PRECAST

CONSTRUCTION
Group 4
Tushar Singh
Suhani Jaiswal
Sejal Boyat
Raghav Goel
 CONTENTS
1)introduction to precast
2)types of precast components
3)material used
4)manufacturing process
5)transportation and handling
6) installation and joinery
7) applications of precast
8) advantages
9) disadvantages
What is PRECAST Technology?
Precast construction Technology is a system of casting
concrete in a reusable mould or “form” which is then
treated in a controlled environment, conveyed to the
construction site and lifted to the place. In this technology
the product is produced by casting concrete in a reusable
“mould” which is then cured in a controlled environment,
transported to the construction site and assembled in the
required form.

It is a sustainable and efficient alternative to conventional

cast-in-situ methods as it reduces on-site labor, shortens
construction time, and minimizes material wastage.
Some precast examples -

Bandra-Worli Sea link Lighthouse Project, Chenna Galaxy Tower, Hyderabad (Tallest
ghtc-india.gov.in Precast Tower)
 Between 1905 and 1910, the Madras Port
was constructed using precast piles and
retaining walls, marking the first recorded
use of precast pile foundations in the
country.

● Pragati Towers, Mumbai is recognized as the first high-rise

residential project in India to employ such technology
extensively.
● Initiated in the early 2010s, this development comprises eleven
residential towers, each approximately 70 meters tall, utilizing
a total precast concrete system.
● www.pci.org
USE OF TECHNOLOGY
● This technology is suitable for construction of high
rise buildings resisting seismic and wind induced
lateral loads along with gravity loads. The building
framing is planned in such a way that maximum
number of repetitions of moulds is obtained.
● The technology shall be used for mass housing
projects, Industrial & Commercial buildings, etc.
● The system would comprise of Precast Columns,
Precast Solid Wall Panels, Pre-stressed Precast
Hollow Core Wall Panels, Pre- stressed Precast
Beams, Pre-stressed Precast Hollow Core Slabs,
Precast Slabs, Precast Staircases.

https://struengineers.com
TYPES OF PRECAST ELEMENTS
1) Precast reinforced concrete elements: 2) Precast pre-stressed concrete elements:

These shall consist of reinforcement bars and/or These shall consist of pre-stressing tendons within
welded wire meshes within the elements to provide the elements to provide a predetermined force
the structural strength as per requirement of the needed to resist external loadings and cracks.
component.
They have a higher load-bearing capacity due to the
They use high-tensile steel strands or cables, which pre-stressing, making it suitable for long spans and
are tensioned before or during concrete casting to heavy loads
improve strength and reduce cracks.
Example : hollow core slabs, beams and planks.
Example : façade walls, beams, columns, slabs,
staircases and parapet wall
PRECAST WALL PANEL PRECAST BEAM PRECAST STAIRCASE

HOLLOW CORE SLAB PRECAST COLUMN Source : BMTPC

SPECIFICATIONS
FOR RAW
MATERIALS
Source : BMTPC
Materials used in precast
Pecrast elements could be made of reinforced or prestressed concrete. Some
materials used are:

● Cement for Precast Concrete Buildings

Ordinary Portland Cements [OPC] 43 grade [IS:8112] and 53 [IS:12269] are
normally used in precast concrete construction.
Portland Pozzolana Cement [IS 1481] and Portland Slag Cement [IS 455] are
preferred

● Supplementary Cementitious Material [SCMs] for Precast Concrete

Buildings
SCMs enhance the results of ordinary portland cement (OPC) hydration reactions
in concrete and are either incorporated into concrete mixes as a partial
replacement for portland cement or blended into the cement during
manufacturing.

● Waterproofing admixture for Precast Concrete Buildings

Waterproofing admixture for precast construction should comply with the
requirements of IS; 9103-1999, when compared with the manufacturers’
https://constrofacilitator.com/different-mate
declared values. rials-used-for-precast-concrete-buildings/
 ● Reinforcement bars for Precast Concrete Buildings
Reinforcement bars should comply with IS; 1786-2008 for high strength
deformed bars for concrete reinforcement, IS; 432 for mild steel and medium
tensile bars.

Welded wire fabric reinforcement is widely used in developed countries and its
use in India is also seeing a rise.

● Protective coatings on reinforcement for Precast Concrete

Buildings
The most commonly used coating is zinc-based. It provides appropriate
thickness in the form of hot-dip galvanization.

● Fibers for Precast Concrete Buildings

Fibers can be used as reinforcement in precast concrete, either as a fiber-only
solution or as a combined solution with conventional rebar reinforcement.
Fiber-reinforced concrete (FRC) in precast construction increases its structural
integrity. In certain specific circumstances, steel fiber or macro synthetic
fibers can entirely replace traditional steel reinforcement bars in reinforced
concrete.

