GROUP 2 -PRECAST CONCRETE SYSTEM

[PANEL]
ABDULLAH AZAM BIN ROZAINI 2020813084

AHMAD KHAIR IMAN BIN AHMAD SIRAJUDDIN 2020621068

WILDAN BIN BUDI ALFAHMI 2020837022

AMIRUL SYAZWAN BIN AZILAH 2019615204

INDUSTRIALISED BUILDING SYSTEM (IBS)
PRECAST CONCRETE SYSTEM [PANEL]
INTRODUCTION

In the postwar period, precast concrete was used in a wide range of Because items were often created off-site in regulated manufacturing
building applications, for example; conditions, the application was further aided by the cost savings of
● as small panels attached to loadbearing structural frames shorter building timeframes and the certainty of higher quality fabrication
● as large loadbearing wall panels (as opposed to in situ concrete)
● as parapets of balconies
● as insulated sandwich panels used in exterior cladding, and
● as claustra in decorative open screens.

DEFINE AS PREFABRICATED EXHIBIT COMPOSED OF CONNECTED

RECTANGULAR PANELS OF VARIOUS SIZES.

MADE IN VARIOUS FORMS AND NORMALLY PREFABRICATED AT

FACTORY.

CONTRIBUTED ONLY FOR AESTHETICAL EXPRESSION OF

BUILDING.

Source:
http://postwarbuildingmaterials.be/material/precast-concrete-facade-panels/
 PRECAST CONCRETE SYSTEM
[PANEL]

Precast Concrete Wall Precast Concrete Slab

● Precast concrete walls are built by casting the concrete into a ● Precast concrete flooring provides a cost-effective and adaptable
reusable wall molds or form, curing it in a controlled environment, solution to ground and suspended floors during the construction of
then transporting it to the job site and lifting it into position. most types of buildings.
● The primary purpose of precast walls is to speed the construction ● It's also commonly utilised in commercial and residential buildings
process. since it has design and financial benefits over traditional methods
including cast in-situ concrete, steel–concrete composite, and wood
flooring.
● Floors can be utilised with or without structural toppings or
non-structural finishes, such as tiles, since they provide optimum
structural performance with little weight.
● The advantages of a precast concrete floor include the flexibility to
manufacture high-strength, long-lasting components off-site and the
ability to quickly install long-span floors on-site.

(Source: IBS Catalogue For Precast Concrete Building System Revision 2017)
 Types of Precast Concrete Wall

Cladding or Curtain
Load-bearing Wall Shear Walls
Walls

● The most often utilised precast wall for ● Load-bearing wall units resist and ● When combined with stomach activity of
building envelopes is cladding or curtain interchange loads from different the floor growth, shear walls are used to
walls. components and are unable to be provide a parallel load opposing structure.
● They are non-load bearing walls designed removed or dismantled without ● The board-to-board associations are often
to block the wind and enclose the area. compromising the building's quality or in need of the viability of precast shear
● Divider boards, window divider units, dependability. dividers.
spandrels, mullions, and section covers
are all included in this form of precast
wall.

Load Bearing Pre-Cast Concrete Walls

Shear Wall Pre-Cast Concrete Walls

Wall Cladiing - Wall Panel

(Source: https://theconstructor.org/concrete/precast-concrete-walls-types-connections-advantages/37998/)
 Panel Systems

Panel in construction building

● SINGLE PANEL ● DOUBLE PANEL ● LANDING PANEL ● STAIRS PANEL ● FLOOR PANEL
This panel is excellent can be used as suitable to be suitable for
perfect for substitute for any plate or slab reinforced and joists and
walls, partitions, reinforced for r.c. which can finished with subsequent
claddings, concrete wall be reinforced in casting at site. casting at site..
floors and such as two directions.
roofing for both load-bearing
civil and wall and
industrial retention wall.
buildings.

