(TITLE)
PRECAST CONSTRUCTION
INTRODUCTION
PRODUCTS 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 ) 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:
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 recast 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 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 ) 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 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.
"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. These systems rely on shear walls to sustain
lateral load effects, whereas the slab column structure resists mainly gravity loads.
Pre-stressed slab-column system were introduced in the last decade of the Soviet
Union (period 1980) Reinforced concrete slabs are poured on the ground in forms.
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.
In the connections, the steel bars (dowels) that project from the edges of the slabs are
welded to the dowels of the adjacent components and transverse reinforcement bars
are installed in place. The connections are then filled with concrete that is poured at
the site.
Most buildings of this type have some kind of lateral load-resisting elements, mainly
consisting of cast-in-place or precast shear walls Good formwork to be used Lubricant
should be applied to forms Quality concrete to be used Suitable method of vibration
should be used Water for Curing should be good Steam curing can be use for mass
production, if cost is available 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 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 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 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 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 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 Hangzhou Bay Bridge Longest trans-oceanic highway
bridge in the world, with a cable-stayed portion across Hangzhou bay in the eastern
coastal region of China (6-lanes) Total length of bridge is 35. 67mt. Construction of the
bridge was completed on June 14, 2007.
The bridge shortened the highway travel distance between Ningbo and Shanghai from
400 km to 280 km and reduced travel time from 4 to 2. 5 hours.40 piers with large
number of girders Girder is of 70m length and 16. 5m wide in plan 830 cubic meter of
concrete for one girder and took 8 hours to cast one girder Barge crane was used for
erection of girders for 25 km. and for other portion special machine was built
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 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
Precast Concrete Construction Considerations 1. Erection Sequence Precast concrete
members shall be erected according to preplanned sequence. The erection plan is
commonly prepared drawings If it is important for structural stability and for access to
connections at specific location. The erection sequence shall avoid multiple handling
of elements. Finally, a trial erection operation should be considered to identify any
unforeseen erection difficulties. 2. Erection Safety Safety during the handling and
erection of precast concrete elements is substantially important. Therefore, all
machines and equipment employed precast concrete element handling and erection
need to be maintained to a high standard, load tested, and be suited to the intended
utilization. 3. Erection Tolerances Generally, the precast unit should be erected in
accordance with the tolerances provided by applicable codes, unless other tolerances
are used in the design and specifications. 4. Rigging A rigging system for handling and
erecting precast elements requires careful and thorough preplanning. It may be
necessary to equalize loads between lifting points on certain precast elements, such as
beams or flat slabs. Lifting accessories may be in the form of slings/cables, hooks or
shackles.
The selection of such components should take into consideration the forces due to all
operations involved in the handling and erection of the precast units. Headroom
availability and maneuverability during erection may also have an impact on the type of
rigging system selected. 5. Temporary bracing Precast concrete elements must be
adequately braced and supported during all phases of erection to ensure proper
alignment and structural integrity until permanent structural connections are
completed. 6. Leveling shims Leveling shims should be formed from a suitably durable
material and should have adequate strength to carry the full imposed loads. Leveling
shims carry the full construction load of the precast element and must provide
adequate support to prevent movement until the element is incorporated in the main
structure. 7. Propping All temporary propping requirements must be shown on the
erection drawings. The design of temporary propping systems should be in accordance
applicable codes. Temporary propping should provide full support for all construction
loads. Precast Concrete Construction Procedure 1. After the completion of
construction preparations, the layout of the structure is set. 2. Then, the foundation of
the columns are constructed
CONSTRAINTS SOLUTIONS Small road in front of site may not allow crane and delivery
trailers up to 3.5m wide to park. Crane and trailer are unable to negotiate small turning
radius at junctions of small roads. Diversion of existing services such as lamp-posts,
fire hydrants and overhead electrical cables may be necessary. Existing trees and
shrubs in front of site require National Parks Board approval before they can be removed
and later reinstated. Use smaller crane and trailers to deliver and install small
components. Study the locality and look for available space for turning. Have one
worker direct traffic while crane and trailer is turning. Diversion must be done before
installation of precast components begins. The consultants must write in to National
Parks Board for approval much earlier before construction begins.
