Technology of precast concrete structures. Prof. Dr. Islam Ezz El-Arab

1. Technology of Precast Reinforcement Concrete
Structures
Prepared by
Prof. Dr. Islam Ezz El-Arab

2. OUT LINE :
1. Introduction
2. Features and benefits
3. General Principals of Precast
4. Project progress
5. General description of products
6. Architectural Façade Elements
7. New techniques of precast HCS
8. Conclusion
Examples of Precast projects (photos)

3. 1- INTRODUCTION
• What is Precast?
• How to produce it?
• How to Install it?
• QA / QC
• Project Progress.

4. •Higher construction efficiency
•Design freedom & flexibility in
•Forms
•Colours
•Shapes
•Textures
•Excellent resistive characteristics
•Thermal
•Acoustic
•Fire
•Higher quality & improved durability
•All weather construction
•Environmentally friendly construction
2. FEATURES & ADVANTAGES OF PRECAST
CONCRETE CONSTRUCTION
• Advantages of precast
• Speed
• Quality
• Cost

5. What is Precast?
• Successful use is largely dependent on an effective structural
layout and carefully conceived connection details.
• The effects of restraint of volume changes caused by creep,
shrinkage and temperature change must be considered in
every structure.
• Architectural Precast panels can be used as cladding as well
as load bearing members. they can be used to support loads
in both the vertical and lateral directions.
• Pre-stressing improves the economy and performance of
precast members, but is usually only feasible with standard
shapes which are capable of being cast in long –line beds.

6. 3. General Principals of Precast
• Precast concrete is basically a “ Simple-Span” material
However, continuity can be achieved with properly
conceived connection details.
• Sizes and shapes of members are often limited by
Production, Handling and Erection consideration.
• Maximum economy is achieved with maximum repetition.

7. TRANSFORMING THE DESIGNER’S VISION INTO A
FINISHED STRUCTURE
Thorough knowledge of the materials
Experience in the design and detailing
High levels of workmanship & ingenuity
Understanding the important design considerations
dictated by:
- Materials characteristics
- Structural analysis
- Manufacturing and installation efficiencies

8. Membership & Qualification
International Industry and Academic Membership:
National Precast Concrete
Association (NPCA)
Precast/Pre-stressed Concrete
Institute (PCI)
The Congress for New
Urbanism (CNU)
Meet the Following National and International Standards:
ISO 9001: 2008
National
Standard of
China
Companhia de
Desenvolvimento
Habitacional e Urbano
INSTITUTO DE
PESQUISAS
TECNOLOGICAS

9. WWhole Process of pprecast structures Construction

10. BIM of whole process
Layout edit
BOM list checking
Closing account
Logistics
Construction
management
Construction simulation
Budget control
BIM Data Base
Engineering department
Materials purchasing
PC components
production
Design and construction of
building information modeling
Completion

11. 4. Project Progress
1. Initial stages
2. Planning
3. Execution
4. Monitoring, control & reporting
5. Final stages

12. Project Progress
1- Initial stages
• Project award memorandum
• Value Engineering (Value Management)
• Budget
• Quantity Survey
• Assigning a Project Coordinator
• QC/QA documents
• Materials Submittal

13. Project Progress
2. Planning
• Overall planning
• Value engineering (Value Management)
• Production and installation techniques for cost effectiveness
and efficiency of work, value engineering is done for:
• Process
• Material
• Moulds
• Moulds planning
• Material procurement
• Detailed production plan
• Detailed Installation plan

14. 3. Execution
Production
Storage
Delivery
Installation
Project Progress

15. Define whole
production
model
Check against
requirements
with
parametric
rules engine
Optimize and
visualize
schedule
Generate
drawings &
BOM
automatically
Provide
product data
to ERP
Intelligent Precast Concrete Factory

16. PC Curing Chamber
Steel Bar
Processing
PC Demoulding
Finished PC Products
Concrete Spreading and Vibrating
Layout of PC Factory

17. PRECASTER ENGINEERING MAPING PLAN
• Design Criteria
• Purpose of the element
• Loading criteria
• Production constraints
• Size
• Shape
• Delivery constraints
• Height
• Length
• Installation constraints
• Weight
https://www.youtube.com/watch?
v=gsklP03biNk

18. 55. Precast Products :
o Precast Slabs
o Load bearing Wall panels
o Insulated exterior Wall panels
o Shear and Core Walls & Stair modules
o Columns, Slabs and Beams
o Precast Strip Footing

19. Standard components
Columns Floor BeamsRoof Beams Floor Slabs

20. Vertical Load Bearing
Precast columns
Example of standard dimensions
Connection details

21. Vertical Load Bearing
Precast columns and walls
Requires skilled labor and consultant technical supervision
Complicated connections
Still under research for seismically active zones
Currently cast-in-situ columns and walls are recommended for
high-rise buildings

