LITERATURE STUDY PRECAST CONCRETE TECHNOLOGY

INTRODUCTION FRAME SYSTEMS

Precast concrete is a construction product produced by casting concrete Precast frames can be constructed using either linear elements or spatial
in a reusable mold or "form" which is then cured in a controlled beam-column sub assemblages. Connecting faces between the sub
environment, transported to the construction site and lifted into place assemblages can be placed away from the critical frame regions
.Producing in a controlled environment is properly cured and be closely
monitored. SLAB-COLUMN SYSTEMS WITH SHEAR WALLS
These systems rely on shear walls to sustain
 Speed-to-market Disadvantages
lateral load effects, the slab-column structure
 Quality & durability  Heavy members resists mainly gravity loads. two main systems
 Integrated project delivery  Cranes to lift panels • Lift-slab system with walls
 Enhances safety  Connections may be difficult • Prestressed slab-column system
 Sustainability  Need for repetition
 Optimization & flexibility  Skilled workmanship The slab panels are lifted to the top
 Fire resistant  Joints between panels of the column and then moved
downwards to the final position
TYPES OF PRECAST SYSTEMS The connections are then filled with concrete that is poured at the site.
• Large-panel systems
• Frame systems PRECAST CONCRETE STRUCTURAL ELEMENTS
• Slab-column systems with walls SLABS Flat slab Hollow Core slab
• Mixed systems Thickness 4", 6" and 8" 4", 6", 8", 10" and 12“
Spans 25’-0“ 40’-0"
LARGE PANEL SYSTEMS
panel width
They are multi-storey structures composed of large wall and floor 4’-0“ 4’-0"
Beams
concrete panels connected in the vertical and horizontal directions.
These panels form a box-like structure. Three configurations of large- Rectangular Beam Beam width = 12" or 16" spans 50’
panel buildings "L" and "IT" (inverted "Tee") beams
• Cross-wall systems Beam width 12" depths of 20", 28", 36", 44", 52" and 60"
• Longitudinal wall systems Double Tee Beam (DT)
• Two-way systems Spans 100’ width 8’ Depths of 12", 18", 24“, 32"
Single Tee Beam Spans 120’ width = 8’ depths of 36" and 48"
• Thickness of wall panels 120 mm f-interior
walls 300 mm for exterior walls Walls 8’-0" widths
• Floor panel thickness is 60 mm
• Wall panel length is equal to the room length,
of 2.7 m to 3.6 m

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LITERATURE STUDY PRECAST CONCRETE TECHNOLOGY
PRECAST COLUMNS TRANSPORTATION
Can either be done in CIS or precast, provided with corbel for simple beam
column connections Precast elements should be
PRECAST STAIRCASE loaded and delivered with
They can either be a single precast unit containing all flights and landings or proper supports ,frames ,
separate precast flights & landings cushioning and tie downs to
Weld Plates prevent in transit damage.
Attachment of precast members is by use of steel weld plates, the Adequate packing or protection
members have embedded plates that can be used as welding surfaces for to the edges of elements should
loose connecting plates or angles also be provided
Rebar and Grout
Reinforcing bars are spliced into slabs and grouted in place STACKING OF PRECAST MEMBERS
The storage support position
for beams and planks should
be within 300 mm from the
lifting points. Do not use more
than two support points in
particular for prestressed
The support spacers should
CONNECTIONS OF PRECAST CONCRETE ELEMENTS not be misangled Wall panels

