LECTURE ON PRE-CAST CONCRETE

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Pre-Cast (also known as Pre-Fab)
Ar. SERGE T. CHUA, Jr. fuap M_Arch CTM Sr MRIAS
Associate Professor II
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INTRODUCTION INTRODUCTION
The concept of precast (also known as
prefabricated) construction includes
those buildings where the majority of
structural components are standardized
and produced in plants in a location away
from the building, and then transported to
the site for assembly.
HISTORY HISTORY
Ancient Romans Ancient Romans
invented and used concrete extensively
Developed technology of form & mould
making and pouring concrete into these,
shaping the concrete into sizes & shapes
to build their complex network
of aqueducts, culverts, and tunnels.

AQUEDUCTS AQUEDUCTS
refinement of pozzolanas, a natural cement, found in the soil.
cements, sand and gravels- the earliest invention of concrete.
the idea to pour this mixture into molds for building precast blocks
marks the beginning of the idea for precast concrete.


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To prevent them from stirring up trouble at home, the Roman armies were
often kept busy with engineering projects, . Concrete molds were filled
locally by the tens of thousands at construction sites
Different Forms of Precast Parts:
Corner Pieces, Narrow, Short Or Long Blocks, Etc.
The Individual Blocks May Have Looked Like Quarried Stone, But They
Were The First Uses Of Precast Concrete
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1905 Liverpool, England 1905 Liverpool, England
Pre-cast paneled buildings were
pioneered by England city
engineer -
John Alexander John Alexander Brodie Brodie
the first to develop and perfect
the idea of using precast
concrete forms in modern
architectural design
Genius also had him inventing the
football goal net. The tram stables
at Walton in Liverpool followed in
1906. The idea was not taken up
extensively in Britain. However, it
was adopted all over the world,
particularly in Eastern
Europe and Scandinavia.

John Alexander John Alexander Brodie Brodie
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Transamerica Pyramid , San Francisco
The Tallest Building To Use Precast Concrete
PRECAST CONCRETE PRODUCTS PRECAST CONCRETE PRODUCTS
1. Structural Members
a. Slabs
b. Beams & Girders
c. Walls
d. Stairs
2. Agricultural
3. Building
4. Sanitary & Stormwater Management
5. Transportation & traffic Related
Products
6. Utility Structures
7. Water & Wastewater Products
POPULAR USES: POPULAR USES:
1. Concrete curtain walls
2. Exterior cladding (exposed
aggregate)
3. Structural walls
4. Ability to precast in three dimensions
allows precast panels to form parts of
mechanical systems
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BUNKERS & SILOS BUNKERS & SILOS
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BUNKERS & SILOS BUNKERS & SILOS
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RETAINING WALLS RETAINING WALLS
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CATCH BASINS CATCH BASINS
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BOX CULVERTS BOX CULVERTS
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UTILITY POLES & BASES UTILITY POLES & BASES
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SEPTIC TANKS SEPTIC TANKS
PRECAST CONCRETE SLAB TYPES: PRECAST CONCRETE SLAB TYPES:
1. (Solid) Flat slab
2. Hollow Core slab
3. Double Tee
4. Single Tee

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PRECAST SLAB TYPES: PRECAST SLAB TYPES:
1. (Solid) Flat slab
Thicknesses of 0.10m, 0.15 and 0.20;
thinnest @ 0.07 m.
Spans up to 25-0 / 7.62 m
Standard panel width = 4-0 or 1.20 m.
when used on several continuous
spans having widths from 120 to 240
cm. with length up to 11 m
2. Hollow Core slab
Thicknesses of 0.10m, 0.15m,
0.20m,0.25m and 0.30m
Spans up to 40-0 / 12.19 m
Standard panel width = 4-0" / 1.2 m
As lightweight member
made by extrusion in special machine
Thickness ranges from 10 to 20 cm.
Widths from 60 to 120 cm.
As roof
Spans augmented up to 9 m when 5
cm topping is applied to act
monolithically with the hollow planks.



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(Solid) Flat slab
Hollow Core
Hollow Core
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PRECAST SLABS PRECAST SLABS
3. Single Tee
As Roofing
Spans up to more than
30m.
Flanges of the tee T
constitute the floor or roof
slab.
4. Double Tee
most widely used section
For Longer Span Having
Depth Of 4.00 To 6.50 M
generally used on roof
having a span up to 18 m
applied concrete topping
of at least 5 cm. acts
monolithically with the
precast members.
could be used on floors up
to 15 m span depending
upon the load and
deflection requirements.
Roofs & Floors are made in wide variety of design to suit the different to suit
conditions of span, magnitude of load, fire ratings and appearance.
Single Tee
Double Tee
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PRECAST BEAMS PRECAST BEAMS ((precast beam shapes depend upon the manner of framing)



