INTRODUCTION
Precast Concrete is a construction product produced by casting concrete in a reusable mold or "form"
which is then cured in a controlled environment, transported to the construction site and lifted into
place. In contrast, standard concrete is poured into site-specific forms and cured on site.
also known as "prefabricated“
produced in plants in a location away from the construction site
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.
PRE-CAST CONCRETE PRODUCTS
Precast concrete building components and site amenities
Earth retaining systems
Sanitary and Storm water management products
Precast concrete transportation products
Marine Products
Pre-stressed / Structural Products
PRECAST IN BUILDING
A whole building can be construct.
Precast beams, columns, footings, floors, roofs, walls and stairs
Erection on site with care
Depending on the load-bearing structure, Precast buildings by former Soviet Union and Eastern
European countries can be divided into the following categories:
· Large-panel systems
· Frame systems
· Slab-column systems
LARGE-PANEL SYSTEMS
"large-panel system“ composed of large wall and floor concrete panels connected in the vertical and
horizontal.
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.
FRAME SYSTEMS
Precast frames can be constructed using either linear elements or spatial beam-column sub-
assemblages.
The connecting faces are at the beam-column junctions.
The beams can be seated on corbels at the columns, for ease of construction.
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.
CARE TO TAKE AT PLANT
Once a piece has been fabricated, it is necessary to remove it from the mold without being damaged.
Breakaway forms should be used to allow a member to lift away from the casting bed without
becoming wedged within the form
Orientation of members during storage, shipping and final in-place position is critical
Sand bed will help protect edge
Tilt tables or turning rigs are used to reduce stripping stresses
Warpage in storage may be caused by
▪ temperature or shrinkage differential between surfaces
▪ creep
The member should be oriented in the yard so that the sun does not overheat one side
CARE TO TAKE DURING TRANSPORTATION
Lifting points must be located to keep member stresses within limits and to ensure proper alignment
of the piece as it is being lifted
Members with unsymmetrical geometry or projecting sections may require supplemental lifting
points to achieve even support during handling
“Come-alongs” or “chain-falls” are frequently used for these auxiliary lines
When the member has areas of small cross section or large cantilevers, it may be necessary to add a
structural steel “strong back” to the piece to provide added strength
temporary loads
The loads and forces on precast and pre-stressed concrete members during production,
transportation or erection will frequently require a separate analysis
Support points and orientation are usually different from members in their final position
it may be necessary to cast in extra lifting devices to facilitate these maneuvers.
The number and location of lifting devices are chosen to keep stresses within the allowable limits
special handling required by the design should be clearly shown on drawings
Cost Analysis Model for Precast Technology
When it comes to the superstructure, the cost analysis for the precast building is entirely different.
Conventional buildings shall have a traditional way of construction with formwork, rebar, and concrete
whereas precast building will have precast segments, elements, their production cost, transportation cost
and erection cost. Finishing works for the superstructure would have the same cost implication on the precast
and conventional method of construction. The difference would arise with respect to the post concrete costs
which is clearly visible from figure It can be inferred that the quality of surface obtained with precast is
superior to the surface achieved with conventional construction. In addition to direct costs, a considerable
difference would be there in indirect costs owing to the reduction in project duration. As a burden to the
present costs, we have excise duty, and Value Added Tax (VAT) applied to production cost for precast elements
which is absent in conventional cost model.
Based on the extensive literature review, following cost analysis model for an Indian precast building,
in
comparison to conventional, is formulated as shown in Figure
Cost model highlights that substructure cost would
be the same for both conventional and precast building as both the buildings would have a
conventional foundation
CARE TO TAKE DURING ERECTION
Columns with eccentric loads from other framing members produce side-sway which means the
columns lean out of plumb
A similar condition can exist when cladding panels are erected on one
side of a multistory structure
Unbalanced loads due to partially complete erection may result in beam rotation
The erection drawings should address these Conditions
Some solutions are:
Install wood wedges between flange of tee and top of beam,
Use connection to columns that prevent rotation,
Erect tees on both sides of beam
Rotations and deflections of framing members may be caused by cladding panels. This may result in
alignment problems and require connections that allow for alignment adjustment after all panels are
erected
Careful planning of the erection sequence is important
CARE ON SITE OF CONSTRUCTION
The project can be economical, considering the following factors:
▪ Stability and stresses on the element during handling
▪ Transportation size and weight regulations and equipment restrictions
▪ Available crane capacity at both the plant and the project site.
▪ Position of the crane must be considered, since capacity is a function of reach
▪ Storage space, truck turning radius, and other site restrictions
CASE STUDY
Koshland Integrated Natural Science Center
Located on the Haverford College campus
4-story laboratory facility with basement
Also contains classrooms, offices, & communal spaces
Total area 185,423 ft2
Total project cost of $42.6 Million
Construction was done in phases
The work was completed in 6 months
Superstructure – Precast concrete framing
Precast beams : 24”x12” spanning 21’
Precast columns : 16”x16” & 20”x20”
Foundation – (concrete masonry unit) CMU foundation/retaining walls, precast piers
Floor System – 10” precast plank with 2” topping
Façade – Stone & precast panels
Roof System – Steel framing with metal deck; precast plank
Typical story height of 13’
Objectives & Methodology
Primarily, this research focusses on identifying the opportunities and challenges associated with the
implementation
of precast technology in India. To achieve the goal set for the research, the following objectives were
formulated:
To present a cost model for precast technology in comparison with conventional methods of construction
for a building project
To analyze time and cost for precast projects in comparison with conventional method of construction
To determine the major challenges that are faced by precast technology at a project site and industry
level
To provide amicable solutions to the challenges faced by precast technology
To achieve the above objectives, following steps were planned (as shown in Figure 1):
Understanding the national and international perspective of precast technology through literature
review
PRECAST IN BRIDGE
Bridge can also construct with precast.
