength when an opening is made in an existing
beam.

CLASSIFICATION OF JOINTS AND THEIR DEFORMABILITY