PRECAST

ELEMENTS OF PRECAST SYSTEM

A. HOLLOW CORE SLAB B. HOLLOW CORE PANEL

SYSTEM Precast concrete slab is a horizontal member, a large, thick, flat piece of
stone or concrete which is rectangular in shape. It is used for floor and roof
deck. Similar to the wall, hollow core slab is used as flooring in our building.
A wall panel is defined as a single piece of material in this case is
concrete usually flat and cut into a rectangular shape. A prefabricated
wall panel is a panel fabricated at an offsite location. The type of panels
Precast system is the system which the Hollow core slab is known as a voided slab and these voids add structural that are used are hollow core panels. Hollow core panels are named
construction product was produced stability, reduce weight and therefore, reduce cost. The result is sound after its circular voids or cores which run throughout the slab in them that
in a controlled environment and proof, fire rated, low maintenance system and shallow depths. Hence, it is reduce weight and cost, and also may be utilized for electrical or
standardized, and then was a precast slab of prestressed concrete typically used in the construction of mechanical runs. Hollow core can be installed either horizontally or
transported to the site for assembly. floors in multistory apartment buildings. vertically to provide an effective wall cladding system, often used with
These structural components are steel structures.
manufactured by industrial methods
according in mass production to
build a large number of buildings in
more efficient way either in time or
cost. Using a precast concrete
system offers many potential
advantages over onsite casting. Figure 1, 2, & 3. Hollow Core Slab Figure 7, 8, & 9. Example of Hollow core panels on site

Figure 5. Hollow Core Slab Parts

Figure 11. Isometric View of Hollow

core panel

Figure 12. Two-way Hollow core

Figure 4. Hollow Core Slab Connection Details Figure 6. Hollow Core Slab Figure 10. Section of hollow core
panel
SOBREMONTE, REGINE I. Details panel
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C. PRECAST CONCRETE COLUMNS D. PRECAST CONCRETE BEAMS F. TOILET BLOCK

Precast concrete columns are designed in a modular form in order to be Beams are used as ledges for other forms of precast flooring to Box type construction system are used to
made into different heights. Generally, the widths will be 12”, 18” and 24” sit on. They are usually manufactured to suit each particular construct the toilet pod. In this system, the
and 12” was used in this case as the building is just a small apartment. situation. Beams can be either reinforced or prestressed, toilet blocks are prefabricated and erected
Columns are not structural, but can be used as such only after a structural however, in our case, reinforced concrete beams are used. at site. This system derives its stability and
engineer has adapted them to a building. Precast columns are available Rectangular beams are used and these beams get their name stiffness from the box unit which are formed
as single Storey corbel column or multi Storey corbel column. Rectangular from the end profile. These beams are usually used to span by the four adjacent walls. Walls are jointed
single Storey corbel columns are used for the site. clear sections. to make rigid connections among
themselves. The box unit rests on the plinth
foundation which is precast type.

Figure 13, 14, & 15. Example of Precast Concrete Columns on site Figure 20, 21, & 22. Precast Reinforced concrete beam

Figure 26. The interior of the toilet

block.

Figure 17. Precast Concrete Figure 23. Types of precast concrete beam
Column to Beam

E. PRECAST STAIRS

Concrete precast stairs are manufactured from bespoke mould

and can be produced as straight flights with separate or attached
landings. There are many advantages with the use of precast
stairs, over in-situ stairs.