(Source:http://www.pm2.com.my/m2_panels.php)
 ADVANTAGES AND DISADVANTAGES OF PRECAST
CONCRETE SYSTEM(PANEL)

Precast concrete wall panels offer a single-source option for providing your building's outer wall system. When compared to insulated metal
panel systems, precast concrete wall panels provide significant long-term economic benefits, including outstanding durability, lower energy
expenses, and lower maintenance costs.

The advantages of a wall system are as follow:

● The quality is high and can be consistent and maintained as long as the environment in factory is easier to control

● Impact, corrosion, weathering, and abrasion resistance are all excellent in precast panels, making them essentially maintenance-free
● Unlimited colors, shapes and textures available

The disadvantages of a wall of a wall system are as follow:

● Heavy and sophisticated machines are needed which require high investment
● Precast members are heavy and large which make difficult to handle without damage
● Transportation can be issue when the site is at a distance
 LIST OF NOTABLE MANUFACTURES

Eastern Pretech (Malaysia) Sdn Bhd

The company manufactured buildings and products are revolutionizing
the traditional construction industry to achieve speed and quality at
competitive prices. A variety of precast concrete products are
manufactured in a controlled factory environment to ensure consistent
quality and accuracy.
HP Precast System Sdn Bhd
The HC Precast System is a highly innovative and innovative precast
panel and construction system. This system provides easy
standardization, faster construction, cost effectiveness, high quality
workmanship, and improved façade design. The company manage to
manufacture, processing and supplying precast components and related
products.

Planks Precast walls

Precast walls Precast staircase

Waffle slabs
 LIST OF NOTABLE MANUFACTURES

Setia Precast Sdn Bhd

Setia Precast Sdn. Bhd. is a one-stop Industrialised Building MTD ACPI Engineering Sdn Bhd
System (IBS) centre specialising in building high-rise
apartment, IBS landed house, and commercial buildings MTD ACPI Engineering Sdn Bhd has extensive experience in
utilising precast technology. the development of mountain roads, highways, and bridges,
building geotechnical works, erosion control and highway
maintenance. has the capability to produce a full range of
precast concrete products for infrastructure such as bridge
crossings, segmental box girders, tunnel segments across
the ASEAN region and buildings including Industrialised
Building System (IBS).

Precast walls Precast staircase

Precast staircase Precast Column

Precast slab
 PRECAST CONCRETE SYSTEM (PANEL) USED IN
BUILDING IN MALAYSIA

Taylor University

● Taylor university lakeside campus.

● Located in subang jaya, Selangor, Malaysia
● Design by NWKA architect.
● Total building size :- 10 000m2
● Project completed in 2009
● Constructed by using industrial building system (IBS)
● Build with precast concrete component such as :- precast concrete wall panel,
precast hollow floor slabs, precast beam, precast beam, precast column, and
precast staircase.
View toward Taylor university lakeside campus

Precast concrete wall

panel - designed
according to structural
requirement for
strength,safety and
other features as
specified.

Precast hollow core

Taylor university lakeside campus during construction stage. slab - smooth-top
hollow core precast
concrete panel is used
to reduce the weight of
the slab, about 35
percent.
 Residential Seri Jati Apartment
● Seri Jati Apartment, located at Setia Alam, own by Sp
Setia Developer.
● Consist of 948 units and 10 storeys
● Achieved score of 83% for the vertical and horizontal
repetition criteria, maintained the quality.
● Low forming and construction cost due to the use of
precast and in-situ building component.

Source :
http://rehdainstitute.com/wp-content/uploads/2017/05/4.-Kow-Choong-Ming.pdf

Industrial Building System (IBS) Used

● Precast load bearing & non-load bearing walls with
vertical & horizontal repetition.
● Precast staircases & landing slabs
● Precast structural frames with in-situ concrete floor
using reusable formwork system.
● Typical cast in-situ floor slabs
● Prefabricated steel roof trusses.
Majority building elements of Seri Jati Apartment uses IBS system of precast concrete
method to construct. Building elements including the roof, floor slabs, walls, columns and
beams.
 IBS Component described

Load Bearing Wall

The structural component that resists the weight of all the

structural components resting on it by transmitting the weight
to the foundation below is known as a load bearing wall.It is
one of the earliest kinds of civil engineering building and has
been employed since ancient times. The wall should be at
least 9 inch thick for its wide.