The precast Factory Manager thru its Managers of different departments and Engineers
will be responsible for the production of precast elements in compliance with the
requirements of Project specifications and Reference Drawings.
Equipment and transportation requirements for the delivery and installation of precast
elements will be arranged by the logistic coordinator following the delivery route plan as
per Appendix G.
The Construction Manager thru its Site Engineer and Erection Personnel is responsible
for the job and proper execution of works in accordance with manufacturers’
installation instructions and approved method statements. He will be present at the site
during working hours together with Safety Officers to monitor all activities and ensure
the safety of the workers.
The Site Engineer will be in charge and directly supervising Supervisors and Foremen,
and carry the job at the site. Any completed activity must be channeled and
coordinated with the Quality Department. Acceptance of completed activity in line with
the approved ITP will be closed through Work Inspection Request (WIR) approval by the
Supervision Engineer.
Plant and Equipment Certifications and Calibrations:
Precast Factory will ensure that updated and recent certifications and calibrations of
batching plants and equipment are in place throughout the production timeframe of
precast elements. Equipment that is near expiration shall be monitored in and timely
calibrated.
The contractor will comply with Precast Concrete Institute (PCI) MNL 116 and 135
Manual for Quality Control for Plants and Production of Structural Precast Concrete
Products for manufacturing procedures, testing requirements, quality control
recommendations, and dimensional tolerances for the types of units required.
For fabrication of precast/prestressed structural products, self-stressing forms, bed
abutments, and anchorage shall be designed by qualified engineers.
The contractor will deploy a qualified concrete installer certified by PCI to install units
for load-bearing members.
Build mock-up will be prepared complete with anchors connections, flashings, joint
fillers, and all accessories. The first completed structural unit of each type of system
will serve as a Quality Benchmark and will be raised thru Work Inspection Request (WIR)
where the location is to be agreed upon by the Supervision Engineer.
Precast casting is planned in such a way that concreting work is done in one complete
operation without breaks. Concrete is brought by either the concrete transport shuttle
from the batch plant or through the transit mixer discharged via mixer chute or extended
chute, to the casting mold.
a)Time interval is observed to avoid the occurrence of the cold joint, QC Inspector will
ensure the batching with the approved mix design & its batching record at the
checkpoint of the lab at the checkpoint material engineer will conduct all fresh
concrete tests according to Inspection & test plan. QC Engineer will ensure the
concrete temperature at the time of concrete placing should not exceed 32°C. Concrete
casting in hot weather shall be according to Project Specifications.
b) Lay the concrete up to the mold in such a manner that the entire mold surface is
covered evenly. Air concrete thermometers shall be kept on the Site. Concrete shall not
be placed in the shade temperature exceeding 36°C or the concrete temperature
exceeding 30°C and 25°C for large pours.
c) Vibration: For casting on table base mold with built-in high-frequency vibrators:
Switch on the vibrator at the pre-determined period of time as instructed by the
Production in charge or QC inspector.
d) For casting on table base mold without built-in vibrators: Compact the concrete
by using poker vibrators, immersion type. Vibration is applied continuously for a
predetermined time during the placement of each concrete batch. Special attention is
given to difficult areas where heavy reinforcement occurs to prevent the presence of
void or honeycomb in the concrete. Level the top surface and remove excess concrete
after concreting. After the initial setting of the concrete surface, apply the required
surface finish as per the requirement of the Specification.
De-mould and strip the precast units off the mold once they have attained the required
lifting strength or as per the approved design. The lifting strength is determined by
crushing one Concrete cube at 8 hours after casting. The crushing results for every
batch of cast units are reflected in the Daily Cube Crushing Data. At the time of lifting,
visually check the cast.
b) As per PCI MNL 116 4th Edition-Division 4 Concrete as per Commentary
C4.18.3 Curing to Attain Specified Stripping or Transfer Strength: Stripping or prestress
transfer strengths are typically specified at a minimum of 2000 psi (13.8 MPa) for non-
prestressed units and 3000 psi (20.7 MPa) or greater for prestressed units. Specified
release strengths higher than this may require special mix designs, special curing
provisions, or longer curing cycles.
c) Once the precast unit is stripped off the mould, mark the precast element taking
into account the identification number and casting date as per the approved unique
numbering style. The marking is placed in such a way that it is visible even when the unit
is in the stacking yard.