Figure 18. Column to footing and

Column to beam connections

Figure 16. Connection of Precast Figure 24. The way of precast Figure 25. Process of installation Figure 27. Different types of units of
Figure 19. Types of precast concrete
Concrete Column to Beam concrete flight assembly on site. of precast concrete stairs. toilet blocks
columns.
TYPES OF PRECAST SYSTEM
SLAB-COLUMN SYSTEM
FRAME SYSTEM LARGE PANEL SYSTEM
These systems rely on shear walls to sustain lateral
Precast frames are usually constructed using either linear elements or “Large-panel system” refers to multistory structures load effects, whereas the slab-column structure
spatial beam-column sub assemblages. The use of linear elements composed of large wall and floor concrete panels resists mainly gravity loads. There are two main
generally means placing the connecting faces at the beam-column connected in the vertical and horizontal directions so that systems in this category: Lift-slab system with
junctions. The beams can be seated on corbels at the columns, for ease the wall panels enclose appropriate spaces for the rooms walls and Prestressed slab-column system
of construction and to help the shear transfer from the beam to the within a building.
column. The beam-column joints accomplished in this way are hinged. ▪ LIFT-SLAB SYSTEM
However, rigid beam-column connections are used in some cases, when Precast concrete floor slabs are lifted from the
the continuity of longitudinal reinforcement through the beam-column ground up to the final height by lifting cranes. The
joint needs to be ensured. The components of a precast reinforced slab panels are lifted to the top of the column and
concrete. The components of the system are shown below. then moved downwards to the final position.

Figure 28. Components are usually Figure 29. The beams are seated on
linear elements. corbels of the pillars.

Figure 33: Large Precast Concrete Panel Wall and

Slab at Rosebery Avenue, London
Figure 35: A typical lifting slab sequence

▪ PRESTRESSED SLAB-COLUMN SYSTEM

Horizontal prestressing in two orthogonal
directions to achieve continuity.

Figure 30. Components of precast concrete frame system.

Figure 31. Joints are filled with Figure 34: Section of a large-panel building showing Figure 36: Prestressed concrete construction
concrete on site. Figure 32. Frame System vertical connection details
APPLICATIONS OF PRECAST SYSTEM

Figure 41: Warehouse, Storage, & Light Figure 45: Aircraft Hangers Figure 49: Liftslab
Figure 37: Rail Landing
Industrial Building

Figure 42: Walls for Warehouse, Storage Figure 46: Office Building Figure 50: Cross Wall
Figure 38: Docks and Moorings

Figure 39: Earth Retention Figure 43: Parking Figure 47: School Figure 51: Longitudinal Wall

Figure 40: Tunnel and Canal coverage Figure 44: Stadium Figure 48: Highrise Figure 52: Two-way
PRESTRESSED TYPES OF PRE-STRESSED CONCRETE SYSTEM
PRE-TENSIONING CONCRETE
POST-TENSIONING CONCRETE

CONCRETE Pre-tensioned concrete is cast around already tensioned tendons. This method
produces a good bond between the tendon and concrete, which both protects the
It is a method of reinforcing (strengthening) concrete or other
materials with high strength steel strands called tendons. Post-
tensioning allows construction that would otherwise be

SYSTEM
tendon from corrosion and allows for direct transfer of tension. impossible due to either site constraints or architectural
requirements.

Prestressed concrete is a method for

overcoming concrete's natural
weakness in tension. A prestressed
concrete structure is different from a
conventional reinforced concrete
structure due to the application of an
initial load on the structure prior to its use.
The initial load or ‘prestress’ is applied to
Figure 1, 2, & 3. Example of Pre-tensioned concrete on site Figure 12,13. Pre-tensioned concrete
enable the structure to counteract the
stresses arising during its service period.

Figure 4. Pre-tensioned concrete

Figure 14. Pre-tensioned concrete

Figure 8. Prior to pre-stressing

Figure 5. Applying tensions to tendons

Figure 15. Casting of concrete

Figure 9. Effect of pre-stressing, ignoring self-

weight

Figure 6. Casting of Concrete

Figure 16. Tensioning of Tendons
Figure 10. Pre-stress plus self-weight

Figure 7. Transferring of Prestress Figure 11. Pre-stress plus self-weight

SOBREMONTE, REGINE I. and live load Figure 17. Anchoring the tendon at the stretching end
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 APPLICATIONS OF PRE-STRESSED CONCRETE SYSTEM

Figure 20. Bridge Figure 21. Nuclear Containment Figure 22. Storage Structures

Figure 18. Tendons (basic element of a post-tensioning)