Parts of a bridge, Substructures and superstructures
In India growth of precast in bridge is slow
But, Precast is growing continues very rapidly in other countries, not only for bridges in the short span
range, but also for spans in excess of 45 meters.
Based on type of bridge and site condition method of construction is to be adopted.
TYPES OF BRIDGES
Culvert
T-Beam deck slab bridge
Arch bridge
Cantilever bridges
Continuous bridges
Suspension bridges
Cable-stayed bridges
PRECAST BRIDGE CONSTRUCTION
T-Beam deck slab bridge
Simplest type of Precast bridge, most of the bridges in India are of this type
Sub- structure is cast in situ
In superstructure, Main girders are precast post tensioned, casted away from site and are transported
to site.
Secondary girders and Deck slab are casted on Precast post tensioned girders on site or precast slab
can be used.
PRESTRESSED GIRDERS
Post tensioning technique is to be used in girders
In post tensioning, the concrete units are casted bye incorporating duct to house the tendons, when
concrete attains sufficient strength, high-tension wires are tensioned bye means of jacks, after then
the duct is grouted.
Forces are transmitted to the concrete at the end anchorage
PRESTRESSED GIRDER MAKING
CARE TO TAKE
During designing all the loads are to considered and losses are also to be considered as per IS1343
for pre-stressed concrete.
Casting and curing is to be done properly for quality concrete. Suitable method of post tensioning is
to be adopted.
Casted elements are to be stoked care fully, details should be given by designer for storing members.
Transportation is to be done carefully to avoid damage to the precast elements.
Erection process is to be well decided and planed based on type of bridge and site condition.
HANGZHOU BAY BRIDGE
ADVANTAGES
Prestressed concrete bridges are usually lower in first cost than all other types of bridges.
With savings in maintenance, precast bridges offer maximum economy.
Every operation in the manufacturing process provides a point of inspection and control over quality
Faster construction
Concrete is cast off site
Identical forms can used several times
Batter quality control
Control on curing
Un affected by weather , when casting
Construction in less time
Less cost
Waste materials can be used ( fly ash)
Fire resistant
Can avoid air born pollution on site ( dusting )
Formwork of the superstructure can be eliminate
Piers, Abutments and wing walls can be made of precast concrete pieces quickly assembled on the
field.
Precast concrete bridges can be installed during all seasons
The durability of precast prestressed concrete bridge is good and the resulting low maintenance
requirements.
No painting is needed.
Superstructure can be made as shallow as possible in order to provide maximum clearance with good
structural designing
Greater fire resistance and design aesthetic is another advantage.
DISADVANTAGES
Costlier for small projects
Required skilled workers
Costlier for small projects
Required skilled workers
Transportation is costly of large members for small projects.
It’s required to be design and detailed for transportation, erection.
Required different site for its production
Transportation is costly of large members for small projects.
It’s required to be design and detailed for transportation, erection.
Required different site for its production
Application of Precast Construction
1. Buildings
• Residential Buildings: Precast concrete panels for walls, floors, and stairs. Modular construction using
precast units accelerates timelines for apartment complexes and housing projects.
• Commercial Buildings: Office spaces, malls, and industrial facilities benefit from precast columns,
beams, and facade panels for structural and aesthetic purposes.
• High-rise Structures: Precast components such as hollow-core slabs and double walls are used to
reduce construction time in high-rise projects.
2. Infrastructure
• Bridges: Precast beams, girders, and deck panels are standard for bridge construction due to their
strength and quick assembly.
• Roads: Precast concrete barriers, culverts, and drainage systems are used for highway construction
and urban roads.
• Railways: Precast segments for railway platforms, tunnels, and track support systems.
3. Utilities
• Water Management: Precast tanks, pipes, and manholes for water supply and sewage systems.
• Electrical Infrastructure: Precast transformer pads, vaults, and utility trenches for power distribution.
4. Specialized Structures
• Parking Structures: Precast double tees and deck slabs are commonly used for parking garages,
providing durability and reduced construction time.
• Stadiums and Arenas: Precast seating units, risers, and facade panels for efficient and cost-effective
assembly.
• Industrial Facilities: Precast panels for warehouses, factories, and silos.
5. Modular Construction
• Healthcare and Education: Precast modules for hospitals, schools, and dormitories where time and
uniformity are critical.
• Temporary Shelters: Quickly deployable precast units for disaster relief and temporary housing.
6. Aesthetic and Decorative Applications
• Architectural Facades: Precast concrete with intricate patterns, textures, and finishes for aesthetic
appeal.
• Urban Furniture: Benches, planters, and bollards in public spaces.
• Monuments and Sculptures: Custom precast elements for artistic and commemorative projects.
