Precast Concrete

PRESENTED BY,
ARSHIYA SYED
PRIYANKA BOBAL
FARAH WAHAJ
MADHU KUMAR
SUMEDHA
RASHI
RITU
MAYANK
DHIRAJ

RCC STRUCTURES

Reinforced concrete is concrete in which
reinforcement bars ("rebars") or fibers have
been incorporated to strengthen the
material that would otherwise be brittle

Concrete Mix
Tied
Rebar

The use of reinforced concrete is a relatively
recent invention, usually dated to 1848 when
jean-Louis Lambot became the first to use it

Joseph Monier, a French gardener, patented a
design for reinforced garden tubs in 1868,
and later patented reinforced concrete beams
and posts for railway and road guardrails

Precast Concrete

"Precast concrete" means a concrete
member
that is cast and cured at a location other than its
final
designated location
Precast concrete blocks
History
Material in RCC
Concrete is a
mixture of Portland
cement and stone
aggregate.

Stone aggregate
can be made up
from small grains of
sand, fist-sized
rocks, or a
combination of
sizes.
Material In Precast
Precast concrete members may be solid or
may contain hollow cores. Many precast
components have thinner cross sections than
cast in place concrete. Precast concrete may
be either normal or lightweight concrete.

Solid Precast Blocks
Hollow Precast Block
Concrete Masonry Units (CMU)
Block is typically formed with large hollow
cores. Block with a minimum 75% solid cross
section is called solid block even though it
contains hollow cores. In many cases,
building codes require steel reinforcing bars
to be placed in the hollow cores, and the
cores to be filled solid with grout.
CMU
Slag Masonry units
It is highly
unsusceptible to
fire and due to
its cellular
structure, has
high sound and
thermal
insulation
quality.

Slag concrete masonry units
have low drying shrinkages.

Slag concrete
masonry units have a
great effect on both
sound absorption and
the reduction in sound
transmission through
walls.

About Precast
Theoretically there
are no restrictions
on the use of
skeletal framed
precast
construction.
Irregular and
challenging
architectural
designs on many
occasions are more
suitable to
precasting.
Suitability of precast construction
Off-site manufacture

The manufacturing of the major
components of the building off-site reduces
the site labour component dramatically,
which in turn, reduces site costs and time.

The erection crew, necessary for precast
construction, will usually consist of only
about 5-6 people, rather than the several
dozen required for in-site construction.



Quality Control
The production of
components off-site,
in a factory
environment allows
each of the facets
involved in
manufacturing to be
strictly controlled,
and hence, optimum
quality to be
maintained.

Architectural finishes
including colours,
surface finishes and
carefully moulded
surfaces allow the
designer considerable
flexibility in the overall
aesthetic appearance of
a structure compared
with conventional
methods.
Appearance and
Finishes

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The erection
procedure, and in turn
the design of the
structure is very much
affected by the weight
and size of the
individual
components. The
transport of the
components is
typically by truck and
as such, it is
imperative to be
aware of allowable
component sizes and
weights. Site
accessibility for
trucks must also be
considered
The selection of crane type and size is
an important ingredient to the viability of
the precast structure. Mobile cranes are
generally the most economical, with the
new generation of high capacity and
highly maneuverable machines allowing
the use of larger components and
access to more restricted sites.


Cranage

Ten times stronger than a block foundation
It prevents water infiltration and moisture build-up.
They keep houses warmer and drier than
conventional foundations while adding valuable living
space and increasing resale values

To enhance strength and durability, they
are manufactured with steel-reinforced concrete
studs, rigid insulation(optional), a reinforced top and
bottom bond (footer) beam and a 2-inch thick
concrete facing.



Foundations can often be installed in
under five hours using a pre-cast
concrete system.
The bond beams and
concrete facing are cast in
one continuous pour. They
connect to the studs by
encapsulating vertical
rebars and galvanized
hooks and pins which
protrude from the top,
bottom and back of each
stud.