PANEL CONNECTIONS HANDLING Columns handled in horizontal

Must be balanced and in line with their position slings are attached to
LOCATION WITHIN THE
CONSTRUCTION METHODS
centre of gravity. The lifting points facilitate rotation
BUILDING
located to limit the bending moments
DRY
JOINT
WET JOINT within the beam element . Multiple
VERTICAL JOINTS- HORIZONTAL JOINTS CONCRETE
CONNECT VERTICAL CONNECT HORIZONTAL
BY
BOLTING
POURED
BETWEEN
lifting points can be designed to
FACES OF ADJOING FACES OF ADJOING WALL OR
WALL PANELS AND FLOOR PANELS WELDING
PRECAST
PANELS FOR minimise undue stresses within the slab
CONNECTIVITY
elements
ISO CODES
IS 15916 : PRECAST
CONSRUCTION
IS 875 : DESIGN LOADS
IS 456 : CONCRETE
IS 1893& IS 13920 :SEISMIC
The entire joint is dry packed with grout after alignment DESIGN
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NET STUDY - PRAGATI TOWERS MUMBAI PRECAST CONCRETE TECHNOLOGY
PRAGATI TOWERS, MUMBAI
HEIGHT 70 m above ground. Each tower -300 apartments with a total
The wall were of shell elements and slabs are
construction area of around 2.6 million sq.ft.G+23 Storey ‘Total Precast
membrane elements. The floors are considered as a rigid
System’ in Seismic Zone-3,Mumbai.Innovative combination of ‘Modular
diaphragm to transfer the lateral forces to wall .The
units’ and ‘Large Panel system’ to suit the construction needs of the
horizontal joints simulate monolithic behaviour . In
project.
absence of a model for shear transfer the vertical joints
between the panels were modelled 2 conditions
INTEGRATED MODEL
DISCRETE MODEL
PROGRESSIVE COLLAPSE
The possibility of gas or other
WIND SPEED 44M/S explosions which can remove primary
Precast Elements were cast in controlled structural elements leading to progressive
collapse, which the failure or displacement of
factory conditions. Rigorous inspection at all
one element of a structure causes the failure
stages ensures smooth and high quality finish.
or displacement of another element
Reduction in wastage of materials as casting
Here tie reinforcements were provided
processes are carried out in stringent quality
horizontally, both internally and peripherally
controlled factory environment.
VERTICAL JOINT
RECORD ERECTION TIME Vertical joints are designed based on shear
Superstructure (1st Floor to 23rd Floor) of Tower A, friction concept as a global practice. Dowel bars
B & C completed in a record time of 12 months. are provided in the form of projected rebar’s.
Planned erection = 3 Dwelling Units/day shear keys to increase shear stiffness and the
Peak erection achieved at Pragati Towers = 10 Dwelling Units/day shear capacity.
EMULATIVE SYSTEM
It involve connecting reinforcing bars across a joint by lap splicing, CONCLUSIONS
welding or couplers. Concrete is made continuous by filling the joint Several aspects and standard practices used overseas were modified to fit
with high quality non-shrink non-metallic high strength grout in the Indian construction practice.
horizontal & vertical joints Emulative design approach was followed instead of jointed design
Battery Moulds – Specialized for high speed of production of Precast approach. Several methodologies were proposed and mock-up samples
Wall Panels without offsets and load tests of critical connections were completed to come up with the
Flat Bed Moulds – Specialized for Precast Wall Panels with offsets. final feasible options that would satisfy the design intent.

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 CASE STUDY DREAM ACRES ,BANGALORE PRECAST CONCRETE TECHNOLOGY
DREAM ACRES ,BANGLORE Building Data
Type: Township Area: 81 acres Column size (Base to 3rd) 300 mm × 675 mm
Column size (4th to 9th) 230 mm × 675 mm
No. of units: 6500
Column size (10th to 13th) 230 mm × 600 mm
1 BHK - 59 Sq. mts to 61 Sq. mts
Column size (14th to 18th) 230 mm × 525 mm
2 BHK Regular - 69.28 Sq.mt- 94. Sq. mts
Beam size = 230 mm × 450 mm
2 BHK Large - 87 Sq. mts - 112.Sq. mts
Thickness of slab = 115 mm
PROMINENT LOCATIONS Hollow core slabs - 150, 200, and 265 mm.
Sarjapur Marathahalli ORR 4.0 km Stair case slab thickness = 150
IT PARKS Embassy Tech Square 4 .4 km Parapet wall 1 m Height = 230 mm
MALLS Forum Value Mall 4.9 km Live load = 2 kN/m2 Floor Finish = 1 kN/m2
DREAM ACRES Yield strength of steel = 415 MPa
Density of concrete = 25kN/m3 5% Damping
Start year 2015
Hybrid design with precast & CIS together
End year 2016
Precast construction of beams, balcony, staircase, wall panels & hollow
Contractor SOBHA LTD- PRECAST DIVISION
core slabs .
Consultant VAN BOXSEL ENGINEERING, GURGAON
This hybrid design facilitated the overall faster
Overall built-up Area (Precast+CIS) 10 Million Sq. ft. erection and allowed for timely production &
Built-up area planned in Precast 3.79 million Sq. ft. delivery of other precast members.
Built-up area of A series (A1-A7) 8.82 lacks Sq. ft. The connection were simple and special dowel
Total apartments 1500 apartments; 12 Structural bars, corbels and provisions for connection were
system (Sub-structure) Raft foundation (CIS) planned in advance for the members as per the
Structural system (Super-structure) Hybrid Precast Const. Basement, design. M40 grade of concrete was used for all
Ground & terrace work Cast In Situ 1st to 18th flr the tilt elements and M60 was used for the
Total precast concrete volume (m3) ~ 16000 production of hollow core slabs.