● Epoxy grouts for Precast Concrete Buildings

Epoxy grouts are used when very high strength is desired to the concrete.
They are mixtures of epoxy resins and filler material, mostly sand.
https://constrofacilitator.com/different-materials-used
-for-precast-concrete-buildings/
Manufacturing process
1. Design and engineering
The process begins with the creation of detailed designs using advanced 3D
computer-aided design tools. These designs specify the structural requirements
and dimensions of the precast components. It’s at this stage where our design
team can help our clients save money by choosing the most efficient way to
manufacture the precast units.
2. Rebar cage assembly and form preparation
Steel reinforcement bars are cut, bent, and assembled to form the rebar cage,
which is essential for structural strength. For small runs, moulds made from
wood will be more cost-effective, but steel moulds are preferred where multiple
units are required as they can be used numerous times without getting
damaged or distorted. This ensures that each unit is exactly the same as
previous ones.
https://poundfield.com/about/precast-concrete-manufacturers/
Cover spacing clips are used to ensure that the correct cover of concrete over
the reinforcement is achieved. Prior to the rebar being placed in the mould,
release agents are sprayed onto the mould to ensure easy demoulding when
the concrete has set. The rebar is installed, along with lifters which are
designed by engineers to be placed in specific positions so that the units can
subsequently handled and moved safely once the concrete is set.

3. Mixing and placement

Before the concrete is poured into the mould, the quality control team carry out a
precheck to ensure everything is correct, and signs the unit off as ready to pour. This
then allows the mix to be prepared and high-quality raw materials, including cement,
aggregates, and water, are mixed to meet specific design requirements. Once the mix
has been tested for compliance by means of a slump/flow test, cubes are taken for
compression testing and the batch of concrete is then poured into the mould,
ensuring it flows around the reinforcement.
4. Curing and monitoring
The concrete undergoes a controlled curing process and this stage is crucial for
achieving the desired strength and durability. Cube tests are carried out where a
sample of the concrete used is placed into a cube, allowed to cure and then
measured for its compressive strength at 7 and 28 days. The results are compared
against the specific specification of the job.
5. Demoulding and quality assurance
After curing, the concrete is carefully demoulded. Each piece undergoes rigorous
quality checks to ensure it meets all the specified standards before it is released
from production and marked as being ready for delivery to the customer. Each
unit is labelled to ensure a fully traceable process.

https://poundfield.com/about/precast-concrete-manufacturers/
6. Transportation and handling
Once the units have passed quality control, the precast components are transported to the construction site and
installed by the customer or by our installation teams.
you need a strong heavy haul trucking partner to move precast concrete. To transport precast concrete, you need to
move them from plant to yard, from the yard to truck, and from the truck to the site. If you want to preserve the
product’s quality throughout the transportation stages, you need to follow the best practices. Before moving the
products from yard to truck, ensure that they have attained good strength for transportation.
INSTALLATION AND JOINERY
PROCESS
1) Proper planning and preparatory works shall be required before the
actual installation of precast concrete elements
2) Method of sequence of assembly and installation: Precast
elements should be identified based on their location number and the
tagged
3) Method of providing temporary support: Elements should be
supported temporarily before these get stabilized. Generally structural
members with adjustable ends shall be used for securing the panels.
Shims should be used to adjust the panels to ensure dimensional
correctness.
4) Installation tolerances: Installation tolerances should be based on
codal provisions and design considerations should be clearly
indicated.
5) Handling and rigging requirements: Elements should be checked for
handling stresses before lifting and the cranes should have sufficient
capacity to handle the precast panels. At least 10% impact should be
considered while calculating the lifting capacity of the crane.
 Precast
Installation

Waterproofing

Fire Rating
At site locations, panels shall be first
unloaded and stacked or directly lifted by
the crane. The element shall then be
installed on the site and supported by Mechanical,Electrical
temporary jacks. The cranes shall be ,PLumbing
released for next lifting once the
temporary supports are in place. Shims
shall be used to carefully align the
element before grouting. The panels shall Finishes
be grouted after the final adjustments are
done.
BEAM AND SLAB CONNECTION Source: BMTPC Precast Construction Technology
WALL PANEL TO WALL PANEL AND
WALL PANEL TO WALL PANEL
WALL PANEL TO SLAB

Source: BMTPC Precast Construction Technology

WALL PANEL TO SLAB WALL PANEL TO PRECAST LANDING

Source: BMTPC Precast Construction Technology

External joints shall be sealed
with baker rods and sealants
after filling the joints with grout
to avoid the leakage. Additional
waterproofing treatment shall
be provided at external joints
and wet areas to ensure water
tightness.

