2023-24

PRECAST RCC
STRUCTURE

KARTIK JAIN
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CONTENT
1. INTRODUCTION
2. PROS & CONS
3. TYPES OF PRECAST SYSTEM
4. ELEMENTS OF PRECAST SYSTEM
5. STRUCTURAL CONCEPT
6. TYPICAL CONNECTIONS
7. CASE STUDY - 1
8. CASE STUDY - 2
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INTRODUCTION
• Precast concrete means a concrete member that is cast and cured at a
location other than its final designated location. 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.

PROS & CONS OF PRECAST CONCRETE

• There are many different kinds of precast concrete products and many
benefits of using these products for various structural purposes. Precast
concrete can be used to create road barriers, building segments such as
walls, and a wide range of shapes and sizes of blocks. Some things to be
aware of when looking at using precast concrete for a job include:

• BENEFITS OF PRECAST CONCRETE

SAVING TIME
Because the parts being used come already created, no time is wasted forming,
framing, pouring, or curing. The project can begin right away.

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UNIFORMITY
Because the concrete components were put together in a factory using the same
moulds over and over, it is fairly easy to maintain uniformity among the precast
concrete components.

HIGH-QUALITY PRODUCTS
Precast Concrete products are monitored and quality checked before going to
the jobsite. The curing process can be watched to ensure that no deformities
occur. Because this form of concrete is cast in a controlled environment, these
products can be more durable and long-lasting than other types of concrete.

SAVING MONEY
Using precast concrete can help to save money by reducing the time spent on a
project and by being less expensive than many other construction materials.

• PRECAST CONCRETE DIFFICULTIES

TRANSPORTATION
It can be complicated to move precast concrete to a jobsite. The weight of the
concrete can do damage to many types of trucks, and it is important to keep it
stable so that the concrete pieces are not compromised. Special transportation
methods, such as picker trucks, are often required.

INSTALLATION
In most cases, mobile cranes are required to install large pieces of precast
concrete. When planning a project that involves this material, it is important to
plan ahead and account for crane rentals.

MODIFICATION
It is extremely difficult to modify a piece of precast concrete if it does not fit its
placement. In many cases, if the precast concrete component is not a perfect fit,
the proper materials must be ordered and brought in. Without careful planning,
this can cost more money and take much more time.

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TYTPES OF PRE CAST SYSTEM

1. Large Panel System
Large panel systems are useful for the
construction of apartments and hotels. It
consists of large walls and floor concrete
panels connected in the vertical and
horizontal directions. Both horizontal and
vertical panels withstand gravity loads.
There are three arrangements of large
panel system based on wall layouts which
include cross-wall system, longitudinal-
wall system, two-way system.

2. Frame System
It is suitable for the construction of car
parks, stadia, and offices. Precast frames
can be constructed using either linear
elements or spatial beam-column sub
assemblages. Precast beam-column sub-
assemblages have the advantages 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.

3. Slab-Column System with Shear Wall

In this system, gravity loads supported by
slab-column structure whereas shear walls
withstand lateral loads. There are two
types of slab-column system with shear
walls namely; lift slab system with walls
and pre-stressed slab-column system.

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ELEMENTS OF PRE CAST SYSTEM

• Precast Beams:
There are two main categories of
beams:
Internal beams – where floor loading
is approximately symmetrical
External beams – where floor loading
is predominantly non-symmetrical.
• 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
Hollow cored slab Double tee slab

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• 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.

STRUCTURAL CONCEPT
Based on considerations of buildability, economy and standardisation of
precast components, the structural concept developed consists of:
• Conventional foundations comprising footings, raft slab or piles and pile
caps.
• Cast in-situ first storey, typically reinforced concrete beam and slab system.
• Precast concrete load bearing walls.
• Precast concrete non-load bearing façade panels.
• Precast concrete floor system, either: - Precast concrete beams and precast
slabs (reinforced concrete or pre-stressed) with a composite in-situ topping or
Precast concrete walls with precast concrete slab system

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TYPICAL CONNECTIONS OF PRECAST

CONCRETE ELEMENTS
• Column to column Connection:
Precast columns can be designed as single-storey or multi-storey components.
One possible solution of a connection between precast concrete columns is the
use of grouted splice bars. In column splice connections, the lower concrete
column has projecting reinforcement bars that fit into sleeves in the upper
element . The upper element is lowered into position and temporarily braced
during grouting. A levelling pad must be provided for a correct position in the
vertical direction. The detailing and execution should ensure that there is no
concentration of vertical stresses in the completed connection caused by the
levelling pad

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• Beam to column connections

An experimental investigation was conducted to study the behavior of semi rigid
precast beam-column connections subjected to simulated seismic forces. Four
full- scale interior beam-column assemblies representing a portion of a frame
subjected to simulated seismic loading were tested, including one monolithic
specimen and three precast specimens. The behavior differences of these types
of connections with respect to strength, ductility, stiffness, energy dissipation,
and deterioration at the joint core are presented and discussed. Test data showed
that properly designed precast beam-column connections maintained ductility
and strength and exhibited excellent energy-dissipating capacity when subjected
to large inelastic deformations under load reversals.

