What is precast structure

P A Precast is a smart way to build any type of buildings, safely

and affordably. Originally developed in the Nordic countries,
R modular precast is one of the world’s most common and
resource-
E efficient ways to build. It ensures faster construction times,
higher profitability and better quality. Still, requirements for
C beautiful, modern buildings are not compromised.

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•Precast is an industrialized way to build. It means transfer of work
T from sites to factories. This improves productivity and quality and
shortens construction time of a building. In short, precast concrete
lowers total construction costs considerably.
 Precast suits well for any type of building: residential, commercial, industrial, public to name a
few. There is a suitable solution for both indoor and outdoor production. The smart match can be
found for different capacities, end product and labour needs. Precast can be made into any shape
P or colour and finished with several techniques. This together with longer spans gives architects
and other designers more freedom than ever.
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Precast also has lower lifetime costs than any other building solution. It is
E possible due to consistent high quality of industrially produced products.
C Precast minimizes e.g. structural and facade maintenance needs during years.
•With precast, logistics needs are minimal. Precast floors, walls, frames and
A foundations are transported to a construction site ready-to-install. Logistics is
S arranged with just one delivery vehicle instead of several raw material
transfers back and forth.
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 The most common precast products are:
• Façades from sandwich to cladding and gray walls
P • Floors with hollow-core, half, ribbed or solid slabs
• Partition and internal walls from Acotec to solid walls
R • Foundations with precast concrete piles
E • Frames with e.g. beams, columns, slabs, etc.
• Stairs, shafts and other special products
C Precast offers a safer and healthier working environment.
A Material handling is easier and less scaffolding is needed.
Precast technology works in virtually all environments – cold,
S hot, moist or dry. Concrete hardens on site basically throughout
T the year, in temperatures from -15 to +40°C. To avoid too fast or
slow hardening in more hot, moist or dry climates, several curing
and concrete mixing solutions can be applied.
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C POPULAR USES OF PRECAST CONCRET
A Concrete curtain wall
S As an exterior cladding
For structural wall
T Ability to precast in three dimensions allows precast panels to form
parts of mechanical systems
 PRECAST USES FOR MANY TYPE OF
BUILDING:
P RESIDENTIAL,
COMMERCIAL,
R INDUSTRIAL,
E PUBLIC.

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 COST OF INSTALLATION PECAST

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P CONSTRUCTION CONSIDERATIONS
The contractor should consider the following:
R • All safety issues on site when handling precast elements, especially so when working
within a tight site
E • The lifting capacity of the crane used
• The working boom-radius of the crane
C • The suitability of construction materials for the purpose of use, i.e. sealant, grouting,
A shim plate, propping etc
• Co-ordination with the precaster and specialist supplier to achieve the best performance
S and working method - precaster often provide relevant technical requirements to the
contractor during the design development phase to avoid discrepancy
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E Precast walls are propped before The pour strip between 2 pieces of Precast planks are installed in
C casting of joints – proper planning
is required for perfect alignment
precast walls are cast place

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Preparation for casting of Preparation of welded mesh and Concreting to topping
landing slab to precast services for cast in-situ topping
staircase
 SEQUENCE OF WORK

P • Ensure the correct panel before hoisting

• Ensure the crane lifting capacity before hoisting the panel
R • Ensure the desired crane’s working radius
• Ensure the anchorage for the propping does not damage cast-in building
E services
• Ensure the desired Reduced Level (R.L.) of panel-base by adjusting the shim
C plate. Shim plate to be at an interval of 500mm c/c
A • Ensure the desired verticality/position is achieved
• Estimated time to install a typical precast element is 1/2 to 3/4 hour
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 Construction Requirements

P • Elements of control
Alignment, Verticality and Levels
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• Tolerance level
E 1. For Wall
C • Vertical deviation +2 mm, -2 mm
• Horizontal deviation 0 mm
A 2. For Beam & Slab
• Departure from intended horizontal position, +2 mm or –2 mm
S • Departure from intended vertical position, +2 mm or – 2 mm

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 The diagrams below illustrated the sequence of installation for the precast beam-slab system:

• Setting Out
P 1. Surveyor to set cross reference.
2. Transfer grid and mark wall position on slab.
R 3. Mark 100mm offset line from rear building edge.
4. Offset wall position by 200 mm.
E 5. Secure 2x2 timber to the floor at wall edge to guide wall.