Features Load Bearing

Wall

The important features of a load bearing wall can be listed as

below:

● It carries the weight of the entire structure particularly the

building weight from the roof and the floor
● It transfer the load down to the down to the foundation
Load bearing wall section
Souce : google image.com ● Provide support to the structural members of the building
● The consecutive load bearing walls are laid one over
another on each floor
● Can be constructed as both interior and exterior wall
 Types of Load Bearing
Wall

Precast Concrete wall Retaining wall Masonry wall

A type of load bearing wall that mostly A specially designed wall that resist the This wall is used in both architectural
constructed by casting in a reusable wall lateral pressure of the overburdened soil. purpose and strengthening the structure. It
mold and will be transported to site. Some Should capable of supporting wedge of also used for thermal control and fire
of the features are as below: the soil. Setback of wall increase while safety. However the stiffness offer is low.
the sliding wedge reduced. It also use as:
● Thermal resistance
● Moisture protection ● Soil erosion control
● Fire safety ● Soil stabilization
● Acoustic ● landscaping
● Durability
● Maintainability
 Types of Precast Concrete Slab

Half slab Hollow core slab Prestressed plank

● Precast concrete elements with a ● Voided prestressed concrete slab is ● Hollowcore planks (also known as
constant cross section are known as another name for precast hollow core slab. hollowcore floor pieces, planks,
half slabs. ● It is a one-way spanning prefabricated panels, or slabs) are created via
● High tensile strength prestressed concrete slab with hollow cylinders that slip-forming or extrusion.
strands or single wire embedded into requires fixed walls and/or beams to ● Hollowcore gets its name from the
the element are used to make them. support it. hollow internal cores that span the
● In residential, social, and commercial ● Because the slab has hollow properties, it length of the plank, lowering its
building, half slabs are used as reduces self-weight and building time. weight.
covering elements. ● The reinforcement is put around the
● Half slabs are utilised in high-loading cores of hollowcore floor boards,
and/or long-span building projects. which are precast, prestressed
pieces.
● The standard width of planks is 1200
mm.

(Source: IBS Catalogue For Precast Concrete Building System Revision 2017)
 Component to component
connection method

TYPE OF
Vertical connection Horizontal connection
CONNECTION

Vertical connection
Horizontal connection
● Vertical connection is refer to
● Horizontal connection is refer
connection between wall to
to connection between floor
wall.
slab and wall panel.
● The joint is divide by two type of
● Usually horizontal connection
joint, wet and dry joint.
used wet joint such as grouting
● Most common choice of
connection is concrete filled & sleeve joint..
joint and welded joint.
 TYPE OF
Wet jointing Dry jointing
JOINTING

Cast in place
Reinforcement
used.
Precast concrete
wall panel

(Wet jointing) Cast in-situ concrete Precast concrete wall

● Cast n-situ is a technology of construction of

building where walls and slab of the buildings are Cast in-situ
cast at the site in formwork. concrete/concrete
Wall to wall (vertical connection)
● This differs from precast concrete technology infill
where slabs are cast elsewhere and the brought
to the construction site and assembled.
Cast in place Precast concrete wall
● In this joint has two type either use reinforced or Reinforcement
unreinforced cast in-situ concrete. used.

Wall to corner wall (vertical connection)

 (Wet jointing) through grouting jointing
(grout installation recommendations)

● Grout is a critical structural component of all

presecast buildings.
● It is imperative to make sure that all grout is
installed in proper connection locations as
required per approved precast erection drawings
and is of the required design strength and quality.