WATERPROOFING

Source: BMTPC Precast Construction Technology

Why choose precast concrete?
● One of the primary benefits is its ability to reduce
construction time and labour costs due to off-site
manufacturing.
● It is very durable and can withstand harsh weather
conditions and heavy loads, making it a
long-lasting material choice.
● It also offers design flexibility, with various shapes,
sizes, and finishes available to suit specific design
requirements.
● It is also a sustainable material choice, made from
recycled materials and fully recyclable at the end
of its life cycle.
● As an industrially produced building product,
precast is always of the highest quality.
https://www.ultratechcement.com/for-homebuild
ers/home-building-explained-single/descriptive-a
rticles/guide-on-precast-concrete
 Precast VS Prefab construction
Construction process
● Precast concrete is poured and cured in controlled factory settings,
creating standardized shapes that are then transported to the
construction site for assembly.
Prefabricated construction involves assembling pre-made building
components on-site, allowing for more customization and flexibility in
design compared to precast methods.

Customizability
● Precast concrete structures are typically more standardized and
mass-produced, limiting the level of customization available. In
contrast, prefabricated construction allows for greater flexibility and
adaptability in design, making it well-suited to meet specific project
requirements.Prefabricated concrete structures can be customized
according to size, shape, color, finishes, and other specifications.

Location of manufacture
● Precast concrete components are predominantly manufactured in
specialized factories with controlled conditions.
This results in tight production control, ensuring high standards of
safety, quality, and durability. On the other hand, prefabricated
components can be produced in a variety of settings, offering more
flexibility but potentially leading to variations in production control.
https://www.vintagecast.com/post/what-is-the-differenc
e-between-precast-and-prefabricated-concrete
Applications
Building Construction:

Precast concrete elements like beams, columns, walls and floor panels
are widely employed in the construction of residential, commercial and
industrial buildings.

Infrastructure Projects:

In infrastructure development, precast concrete is utilised for bridges,

tunnels, retaining walls

Water Management Structures:

Precast concrete products can be used to construct structures for

storing water and other fluids. Common examples include manholes,
septic tanks, pipes, stormwater detention systems and sewage
treatment.

Landscaping:

Precast concrete is utilised for various landscaping and hardscaping

features like retaining walls, pavers, steps and decorative elements.
https://www.jkcement.com/blog/basi
cs-of-cement/what-is-precast-concre
te/#uses-of-precast-concrete
Advantages
● Precast Concrete construction saves time, and the risk of project
delay is also less.
● The key factors which regulate the quality of construction such as
curing, temperature, mix design, formwork, etc. can be monitored
for precast concrete. So, improved quality construction can be
performed.
● By using prestressed precast, structural materials of high strength
and load-bearing capacity can be achieved, which can result in
greater clear span, reduced size of the cross-section of structural
members, etc.
● The simplified construction process reduces time, increases
productivity, quality and safety and thus the cost is reduced.
● Precast Concrete structure has a longer service time period and
minimal maintenance. The high-density Precast Concrete is more
durable against acid attack, corrosion, and impact, reduces surface
voids, and resists the accumulation of dust.
● It reduces the requirement of traditional formworks and props,
wastage, workers, etc., and thus provides a safe working platform.
● As the structures are made of prefabricated concrete in a controlled
factory environment, several combinations of colors and textures
can be used. A wide range of shapes and sizes are available to
choose from with smooth finishing and thus the aesthetic value of
products is increased. https://civiltoday.com/civil-engineering-materia
ls/concrete/232-advantages-and-disadvantag
es-of-precast-concrete
 Disadvantages
● For installing a precast concrete plant, heavy and sophisticated machines
are necessary which requires a high initial investment. A large scale of
precast construction projects must be available to ensure sufficient profit.
● The construction site can be at a distant location from the precast
concrete plant. in that case, the precast members must be carried to the
site using trailers. in many cases, the reduced costs of pre cast concrete
are compensated by the transportation cost.
● Limitation in the case of precast structures, it is difficult to modify the
structure. For example, if structural precast concrete walls are to be
dismantled for modification it will impact the overall stability of the
structure.
● Proper care and precaution have to be taken for handling precast
concrete. Usually, precast members are heavy and large which makes
them difficult to handle without damage. Generally, portable or tower
cranes are used to handle precast members.
● Assembling the precast members is one of the key points for ensuring
strong structural behavior. Connections between several structural
members must be supervised and done properly to ensure the intended
behavior of the connection such as simple, semi-rigid, or rigid
https://civiltoday.com/civil-engineerin
connections. Besides this, faulty connections in precast concrete may lead g-materials/concrete/232-advantage
to water leakage and failed sound insulation. s-and-disadvantages-of-precast-con
crete