Precast elements are stripped off the mould and loaded onto a truck and get picked up
eventually by the overhead tower crane and stacked in the stockyard. If the immediate
transfer is deemed not possible, precast elements are stripped off the mould and
stacked temporarily in a holding area provided in the factory until their transfer on-site is
required for transfer of units from the factory to the on-site stackyard by the flatbed
trailer or A-Frame trailer depending on the geometry of the precast panel.
2.6 Detensioning
a) Force shall not be transferred to the pre-tensioned members until concrete
strength determined from test results is in accordance with the specified transfer
strength.
b) As per PCI MNL 116 4th Edition – Division 5 – The Reinforcement and
Prestressing Part 5.3.17 Detensioning- Force shall not be transferred to pre-tensioned
members until concrete strength, as indicated by test cylinders or other properly
calibrated nondestructive test techniques, is in accordance with the specified transfer
strength., Commentary C5.3.17-Detensioning A minimum concrete transfer strength of
3000 psi (20.7 MPa) is recommended.
c) Detensioning tendons will be done by gradually releasing tensioning jacks or by
heat-cutting to prevent shock or unbalanced loading.
Detensioning heat-cured concrete will be done while the concrete still warm and moist
to avoid dimensional changes and avoid cracking or undesirable stresses.
e) Apply approved bituminous, zinc-rich, or epoxy paint at the strand ends to avoid
corrosion and possible rust spots.
Repair of Damaged Precast Elements (if any)
Inspection and Preparation
a) QC inspector will conduct the inspection. Standard identification of defects and
conducting repairs if applicable, only approved material will be used for repair work by
following procedures recommended by the manufacturer.
b) Repairs to be carried out either in the Factory or at the site.
c) Inspection will be carried out to check the repairable concrete elements.
Subject to repair elements will be kept in separate designated areas. Prior to starting
repair works, it will be verified that elements surfaces are free of dirt, grease, oil, curing
compound, paints, and all loose material.
d) It will be confirmed that the concrete has been cured enough to achieve design
strength.
e) The surface will be roughened by chipping, sandblasting, or other mechanical
means to assure the bond of the repair mortar to the existing concrete.
f) Prior to conducting the concrete repair/patching, the defect/damaged precast
elements shall be inspected by the AEC inspector for acceptance to proceed with the
repair activity.
Substrate Preparation
a) Areas to be repaired will be determined by visual inspection and hammer
sounding. Highlight all areas where concrete quality is suspected.
b) Saw cut perimeter maximum 10mm depth but do not cut steel.
c) Remove poor-quality concrete in the repair area until sound concrete appears.
Ensure the surface is left in rough condition. All edges ideally should be cut at right
angles.
d) The concrete steel reinforcement to receive the repair must be cleaned. If half of
the diameter of the bar is exposed, chip out behind the rebar minimum of 10mm.
Resurfacing Application
a) Pre-wet the concrete surfaces before application of repair mortar with clean
water. The surface to be repaired must not be allowed to dry out before application.
b) Mix repair material following the manufacturer’s instructions.
c) Apply repair mortar to the prepared area by hand or trowel.
d) Apply the repair material as recommended by the manufacturer’s technical
datasheet.
e) Finish off and smooth the repaired area.
Fabrication Tolerance
Precast concrete units must be straight and true to size and shape and comply with PCI
MNL 116 and the following product tolerances:
a) Overall height and width of units, measured at the face exposed to view, as
follows:
1. 3m or under, ±3mm.
2. 3m to 6m, to +3mm, -5mm.
3. 6m to 12m, ±6mm.