Souce : zurichservices.com

Wall-wall grouted joint (vertical joint) Wall-foundation grouted joint

Souce : zurichservices.com Souce : zurichservices.com

(Dry jointing) welded plates

Precast member
● Welded joints are made by welding plates or rods Embedded plate
with the embeds details in precast panels.
● It is a rigid joint that can provide stability in the Loose plate field welded to
process of the erection of the elements. embedded plates
● The quality of the welding could influence on the Embedded plate
durability of the joint
● Disadvantage of the joint with the plate are the
eccentricity of the load transferred from one panel
to the other and difficulties with the grouting.
 Wall is installed The nuts and washers
on pre leveled are screwed on and
shim plates tightened

(Dry jointing) wall shoes

● Horizontal joints of the wall panels.

● The connection is the system that consists of the
wall shoes and anchor bolts.
● Wall shoes include the steel box with the anchor
bars welded to the box, nut, and the washer.
● Wall shoes are placed into the formwork together
with the main and supplementary reinforcement.

Wall shoes jointing technique

Source
:https://www.theseus.fi/bitstream/handle/10024/151739/Artem
eva_Mariia.pdf;jsessionid=305E883670C1F0D488CB3C4AE7586
F38?sequence=1

(Wet jointing) grouting & sleeve jointing

● Core holes within the wall panel are formed using

proprietary splice sleeve or corrugated pipe
sleeves.
● These holes together with the vertical continuity
bars are filled with grout after wall installation.

Wall to floor (horizontal connection)

Source :
https://www.bca.gov.sg/publications/BuildabilitySeries/others/bsh_ch2.pdf
 IBS to Non-IBS connection
An assemblage of metal components and anchors methods The goal of this guide is to show you how to employ
supports each precast panel independently to the panelized options and connecting details with
building structure. architectural precast concrete.

Sealant is frequently used to fill the joints

surrounding each of the precast panels.

TYPE OF
CONNECTION

Dowel/Anchor Bolt
Bolted Connections
Connections

● Bolted connections are the simplest and ● The strength of dowels in tension or shear
quickest way to create a structure. is determined by dowel diameter,
Welded Connections
● Without tying up crane time, the final embedding length, and the bond created
alignment and correction may be done in a dowel connection.
afterwards. ● The first connection to precast members is
● Bolting should be done in line with the made with threaded anchor bolts and
● The connections are normally
erection plans and with the designer's rebar anchor dowels that protrude from
accomplished by welding together a loose
materials. the foundation.
plate between two structural steel plates
embedded in the cast-in-place or precast
concrete panel.
● Some connections are made to bend and
give in one direction but stay inflexible in
all others.

Bolt Connection

Welding Connection Dowel Connection

Source: Architectural Precast Concrete Wall Panels: Connection Guide

 Connection Ground to Panel

Dowel/Anchor Bolt
Bolted Connections Welded Connections
Connections

Connection Detail – Fixed Tie Back Connection Detail – Shim Bearing Connection Detail – Dowel Pin
Precast Concrete Wall to Cast-In-Place Beam/Slab Precast Concrete Wall to Cast-In-Place Beam Precast Concrete Wall to Cast-In-Place Beam
Source: Architectural Precast Concrete Wall Panels: Connection Guide Source: Architectural Precast Concrete Wall Panels: Connection Guide Source: Architectural Precast Concrete Wall Panels: Connection Guide
 Connection Panel to Panel

Dowel/Anchor Bolt
Bolted Connections Welded Connections
Connections

Connection Detail – Panel to Panel Connection Detail – Panel to Panel Connection Detail – Dowel Pin
Source: Architectural Precast Concrete Wall Panels: Connection Guide Source: Architectural Precast Concrete Wall Panels: Connection Guide Source: Architectural Precast Concrete Wall Panels: Connection Guide
 Connection Slab to Panel