22. Precast Columns

23. PRECAST COLUMNS WITH CORBELS

25. Erection of precast column

26. Vertical Load Bearing
Precast walls
Connection details
B C H
Minimum 4.00 m 2.40 m -
Normal 6.00 - 12.00 3.60 - 6.00 2.60 - 3.30
Maximum 14.00 12.00 4.20 - 4.50
Shear wall
Cross wall FloorCross wall Floor

27. Beams
Secondary roof beams
Straight I beamsRectangular floor beams
Rectangular beams
Inverted floor beams
Sloped I beamsPrimary roof beams

28. Precast floors
Floor type Span Height Width kN/m²
9 m 100 - 300 mm 300 - 1200 mm 2.0 - 4.0
20 120 - 550 1200 2.0 - 4.8
24 (30) 200 - 800 2400 2.0 - 5.0
9 150 - 300 600 1.5 - 3.5
6 100 - 250 300 - 600 0.7 - 3.0
7 100 - 200 600 - 2400 2.4 - 4.8
7 200 - 300 - 1.8 - 2.4

29. Precast floors
Basic module normally 1200 mm
Large flexibility in floor layout
Punching resistance is a function of the slab cross-section
and thickness of topping
Hollow core slabs

30. Hollow Core Slab (HCS)

31. HCS Stationary Casting Bed and production table

32. Precast beam and precast cantilever slab connection detail

33. Precast beam and precast floor slab connection detail

34. Full precast commercial and
administration structures .

36. PPrecast pre stressed double T slab section

39. B- PRECAST BEAMS

40. Precast BEAMS SECTIONS

41. Precast BEAMS SECTIONS

50. D- PRECAST WALLS

51. PRECAST WALL
1 SECTION
1
REINFORCEMENT DETAIL OF PRECAST EXTERNAL WALL (SW1)
SANDWITCH PANEL

52. PRECAST WALL
REINFORCEMENT DETAIL OF PRECAST EXTERNAL WALL
2
SECTION2
DETAIL-X
SANDWITCH PANEL - WITH OPENING

53. PRECAST WALL
2
SECTION2
DETAIL OF PRECAST INTERNAL SOLID BEARING WALL

54. PRECAST WALL
SECTION1
1
DETAIL OF PRECAST INTERNAL SOLID BEARING WALL
WITH DOOR OPENING

56. Precast wall plant technology

62. E- PRECAST STAIR

63. PRECAST STAIR CASE
PRECAST STAIR---
SCALE 1:25

64. Precast Stair case

66. What is Precast?

68. H- PRECAST CLADDING

69. PRECAST CLADDING PANELS
C7
C3
C25
+5.500
T.O. PANEL
(B46)
+
+10
T.O
(B90)
C4
C3

70. Precast cladding panel

71. 6-Pre cast Finishing
o Face Concrete Finishing
o Exposed Aggregates
o Sandblasting
o Acid Etching
o Pigments
o Form Liners
o Veneer Faced Panels

72. Architectural Finishes
Texture
- Form Liner
- Exposed Aggregate
- Acid Etched
- Sand Blasted
- Bush Hammered
Veneer-faced, stone, brick, or ceramic
Color
- Pigmented
- Naturally colored aggregates
Shape
- Unlimited shapes

73. Face Concrete Finishing
Smooth as Cast (Post paint)
Smooth, as cast finish is the most
economical. Unfortunately, this finish
is seldom aesthetically acceptable
due to pinholes on return surfaces
and because of color variation.
Smooth as cast precast concrete
panels have a smooth film of
hardened cement paste, and the
finished color is therefore
determined primarily by the color of
the cement.

74. Exposed Aggregates
(washed finish)
Exposed aggregates finishes
are achieved by coating the
form into which the concrete
will be poured with a concrete
retarder. The retarder arrests
the hardening of the concrete
which comes in contact with it,
to a depth determined by the
strength of the retarder. The
final product of the exposed
aggregates can be in Light
exposure, Medium exposure
or Deep Exposure.

75. Sandblasting
Sandblasting
removes the cement
sand matrix by
abrasion, a result of
the impact of sand
on the panel surface.
The final product of
the product can be in
Light exposure,
Medium exposure or
Deep exposure.

76. 7. New techniques of precast HCS

77. 1- NEW SPECIAL DETAILS HCS OF STEEL
STRUCTURES

78. 22- NEW details of shear strengthen
WWeb Shear Strengthening Technique of Deep Precast Prestressed
Hollow Core Slabs under Truck Loads
https://www.scirp.org/journal/paperinformation.aspx?paperid=79451

79. What is Precast?

80. 33- New Technique for Partial Continuity of Simple Support Beam-
CColumn Connection
http://www.iosrjournals
.org/iosr-
jmce/papers/vol13-
issue5/Version-
8/F1305083950.pdf

81. Conclusion
Precast concrete structures is
1 - Experience in the design and detailing
2 - Understanding the important design considerations
dictated by:
- Materials characteristics
- Structural analysis
- Manufacturing and installation efficiencies.

82. Examples of precast projects

106. THANK YOU