After casting on the production line, the panel RESULTS

is brought to its final location for straightening • 6 buildings of 2B+G+18 floors were completed in 14 months of
and bracing installation. timeline with superior quality .
Locally sourced non-shrink grout is inserted • Achieved a slab cycle of 10-12 days for a slab area of 7000 Sq. ft.
into the cavity by injection. After injection, • Reduction in concrete & steel factor per Sq. ft. of built-up area.
the bracing around the precast panel may • Automation & mechanisation of construction project improved
then be removed after only 3 days overall productivity
• Improved site safety & considerable reduction in wastage,
noise on site, reduced ecological footprint of project.
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LIVE CASE STUDY &CONVENTIONAL CONCRETE QUALITY MANAGEMENT PRECAST CONCRETE TECHNOLOGY
INSPECTION
SHOBHA WINCHESTER PALLAVARAM CHENNAI
• Material inspection at supplier’s end
4.29 ACRES – LAND AREA
• Material inspection at the stage of receipt
STRUCTURE 38+G + 19 FLOORS
• Material inspection at the stage of issue
NO. OF BLOCKS 4 Blocks
• Inspection of the process at the time initial setting of
NO OF UNITS 344 UNITS
machine/equipment
TYPE OF UNITS 1,2,3,4 BED ROOMS
• Inspection of the trial run batch
• Inspection while the execution in progress
• Inspection of finished process
• Inspection before erection and commission
• Inspection of commissioning
• Inspection of machinery and equipment commissioned.