Dowel/Anchor Bolt
Bolted Connections Welded Connections
Connections

Connection Detail – Adjustable Tie Back Connection Detail – Fixed Tie Back Connection Detail – Dowel Pin
Source: Architectural Precast Concrete Wall Panels: Connection Guide Source: Architectural Precast Concrete Wall Panels: Connection Guide Source: Architectural Precast Concrete Wall Panels: Connection Guide
 Connection Slab to Slab

Section of slab with change in slab thickness

Section of pour strip for precast slab Source: Chapter 3 DESIGN CONCEPT FOR PRECAST SYSTEM. (n.d.).
Source: Chapter 3 DESIGN CONCEPT FOR PRECAST SYSTEM. (n.d.). https://www.bca.gov.sg/publications/buildabilityseries/others/bsl_cp
https://www.bca.gov.sg/publications/buildabilityseries/others/bsl_cp 3.pdf
3.pdf

Section of pour strip with additional bars for slab support Section of pour strip with top drops for slabs
Source: Chapter 3 DESIGN CONCEPT FOR PRECAST SYSTEM. (n.d.). Source: Chapter 3 DESIGN CONCEPT FOR PRECAST SYSTEM. (n.d.).
https://www.bca.gov.sg/publications/buildabilityseries/others/bsl_cp https://www.bca.gov.sg/publications/buildabilityseries/others/bsl_cp
3.pdf 3.pdf
 Step by step construction
method

Wall Panel to ground floor method

Step 1 Step 2 Step 3

Setting up grid lines and Unload / lift up wall

leveling shim panel relevel/adjust wall panel

● This process is to make sure wall ● Usually after unload/lift up process to

panel is install correctly in places. the making place, site
● Shims is function to leveled the wall ● Heavy machinery need to lift up precast wall supervisor/engineer will
panel before connection process panel and place it to making area. relevel/adjust wall panel to avoid
between wall and ground floor. ● In this process engineer/site supervisor will tilted on wall panel.
guard to prevent any issues during unloading/
lift up process.

Source : (https://www.youtube.com/watch?v=CkTH8C5u8tM) (https://www.youtube.com/watch?v=LGTj6TswAO8)

 Step 5 Step 4

Jointing technique Shoring process

Precast shoe
Corrugated duct
● Mainly used for for connecting precast column
● Traditional method to connect precast wall
and foundation.
to foundations.
● Also can be used to connect precast wall to Shoring process
● Corrugated duct is used as a hole former
foundation. ● Shoring is process of temporarily
for a variety of precast and cast-in-situ
● Suitable for anchoring in flat structures such as supporting structures to avoid collapse
concrete work.
the foundations or walls that have sufficiently structure.
● Disadvantages of application is the huge
large edge distance. ● Shoring may be vertical,angled, or
amount of grout needed to fill up the duct
● The advantage used precast shoe is prescast horizontal depends on site or structural
in order to secure the connection between
system with screw connection is the quick condition.
wall and foundation .
assembly.

Source :concrete wall panel to ground floor

(https://www.moment-solutions.com/ways-to-connect-precast-concrete-wall-to-foundation-effortlessly/)
 Step by step construction
method

Floor Slab Construction

Step 1 Step 2 Step 3 Step 4

Moulding Concrete filling Remove moulds Transport to site

● A custom shaped mould of ● Prestressed concrete is ● When the concrete is cured ● The installation of the slab is
formwork is prepared for poured into the moulds. the moulds are carefully done through lifting it with
precast removed leaving the cavities crane and placing it to specific
● This process is carried out in the slab position for connection.
offsite at the factory.