A crane is used
to lift the pre-
cast foundations
walls into place

Prep work on the
crushed stone sub-
footer.
Once panels are
erected, sealed, and
bolted together, the
basement slab is
poured. Floor joists
above the foundation
are conventionally
installed and provide
some of the bracing for
the foundation walls.
Once braced by the
slab and floor system,
backfilling against the
walls can take place.



Precast piles
Typical shapes of precast prestressed
concrete piling are square, hexagonal,
octagonal and round - with a solid or hollow
core. Piles are designed to resist
compression, tension, bending and torsion
forces during the manufacturing,
transportation, handling and installation so
the structural integrity and design purpose
are achieved.

A beam is a structural
element that carries
load primarily in
bending (flexure).
Beams are
characterized by their
profile (the shape of
their cross-section),
their length, and their
materials.

Precast beams
Laying precast beams

Precast prestressed
concrete rectangular
beams with simple
support
Precast prestressed concrete ledger
beams with simple supports
L beam
T-Beams
L- Beams
A column is a part of a
structure whose
purpose is to transmit
through compression
the weight of the
structure. Columns are
frequently used to
support beams or
arches on which the
upper parts of walls or
ceilings rest.
Precast columns
Column original cored
out.
Bench running the
original column

Precast columns can be produced as either multi-
storey corbelled columns or single floor-to-floor
elements


Single storey
reinforced
columns are
simple to design,
detail and
construct.
Extra
reinforcemen
t is usually
provided at
the top and
bottom of the
column,
these
additional
ties act as
anti-splitting
reinforcemen
t


The base connection is
generally analyzed as a
pin joint and due to
connection details the
columns tend to be
conservatively sized,
manufactured with high
strength concrete, and
reinforcement typically
limited to four corner
bars with nominal ties.
This approach results
in extremely simple
components that can
easily be mass-
produced.



Benefits of Precast Beams and Columns

Maximum durability and structural strength

Excellent for fast-track construction

Can be manufactured and erected during
inclement weather

Provides superior loading and clear spans

Cuts overall construction costs

3 Precast Floor Systems

There are numerous precast flooring components
to choose from, including
Hollow core slabs
Composite Beam / Slab (Ultra floor / Transfloor)
Composite Prestressed Planks (MiniSlabs)
Single and Double Tee components

Hollowcore slabs are manufactured on
long line casting beds (over 100 meters in
length) and saw cut to the required length
after curing.
A dry cast extrusion system in which a
very low sump concrete is forced, or
extruded, through a machine.
A wet mix method in which a higher sump
concrete is poured in two or more layers
by a machine similar to a large kerb and
channel machine.


The hollow
core slabs are
oriented to
either span
between load
bearing shear
walls or to span
from the central
corridor to an
exterior wall.
Slabs can be cantilevered up to 1.8 ft (6 m) to form
exterior balconies.

Slab resting over
T-beam
Composite Beam / Slab
Composite Prestressed Plank
Is a precast, prestressed thin concrete plate which contains
bottom prestressed steel and with a very rough surface and a very
smooth bottom used as a slab.
A worker
carefully
fits the
concrete
slabs into
place

Double tees used for spans and loads that
exceed the capacity of hollow core slabs
(parking garages, swimming pools, food
processing, large industrial buildings, etc.).

Double tees are
ideal for floor
and roof systems
requiring
medium to long,
uninterrupted
spans and heavy
load carrying
capabilities

The cast in
place concrete
characteristics
of the system
offer unlimited
architectural
freedom in
shape design
From the drawings, Engineers will determine the
optimum arrangement of steel reinforcement,
concrete and lattice and provide all necessary
calculations prior to manufacture and then the slab is
precast .
FINISHED CEILINGS
FIRE RESISTANCE
SOUND PROOF
EARTHQUAKE
RESISTANCE

Applications
- Housing
- Office and
Warehouse
- High rise
Building
- Jetty and
Harbour Slab
- Bridge
- Plant
- Any floor
construction

Merits of the precast
slabs
Prestressed Lintels
Precast lintels
are easy to
install, and offer
significant
advantages
over those
poured in place
Precast lintels
save time and
money by
eliminating
unnecessary
man hours in
the preparation
of forms, cutting
rebar, concrete
pouring, and
curing.
No need to fabricate steel
angles to span openings and
rust proofing is not required.