3 BASEMENTS +GROUND +19 storeyed RCC framed structure with CHECKLIST

concrete block masonry walls Following items must be checked by Quality Control Engineer
Column Size = 350 mm x350 mm 1. Preliminary 8. Plant and Machinery
Beam size = 230 mm × 450 mm 2. Proportioning 9. Batching & Mixing of concrete
Parapet wall 1 m Height =230 mm 3. Materials 10. Embedded parts
Live load = 2 kN/m2 4. Stockpiling 11. Reinforcements in place
Floor Finish = 1 kN/m2 5. Before concreting 12. Concreting
6. Formwork 13. After Concreting
STANDARDS AND SPECIFICATIONS FOR MAKING & TRANSPORTING 7. Gangway &ladders
CONCRETE QUALITY ASSURANCE ORGANISATION/ UNIT AT SITE
• Quality tests are conducted in laboratories and inspection.
The managerial process which determine the organisation’s design,
• Supervision are carried out on the site and
objectives and resources, the project team, funding agencies, performance
• The data analysis is done by experts in office
standards and feedback on the project’s performance, appropriate actions
SPECIFICATIONS
The quality control of concrete comprises of the following four to deal with deviations and all steps necessary for promoting quality
functions: awareness at all levels and in all parts of the project organisation.
• Control of ingredients of concrete viz. cement, coarse and fine • Setting up of standards and specifications
aggregates, water and mixtures. • Evaluating materials, processes and outputs through appropriate t
• Concrete mix proportioning of concrete mix design to attain the ests, inspection etc.
required strength specifications. • Appraising failures to these standard and acting when standards
• Concrete production and placement operations. are not being adhered to
• Acceptance. • Planning improvements in the standards and specifications.
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 PRECAST CONCRETE QUALITY MANAGEMENT PRECAST CONCRETE TECHNOLOGY
TRANSPORTATION AND ERECTION PRODUCTION CHECKLIST – CONTROL POINT PROCESS SEQUENCE
Height: 4 – 4½ m. Length: 22m. Transporting large box units by road can PRE - CASTING
cause problem. The width of the box is generally limited to a maximum of • Dimension
2.8m. In a case of housing unit, this restricts the room width of about 2.5m.• Angle of the Flanges
ERECTION TOLERANCE • Surface Finish
• Fixing & Lifting Mould Defects Application of
Release agent
CASTING
• Mix ratio as Specified
• Bag & Bucket Test
• Thickness of the Face Coat
• Thickness of the Back coat
INSPECTION ACTIVITY – MOULDS • Application of the Trowel Finishing work
CURING AND POST CURING
• Curing of the panels
• Stacking of the panels
• Dimension of panel after curing
• Bonding of Fixing & Lifting locations
• Acid Washing - Concentration & duration of wash
CHECKLIST • Acid Washing - Finishing work
FINAL PRODUCT FINISHING AND DISPATCH
1.Requirement/pre requisite prior to activity
Check and verify approved shop drawings ,method of statement and ITP • Panel Identification
• Filling & Final finish of the panels
2.Material inspection • Colour & Texture of the Panels
Verification of materials delivered on site are approved by the consultant • Storage of the panels
Ensure precast sample approval • Dispatching of the Panels
3. Activity of work
• Precast element check
 No broken edges or cracks in the panel
 Surface is free from oil grease ,dirt ,or any form of contaminants
 Check for level/even ness /finish of surface
 Texture and colour of the panel is as per approved sample
• Installation of precast panel
 Ensure layout and setting out as per approved shop drawings
 Ensure temporary support for pc element (if required)
 Ensure position alignment and plumb of precast elements within
tolerance
 Ensure grounding an sealant works found ok
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ANALYSIS & INFERENCE PRECAST CONCRETE TECHNOLOGY
DREAM ACRES VS SHOBHA WINCHESTERS Description Dream acres Shobha PRODUCTIVITY ANALYSIS
Sub structure 88 days 88 days The labour productivity of a precast
COST ANALYSIS structure is more, The variability of
Cost of precast may vary with the type and the size of construction. 480 days
Super structure 180 days the productivity in precast method is
Significantly Cost of construction is less in large size Projects in precast also small. The precast uses 20% less
as production is in bulk quantity so labour cost , steel, concrete wastage Finishing works 154 days 240 days concrete, 30% less steel, 50% less
and also finishing item cost will be less as compare to cast in situ. But 605 days manpower, and 50% less wastage
Total 450 days
transportation cost may be higher depend on distance between precast during construction
factory to construction site QUALITY ANALYSIS
S.N Elements Precast Conventional Difference In precast factory quality checking of each element is done at different stage.
Each stage have different check list. Only after quality supervisors approval after
1 Column Rs.165096 Rs.192420 27324 checking elements are promoted to next stage. Quality checking is starting from
2 Beam Rs.190602 Rs.225385 34783 mould preparation till erection at site. In controlled environment at factory desired
concrete properties can be achieved which may not be possible in case of cast in situ
3 Lintel Rs.11133 Rs.11632 499
projects because of environment factory
4 Slab Rs.281995 Rs.356044 74049
5 chajja Rs.16682 Rs.17316 634
6 Staircase Rs.19880 Rs.25416 5536
Total cost Rs.685388 Rs.828213 142825
COST ANALYSIS OF PRECAST VS. CONVENTIONAL
Description Dream acres Shobha
Carbon emission
Sub structure 2.4 cr. 2.5 cr. The carbon emission
comparing the precast
Super structure 6.8 cr. 8.2 cr. and Cast in situ differs
2.8 cr. only for 5%.Further study
Finishing works 4.5 cr.
should be made on
Total 12+2.5 =14.5cr. 15.2 cr. reducing carbon emission
on precast method
TIME COMPARISON
Compared to cast-in-situ method, the precast method consumes less time because
the prepared materials and elements are delivered just in time and placed on site.
Cast-in-situ method of concreting requires lots of time because concrete requires
minimum 28 days to achieve 99% strength of its total strength
To escalate the advantages of precast these two factors should be taken
• Design the building layout to maximize repetition of precast units.
• Design construction details to maximize the number of standardized
components.

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