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1. Rectangular (RB)
Typical beam width = 0.30 m and
0.40m
Spans up to 50-0" / 15.240 m
Typical designation = 16RB24 (16 =
width in inches, 24 = depth in
inches)
Where the floor and roof
members are supported on top of
the beam
2. "L" and "IT" (inverted "Tee")
beams (LB and IT)
Ledger beam
designed to reduce the height of
the floor and roof construction.
used to provide bearing
Typically used to support slabs,
walls, masonry, and beams
Typical beam width = 0.30m
Depths of 0.50m, 0.71m, 0.91m,
1.1m, 1.32m, & 1,5m.
3. Single Tee" beams (ST)
Combination beam and slab
Spans up to 120-0" / 36. 58m
Typical width = 8-0" / 2.4m
Typical depths of 36" and 48
4. Double Tee" beams (DT)
Combination beam and slab
Spans up to 100-0" / 30.48m
Typical width = 8-0" / 2.4m
Depths of 12", 18", 24" and 32"
PRECAST RECTANGULAR BEAMS PRECAST RECTANGULAR BEAMS
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PRECAST L & IT BEAMS PRECAST L & IT BEAMS
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PRECAST L BEAMS PRECAST L BEAMS
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PRECAST Ledger & IT BEAMS PRECAST Ledger & IT BEAMS
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PRECAST ST BEAMS PRECAST ST BEAMS
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PRECAST DT BEAMS PRECAST DT BEAMS
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PRECAST DT BEAMS PRECAST DT BEAMS
PRECAST IT BEAMS PRECAST IT BEAMS
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PRECAST COLUMN PRECAST COLUMN
Axial Support
Size ranges from 30 to 60
cm.
Multi storey construction
columns are made
continuous up to four
stories using corbels to
provide bearing for the
beam.
sometimes used directly
to support double tee
floor members without
the use of immediate
member.
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PRECAST COLUMNS
Dimensions SINGLE TIER WITH CORBELS DOUBLE TIER WITH CORBELS
Width (B): 300 ~ 900 at 50 mm increment 300 ~ 900 at 50 mm increment
Depth (H): 300 ~ 900 at 50 mm increment 300 ~ 900 at 50 mm increment
Height (L): 3.0 m ~14.0 m at 50 mm increment 6.0 m ~14.0 m at 50 mm increment
Wall Panels Wall Panels
Standard widths: 8-0/ 2.4m
Features: Flat or have architectural
features such as window and door
openings, ribs, reveals, textures,
sandwich (insulation built-in),
sculptured, etc.
Designs: depending upon the
Architectural requirements.
Uses: as curtain walls attached to
columns, beams or sometimes on
bearing walls.
improve the thermal insulation of a
panel, glass foam, glass fibers or
expanded plastic is inserted between
the two layers of interconnecting
lightweight concrete adequately
bonded to act as one unit.
The stress on the precast unit made in
the in the factory is greater than
those cast in place due to handling
and erection. Hence, control of
cracking is of great importance.
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Wall Panel Types Wall Panel Types
1. Flat Panel
2. Vertical Window or Mullion Panel
3. Horizontal Window or Mullion Panel
4. Ribbed Panel
5. Double Tee Panel
6. Spandrel

3.
1.
2. 4. 5.
6.
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MODERN DAY USES MODERN DAY USES
Concrete curtain walls
Exterior cladding (may include
exposed aggregate)
Structural walls
Parts of mechanical systems
3-dimensional ability
ATTACHMENT METHODS: ATTACHMENT METHODS:
1. Weld Plates
most common method of
attachment
use of steel weld plates.
embedded plates in the
precast members are used as
welding surfaces for loose
connecting plates or angles
2. Rebar & Grout
with slabs, reinforcing bars are
spliced into slabs and grouted
in place



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DOUBLE WALL PRECAST DOUBLE WALL PRECAST
CONCRETE SANDWICH PANELS CONCRETE SANDWICH PANELS
Advantages
Very rapid speed of erection
Good quality control
Entire building can be
precast - walls, floors, beams,
etc.
Disadvantages
Very heavy members
Camber in beams and slabs
Very small margin for error
Connections may be difficult
Need bracing during on-site
erection of structure
Somewhat limited building
design flexibility
Consists of two wythes of concrete
separated by an insulated void.
Thickness (commonly specified)-
8 inches.
Connection: the two wythes of the
interior and exterior concrete layers
are held together with steel
Height : up to a limit of 12 feet.
a 9-foot clear height preferred for the
quality of look and feel it affords a
building trusses
Uses : multi-family, townhouses,
condominiums, apartments, hotels
and motels, dormitories and schools,
and single-family homes
Qualities: Speed of construction,
durability of finished structure, and
energy-efficiency
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FLOOR & ROOF SLAB SYSTEM
REMOVABLE STEEL FORM
PERMANENT CONCRETE FORM
PREFAB SYSTEMS
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CC--JOIST/PCF/R.C. Slab JOIST/PCF/R.C. Slab
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PCF Dimensions PCF Dimensions
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CC--JOIST on Steel I JOIST on Steel I--Beam Beam
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CC--JOIST on Top of Beam JOIST on Top of Beam
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Pre Pre--Cast Concrete Forms Cast Concrete Forms
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INSTALLATION GUIDE FOR C INSTALLATION GUIDE FOR C--JOIST/PCF SYSTEM: JOIST/PCF SYSTEM:
1. May be installed or placed manually or with the use of hoisting
equipment.
2. Laid on top of beams (concrete or steel I-beams) on its specified
spacing using a minimum of 4 seating clearance on concrete beams
and at least 3 bearing capacity for steel I-beams.
3. With joists set in its final spacing, PCF(s) are then placed on top of C-
Joists shoulder in between distances, piece by piece from beam
interior face to end of span.
4. Minimum 10 dowel bars spaced @ 0.30 m. to 0.60 m. o. c. with
about L/5 bend development length are required as shear
connectors.
5. 6mm slab temperature reinforcement @ 0.15 m. o. c. b. w., welded
wire fabric or equivalent. Temperature bars are placed d/2 of
specified slab thickness.
6. 50 to 75 cm thick structural concrete slab with minimum compressive
strength of 3,000 psi @ 28 days taken from top line of C-Joist.
7. Shoring: NO shoring is needed for C-Joist 2.50 m. span and below.
Mid-span shoring for spans above 2.50 m. to 5.00 m. and released
ONL after 7 days.
8. Standard installation of utilities as per conventional reinforced
concrete systems.