Source : Project 1-Industrialised Building System [ IBS ] (https://www.slideshare.net/JerotichMaswan/project-1-industrialised-building-system-ibs)

 Correct installation/assembly
methods

Installation of Precast Concrete Wall

Step 1 Step 2.i

Installing Precast Wall

Unloading Precast Wall with integrated steel
tie-bars

● This activity necessitates the

1 Place the wall plumb in its
3 The flexible tie-bars in 4 The two Precast Walls are
participation of two people: one to new spot, on the plastic Precast Wall "B" slot in now connected: all of the
manage the wall and the other to shims, and parallel to the B between the rigid tie-bars in flexible bars in Precast Wall
supervise the activities. marks. Precast Wall "A" as it falls. "B" have fitted in between the
● The container's walls must be removed
in the order of presentation and access 2 stiff bars in Precast Wall "A"
Precast Wall "B" should be
to the slings. and are horizontally
placed next to Precast Wall
positioned, as can be seen at
"A."
the junction.
6 The straight steel bar must be Adjust the wall's plumbness
8
positioned between the loops with push-pull props till it's
Head in the tie-bar to complete the ideal.
ring connection.
Fixed Sling with adjustable 9 To prevent laitance leaks, fill
leg leg 7 Incorporate the steel bars at spaces with foam tape.
the top of the wall once it has
been concreted.

5 Check that the Precast Wall

is positioned appropriately on
the shims and in accordance (Source :Installation of precast wall panels by Proud to be Civil Engineer
with the indications (in (https://www.youtube.com/watch?v=_rWJgasNQ-0)
particular as regards the (Source: Fehr Groupe SAS (n.d.). Precast Wall. Architect : Agence G.P.A.A..
https://fehrgroup.com/static/b329cee21897671ddac721d82f29b7e9/FEHR-Precast-wall.pdf)
position of the joints).
 Step 2.ii Step 3

Installing Precast Wall

Method of anchoring
without integrated steel
and type of shoring
tie-bars

1 Install the steel tie-bars (as 3 Place any straight steel bars
you go along)
Adjust the wall's plumbness
2 Place the wall plumb in its 4 with push-pull props till it's 1 Fixing the top part of the push-pull 2 Different types of ground stabilisation
new location, on the plastic ideal. props onto the Precast Wall before are possible. Any form of shoring that
shims, and in accordance installing it. is being considered should be verified
with the indications. by engineering design office.
.

3 During the interim phase, walls that

are subjected to heavy loads
require considerable stabilisation at
the top and bottom.

Horizontal props
5 To prevent laitance leaks, fill
spaces with foam tape.
Concrete block (or foundation)

(Source :Installation of precast wall panels by Proud to be Civil Engineer

(https://www.youtube.com/watch?v=_rWJgasNQ-0)
(Source: Fehr Groupe SAS (n.d.). Precast Wall. Architect : Agence G.P.A.A..
https://fehrgroup.com/static/b329cee21897671ddac721d82f29b7e9/FEHR-Precast-wall.pdf)
 Step 4

Infilling with concrete

1 Hydrate the inside of the Precast Wall to improve the flow of the
concrete during infilling and achieve better adherence to the sides.

2 Place the formwork for the slab or install the precast slab.

3 Concrete the rest of the wall from the precast slab.

4 Before the finishing trades begin work on the Precast Wall, the joints
are treated during the finishing phase of the construction structure.

(Source :Installation of precast wall panels by Proud to be Civil Engineer

(https://www.youtube.com/watch?v=_rWJgasNQ-0)
(Source: Fehr Groupe SAS (n.d.). Precast Wall. Architect : Agence G.P.A.A..
https://fehrgroup.com/static/b329cee21897671ddac721d82f29b7e9/FEHR-Precast-wall.pdf)
 Correct installation/assembly
methods

Installation of Precast Concrete slab

Step 1 Step 2 Step 3 Step 4

● Precast walls are propped ● The pour strip between 2 ● Precast planks are installed in ● Preparation for casting of
before casting of joints – pieces of precast walls are place landing slab to precast
proper planning is required for cast staircase
perfect alignment

Step 5 Step 6

● Preparation of welded mesh ● Concreting to topping

and services for cast in-situ
topping