4. Each additional 3m, ±1 .5mm.
b) Overall height and width of units, measured at the face not exposed to view, as
follows:
1. 3m or under, ±6mm.
2. 3m to 6m, +6mm, -10mm.
3. 6m to 12m, ±10mm.
4. Each additional 3m, ±3mm.
Storage and Stacking
a) Precast units will be stored with adequate dunnage and bracing and protect
units to prevent contact with soil prevent staining and prevent cracking, distortion,
warping, or other physical damage.
b) It must be stacked the right way up with the timber bearers placed just in from
the ends, (maximum four times unit depth, “H”) vertically above one another. Similar
lengths should be stacked together.
c) Place stored units so identification marks are clearly visible and units can be
inspected.
Delivery and Handling
a) Precast units will be handled and transported in a position consistent with their
shape and design to avoid excessive stress which would cause damage.
b) Precast concrete shall not be moved, struck, or propped until the concrete has
reached a cube strength of at least 3 times the maximum stress to which it is subjected.
c) Lift and support precast units only at designated points on the Shop Drawing.
Lifting shall be carried out through designed lifting points.
d) Delivery vehicle operators shall drive with care and will be assisted by a signaler
knowledgeable with traffic control procedures in areas wherein maneuvering is difficult
and operators’ view is obstructed.
e) Cranes supplied will be of adequate size to safely lift the precast units in off-
loading from the delivery vehicles.
f) Delivery vehicles will be positioned as close to the crane unloading area as
possible. It must be situated on terrain that is as level as possible.
g) Lifting Supervisor will ensure a safe working load of the hoisting equipment,
rigging, and hardware before use.
h) Before mounting the precast units ensure that all safety precautions are in
place.
i) Make sure all loads are properly rigged, balanced, and stable before hoisting.
Tag lines must be in place and be used to control the loads and prevent rotation.
Production of Precast Elements
Concrete Constituents
Concrete raw material components (Cement, sand, aggregates, water & Admixture) are
being used in the production of precast elements from the factory batching plant.
1.3 Testing of Concrete Constituents
The testing procedures and frequency of concrete constituents testing shall be as per
Project Specifications Section xxxxxxxx
1.4 Sequence of Work for Precast Element
Unless otherwise specified:
• Mold fabrication & preparation
• Fabrication and assembly of steel reinforcement
• Placement of steel reinforcement into the mold
• Embedded parts (if any)
• Prestressing of wire strands
• Concreting works
• Curing
• De-molding
• Stripping
• Detensioning
• Defects and Repairs if any
• Curing
• Storage & Stacking
•
Handling
• Delivery
• Site installation/Erection – Proper surveying and setting out of the installation
area are required
1.5 Embedded Parts/Items
a) Place the embedded items as per approved drawings and approved submittals (if
required)
b) Embedded items must be checked by the production engineer/supervisor prior to
casting of the element before concrete. All embedded items, insulation grouts;
sealants, backing rods, and other materials to be used shall be as per the approved
Material Submittal (MAS). All cast-in parts shall be fixed in position as per approved
shop drawings.
MEP Inserts
Prior to the casting of precast elements, it will ensure that all MEP inserts & points i.e.
Electrical boxes, conduits, etc. are provided based on approved drawing locations. QC
will ensure that it’s properly fixed based on approved drawings.
Safety and Health induction shall be conducted by the Health & Safety Department
prior to the commencement of work to each person involved in the work. All applicators
involved in the works execution and the workers who undertook critical tasks shall be
competent and certified to undertake the works. All workers will receive a daily briefing
about the work they are to undertake that day.
Training in the factory and in the site shall be a must requirement harnessing the
competencies of the workers directly involved in the precast production and precast
installation. In line with Precast Factory quality control procedure Quality Engineers will
ensure adherence to the production process flow and Standards through a quality
toolbox among personnel, operators, supervisors, and skilled workers assigned in the
factory.
The Contractor will guarantee updated certifications to its personnel and operators and
will ensure that works at the factory and on the project site follow the Project
Specifications and governing Standards
THANK YOU