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• Wall Positioning
A 1. The first wall in place has to be the partition wall at the
rear.
S 2. Mark a line parallel to and 100mm from the external
edge of the wall.
T 3. Place shim plate @~500 c/c on the floor and level to wall
soffit. Shim plate may also be placed on Non-shrink mortar
bed and allow to set.
4. Adjust position of the dowel bar.
 • Wall Adjustment
1. Position adjacent walls and plumb wall corners at 200 mm
offset
P 2. Adjust verticality until within +2 or –2 mm
3. Ensure the four faces of every walls are adjusted
R 4. Position string 250 mm from face of walls
5. Walls within the same line are to be adjusted within same
E tolerance
6. Ensure air-pocket is fully grouted.
C • Beam Setting Out
A 1. Cast wall joint.
2. Mark 1 m reference line.
S 3. Confirm pocket level. Position shim plate to correct beam
soffit level if required.
T 4. Mark position of beam on floor.
5. Hoist beam in place and check top level.
6. Plumb beam to verify position on floor below.
7. Ensure beam verticality with a spirit level.
8. Wedge beam against pocket and grout the gap between the
beam and the wall.
 • Slab Setting Out-I:
P 1. Position the slab temporary supports and adjust the
slab soffit level approximately.
R 2. Raise the height of the supports about 5 mm above slab
soffit level.
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• Slab Setting Out-II:
S 1. Hoist slab in place on top of beam and support.
2. Verify level of every plank soffit at four corners and
T center.
3. Adjust level of temporary support accordingly.
 • Staircase
1. Position landing or slab and verify soffit level at four
P corners.
2. Adjust level to within tolerance.
R 3. Position shim plates at staircase support location to
correct level.
E 4. Verify level difference between pegs on top and below.
5. Hoist staircase in place.
C 6. 10mm gap between precast plank and staircase

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 Precaution

P 1. Specify items which cannot be compromised

• Zero tolerance on partition walls.
R • Dividing boundary line between units.
• External building lines.
E • Staircase dimension.
• HS internal dimensions.
C 2. Alignment Priority
A • Alignment of grooves.
• Uniformity of grooves.
S • Horizontality of architectural treatment ie. Brick Tile

T Post Installation
1. Verify alignment and verticality of every wall.
2. Verify cast slab level at 1m grid.
3. Report deviation and rectify if required.
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P JOINING PRECAST
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 1.Example Column-to-Column Connection
Metal bearing plates and embedded anchor bolts are cast into the ends of the
P columns. • After the columns are mechanically joined, the connection is grouted
R to provide full bearing between elements and protect the metal components
from fire and corrosion.
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A THE ENTIRE JOINT IS
S DRY-PACKED WITH
GROUT AFTER
T ALLIGNMENT

BEFORE ASSEMBLY ASSEMBLED GROUTED

 2.Example Beam- to-Column Connection
• Beams are set on bearing pads on the column corbels.
P • Steel angles are welded to metal plates cast into the beams and columns and
the joint is grouted solid.
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COLUMN BARS
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COLUMN TIES
C WELL PLATED
CAST INTO BEAM
A WELL PLATED
CAST INTO
S COLUMNS

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STIRUPS
 3. Example Slab-to- Beam WELDED ANGLED
CONNECTOR
Connection
P • Hollow core slabs are set on
R bearing pads on precast GROUT
beams.
E • Steel reinforcing bars are in
C inserted into the slab keyways
to span the joint.
A • The joint is grouted solid.
• The
S slab may
unstopped as shown, or
remain
BEARING PAD
T topped with several inches of
cast in place concrete.
 PRECAST CONCRETE STRUCTURAL
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ELEMENTS
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 1. Precast Concrete Slabs
• Used for floor and roof decks.
P • Deeper elements (toward the right
R below) span further than those that are
shallower (toward the left).
E • Right: Hollow core slabs stacked at the
C pre casting plant

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 2. Precast Concrete Beams and Girders
P • Provide support for slabs.
• The projecting reinforcing bars will bond with concrete cast on site.
R • Right: Inverted tee beams supported by precast columns.
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 3. Precast Concrete
P Columns and Wall Panels
• Provide support for beam and
R slab elements.
E • Since these elements carry mainly
axial loads with little bending
C force, they may be conventionally
A reinforced without pre stressing.
• Or, long, slender multi story
S elements may be pre stressed to
T provide resistance to bending
forces during handling and
erection (columns at right).
 4. Precast Concrete Columns
and Wall Panels
P • Precast concrete wall panels may be solid
R (right), hollow, or sandwiched (with an
insulating core).
E • Wall panels can be ribbed, to increase
C their vertical span capacity while
minimizing weight, or formed into other
A special shapes (below).
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 5. Other Precast Concrete
P Elements
• Precast concrete stairs (below)
R • Uniquely shaped structural elements for
E a sports stadium (right)
• Etc.
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 6. Assembly Concepts for
Precast Concrete Buildings
P • Vertical support can be provided by
R precast columns and beams
(above), wall panels (below), or a
E combination of all three.
C • The choice of roof and floor slab
elements depends mainly on span
A requirements.
S • Precast slab elements are frequently
also used with other vertical
T loadbearing systems such as
sitecast concrete, reinforced
masonry, or steel.
 ADVANTAGES AND DISADVANTAGES
ADVANTAGES
 Quick erection times.
P  Reduced need for plant on site.
R  Easier management of construction
sites.
E  Better overall construction quality.
 Ideal fit for simple and complex
C structures.
A  The forms used in a precast plant
S nay be reused hundreds to
thousands of tines before they have
T to be replaced, which allow cost of
formwork per unit to be lower than
for site-cast productions.
DISADVANTAGES
 Very heavy member
 Camber in beams and slab
 Very small margin for error
 Connection may be difficult
 Some limited building design
flexibility
 Because panel size is limited
precast can not be used for two
way structure systems
 Economical of scale demand
regular shaped building
 Joints between panels are expensive
and complicated
 Cranes are required to lift panels