Precast Walls some consist of steel-reinforced
concrete ribs that run vertically and horizontally in the
panels. Others are solid precast concrete panels.

Horizontal light wall
Vertical Light
wall
Precast wall panels
offer many benefits
Uniformity of joints
Modular dry fix panels
Ease and speed of
installation
Standard size panels
The advantages of
quality control
Precast stair
flights are
manufactured to
incorporate the
stair flight and
landings as a
refinished product.
They are designed
in a similar fashion
to standard in-site
stair flights and
landings with
special attention
required in the
detailing and
connections.


Precast Staircases





Spandrels
Non load
bearing
Load bearing spandrel
Structural spandrel
Sandwich
spandrel
Architectural spandrel
Precast stair flights are manufactured to incorporate the stair flight and landings as a refinished product. They are designed in a similar
fashion to standard in-site stair flights and landings with special attention required in the detailing and connections.


Precast stadium seats
, precast balcony units
Installation very easy.
No footing required.
It needs to go only 3-4 feet into the earth.

Precast fences
Precast fences
Comes in
many textures
Maintenance
not required
Made of steel
reinforcement
so it is more
durable and
strengthened.

PRECAST
ORNAMANTATION
UNITS

PRECAST ARCH

Providing and fixing precast plain cement concrete 1:2:4 (1 cement : 2 sand : 4 well
graded stone aggregate 20mm) in string courses, bands, copings, bed plates, anchor
blocks, plain window sills and the like including centering and shuttering and finishing
smooth with 6mm thick cement plaster 1:3 (1cement : 3 fine sand) on exposed
surfaces complete upto floor five level.
Rs.5,355.90
Providing and fixing precast reinforced cement concrete 1:2:4 (1 cement : 2
sand 4 well graded stone aggregate 20mm) in string courses, bands, copings,
bed plates, anchor blocks, plain window sills and the like including centering
and shuttering and finishing smooth with 6mm thick cement plaster 1:3
(1cement : 3fine sand) on exposed surfaces complete but excluding cost of
reinforcement upto floor five level.
Rs.5,415.80
COST ESTIMATION
Providing and laying precast cement concrete hollow blocks of standard size
39cm x 19cm x 9cm in cement mortar 1 : 4 in superstructure including curing
etc. complete
Rs.389.60 sq.mt
Providing and fixing 15cm dia at top and 20cm at bottom 90cm high
precast RCC 1:2:4 (1 cement : 2 coarse sand : 4 graded stone
aggregate 20mm size) boundary stone as per standard design including
smooth finishing with cement mortar 1:3 (1cement : 3 fine sand), curing
etc. complete. (excluding cost of excavation, refilling and concreting).
Rs.245.10 each
Providing and fixing precast Rcc standard post 1.8m long concrete 1:2:4 (1
cement : 2 coarse sand : 4 well graded stone aggregates 12.50mm size)
standard posts with wooden plugs or 6mm bar nibs including smooth finishing
with cement mortar 1:3 (1cement : 3 fine sand), curing etc. complete.
(excluding cost of excavation, refilling and concreting).
Rs.384.90 each
The Double-storey Verandah With Its
Signature 63-metre-long Precast
Concrete Screen.

No false work is necessary
Can be placed across highways in service
Short delivery time
Does not require skilled labor for erection
Bottom surface is smooth
Thinner deck resulting in higher vertical clearance
Fast construction
Economical construction
Provides a precast solution with a range of sizes
Provides a safe working platform