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PRECAST CONCRETE STRUCTURES

1. INTRODUCTION
The concept of precast (also known as “prefabricated”) construction includes

those buildings, where the majority of structural components are standardized and

produced in plants in a location away from the building, and then transported to the site

for assembly. These components are manufactured by industrial methods based on mass

production in order to build a large number of buildings in a short time at low cost.
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The main features of this construction process are as follows:

 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..

This type of construction requires a restructuring of entire conventional construction

process to enable interaction between design phase and production planning in order to

improve and speed up construction.

1.1 TYPES OF PRECAST SYSTEMS

Depending on the load-bearing structure, precast systems can be divided into the following

categories:

 Large-panel systems

 Frame systems

 Slab-column systems with walls

 Mixed systems
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1. 1. 1 LARGE PANEL SYSTEMS

The designation “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 story high. Horizontal floor and roof panels span either as

one-way or two-way slabs. When properly joined together, these horizontal elements

act as diaphragms that transfer the lateral loads to the walls.

A large-panel concrete building under construction

Depending on wall layout , there are three basic configurations of large-panel buildings:

 Cross-wall systems

 Longitudinal wall systems

 Two-way systems
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1. 1. 2 FRAME SYSTEMS
Precast frames can be constructed using either linear elements or spatial beam-

column sub-assemblages. Precast beam-column sub-assemblages have the advantage that

the connecting faces between the sub-assemblages can be placed away from the critical

frame regions; however, linear elements are generally preferred because of the

difficulties associated with forming, handling, and erecting spatial elements. 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. The components of a precast reinforced concrete frame are

shown in Figure
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1. 1. 3 SLAB-COLUMN SYSTEMS WITH SHEAR 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

• Prestressed slab-column system

In the Lift –slab system, the load-bearing structure consists of precast

reinforced concrete columns and slabs,. Precast columns are usually two stories high. All

precast structural elements are assembled by means of special joints. Reinforced

concrete slabs are poured on the ground in forms, one on top of the other. Precast

concrete floor slabs are lifted from the ground up to the final height by lifting cranes.

The slab panels are lifted to the top of the column and then moved downwards to the

final position. Temporary supports are used to keep the slabs in the position until the

connection with the columns has been achieved.

A lift-slab building
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The prestressed slab-column system uses horizontal prestressing in two

orthogonal directions to achieve continuity. The precast concrete column elements are 1

to 3 stories high. The reinforced concrete floor slabs fit the clear span between

columns. After erecting the slabs and columns of a story, the columns and floor slabs are

prestressed by means of prestressing tendons that pass through ducts in the columns at

the floor level and along the gaps left between adjacent slabs. After prestressing, the

gaps between the slabs are filled with in situ concrete and the tendons then become

bonded with the spans. Seismic loads are resisted mainly by the shear walls (precast or

cast-in-place) positioned between the columns at appropriate locations.

Post-tensioned slab-column connection

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2. PRECAST CONCRETE STRUCTURAL ELEMENTS

1.1 Precast Slabs

Hollow core slabs

1.2 Precast Beam & Girders

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1.3 Precast Columns

Precast columns Inverted Tee beams supported on precast columns

1.4 Precast Walls

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1.5 Other Elements

2.

Precast concrete Stairs Uniquely shaped structural elements for a sports stadium
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DESIGN CONCEPTS FOR PRECAST CONCRETE BUILDINGS

The design concept of the precast buildings is based on the buildability,

economy and standardization of precast components.