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• Beam to slab joint:
In the beam to slab joint, the slab is
placed with the connection of the
beam. It is properly attached with the
beam. It is also known as column-
beam-slab connection. The hollow
core slab is used as prefabricated slab
because is easily attached to the
beam.

• Wall to slab connection

Slab to Wall Connections Projections in
precast concrete walls to support the
inverted-tee beams or the double-tee floor
slabs. Beam to Column Connections
Projecting Bracket.

• Column to foundation connections

The method of connection to the foundation and to the column above will vary
with manufacturer. Foundation connection may be via a base plate connected
to the column or by reinforcing bars projecting from the end of the column
passing into sleeves that are subsequently filled with grout. Alternatively, a
column may be set into a preformed hole in a foundation block and grouted
into position. Column to base connections may be by threaded rods joined with
an appropriate connector; with concrete subsequently cast round to the
dimensions of the cross-section of the column. Precast Concrete Extra Details
Partial precast concrete hollow core slab over metal hanger to provide an
opening. Lifting hooks are very important component in precast concrete units.

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CASE STUDY

Project: Mercy Health-West Hospital

Location: Cincinnati
Architect: Champlin
Architecture Engineer of Record: THP Ltd.
Contractor: Turner Construction Company
Owner: Mercy Health Partners Project Producer and Precast Specialty Engineer:
High Concrete Group
Features: The total project cost was $200 million.
The goal was to design and build a six-story, 645,000-square-foot hospital clad in
colorful glazed tiles on a thin-brick veneer. Architectural precast concrete panels
were embellished with 160,000 pieces of glazed tiles in multiple shapes and colors.
Insulated precast concrete sandwich wall panels feature two pre-stressed solid
concrete wythes with steel and wire-mesh reinforcement. The new state-of-the-
art Mercy Health – West Hospital in Cincinnati would become a centerpiece for the
health-care center, replacing another aging facility within the network. The owners
wanted a design that was both beautiful and high performing, and designers
turned to precast concrete to make that happen.

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CASE STUDY
Project: Jindal Global City
Location: Sector 35, Sonipat -131001
Project Ownership: Jindal Realty
Area: 214 acres

• Situated at a prime location of Sector 35, Jindal Global City is a meticulously

designed project of Sonipat. Jindal Sonepat Global City township is
conveniently located just 2kms KMP Expressway, KGP Expressway and NH 1
junction.
• The residential plots are well planned with all the prime civic elements like
water resource, electricity connection and the underground drainage system is
also well-constructed. Jindal Realty Sonepat reviews are highly favourable and
the flats are carefully designed for great ventilation and good natural light

MANUFACTURING PROCESS:-

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• Procurement of concrete materials: It is the process in which concrete

material is selected, ordered or bought for the required construction. This
process also involves identifying the suppliers, negotiating prices, terms and
conditions, awarding contracts, etc. In simple words, it is the purchasing
process of concrete materials.

• Storage and handling: The storage of cement should be in the waterproof shed
and kept dry. It should be carried safely from one place to another. There
shouldn’t be any leakage in the storage shed. The roof of the storage should be
waterproof so that rainwater penetration should be controlled.

• Batching of concrete components: It is the process in which the materials used

for the construction of concrete components are measured on the basis of
volume or kilograms to prepare the concrete mix. It also involves the
workability of concrete by reducing the bleeding in concrete.

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• Laying of concrete in required formwork with or without reinforcement as per

design: In this process, concrete is filled in the mould or form to get the required
shape for the construction. In case of reinforcement, the reinforcement is
properly tied up according to the need and set up inside the mould. After this
setup, the concrete is filled up inside the mould and treated in a controlled
environment to get the required result. In case where reinforcement is not
required then the concrete is directly filled into the mould and treated
accordingly.

• Concrete compaction: It is the process in which the extra air is expelled out from
the freshly prepared concrete. This process helps in increasing the density of the
concrete. The load is provided on the freshly prepared concrete, which makes the
aggregate closely packed and increases the density of the concrete.

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FOUNDATION
• 11ft deep foundation bed.
• Shear walls are used as foundation.
• Before the beginning of super-structure
starter filling is done so that the form
work can rest on it.

SLABS
• The slabs have an upliftment so that when force
drops on it won’t bend.
• The slabs are pre-stressed.
• Pre-cast slab has LMNR reinforcement for better
strength.
• Hollow slabs are made to minimize weight.
• These also helps in thermal insulation.

WALLS
• 1 wall panel weighs 9 tons app. and is
usually 12 ft. high.
• 2 walls are joined with help of 12 mm
TMT wire and grouting.
• Groves in panels are provided for
electrical and plumbing purposes

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