Figure 23. Slab on grade Figure 24. Water Tanks Figure 25. Pre-Cast Members

Figure 26. Seward Silo Figure 27. Parking Garage Figure 28. Pavements
Figure 19. Typical Details of Post Tensioning
POST- WORKING PRINCIPLE OF POST-TENSIONING SYSTEM TWO CATEGORIES OF POST-TENSIONING SYSTEM

BONDED SYSTEM

TENSIONING For bonded system the post-tensioned strands are installed in

galvanized steel or plastic ducts. The duct can be either circular-

SYSTEM or oval-shaped. The anchorage transfers the force from the

stressing jack into the concrete. The duct and the strands
contained within are collectively called a tendon. Due to the
Post-tensioning is a method of producing concentrated arrangement of the strands within the ducts a
prestressed concrete, masonry and high force can be applied to a small concrete section.
other structural elements. In post-
tensioning, the concrete units are first
cast by incorporating ducts or grooves
to house the tendons. when the
concrete attains sufficient strength, the
high-tensile wires are tensioned by
means of jack bearing on the end face
of the member and anchored by
wedges or nuts.

UNBONDED SYSTEM

In an unbonded system the individual steel strands are

encapsulated in a polyurethane sheath & the voids between
the sheath & the strand are filled with rust-inhibiting grease the
tendon can be prefabricated off site. The force loss due to
friction is lower than for bonded tendons due to the action of
the grease. A broken tendon cause’s prestress to be lost for the
full length of that tendon. Careful attention is required in design
to ensure against progressive collapse.

GENERAL STRUCTURE OF POST-TENSIONING SYSTEM

SOBREMONTE, REGINE I.
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TYPES OF POST-TENSIONING SYSTEM

A. FREYSSINET SYSTEM

Freyssinet system was introduced by the French Engineer Concrete cylinder is heavily reinforced. Members are In this system, the anchorage device consists of
Freyssinet and it was the first method to be introduced. fabricated with the cylinder placed in position. Wires are sandwich plate having grooves to hold the wires and
High strength steel wires of 5mm or 7mm diameter, pulled by Freyssinet double acting jacks which can pull wedges which are also grooved. Each plate carries
numbering 8 or 12 or 16 or 24 are grouped into a cable through suitable grooves all the wires in the cable at a eight wires.
with a helical spring inside. Spring keeps proper spacing time. One end of the wires is anchored and the other
for the wire. Cable is inserted in the duct.
end is pulled till the wires are stretched to the required
length. An inner piston in the jack then pushes the plug
into the cylinder to grip the wires.

Anchorage device consists of a concrete cylinder with

B. MAGNEL BLATON SYSTEM Cables with as much as 64 wires are also used under
a concentric conical hole and corrugations on its
special conditions. A specially device jack pulls two
surface, and a conical plug carrying grooves on its In Freyssinet system several wires are stretched at a time. wires at a time and anchors them. The wires with the
surface. Steel wires are carried along these grooves at In Magnel Blaton system, two wires are stretched at a
sandwich plate using tapered wedge.
the ends time. This method was introduced by a famous engineer,
Prof. Magnel of Belgium.
C. GIFFORD UDALL SYSTEM D. LEE MCCALL SYSTEM OTHER TYPES OF POST-TENSIONING SYSTEM

This system originated in Great Britain, is widely used in India. This method is used to prestress steel bars. The diameter of the E. BUTTON HEAD BBRV SYSTEM
This is a single wire system. Each wire is stressed independently bar is between 12 and 28mm. bars provided with threads at
using a double acting jack. Any number of wires can be the ends are inserted in the performed ducts.
grouped together to form a cable in this system. There are
two types of anchorage device in this system: Tube
anchorages and Plate anchorages.

F. BBRV SYSTEM

G. BAUR-LEONHARDT SYSTEM

There are two types of anchorage device in this system:

After stretching the bars to the required length, they are
a. Tube anchorages tightened using nuts against bearing plates provided at the
b. Plate anchorages end sections of the member

H. PRESCON SYSTEM