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HANDBOOK ON PRECAST CONCRETE FOR BUILDINGS − A PRIMER
Amlan K. Sengupta, PhD, PE
Department of Civil Engineering
Indian Institute of Technology Madras
NAVARITIH 2021School of Planning and Architecture, New Delhi
Building Materials and Technology Promotion Council
EARLY EFFORTS
Courtesy: Hindustan Prefab Ltd. (Estd. 1953)
EARLY EFFORTS
Industrial Buildings (1963)Hindusthan Cables Ltd., Rupnarayanpur
Precast segmental PT girders
Pre‐tensioned purlinsCourtesy: Pinaki Chakraborti
EARLY EFFORTS
Residential Buildings (1964)Heavy Engineering Corporation Ltd., RanchiCourtesy: Pinaki Chakraborti
EARLY EFFORTS
Courtesy: CSIR Structural Engineering Research Centre
Residential apartments (1972‐76)
INDIAN PIONEERS
Baburao G Shirke (1917 – 2010),Padma Shri (2003)
Navi Mumbai
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INDIAN PIONEERS
Shirish Patel (1932),Petit Hall, Mumbai, 1973
INDIAN PIONEERS
A Ramakrishna (1939 – 2014),
Padma Bhushan (2014)
EDRC Building, L & T, Chennai
INDIAN PIONEERS
R SundaramPresident, Structural Engineers World Congress (SEWC)
Kanteerava Indoor Stadium, Bangalore
INTRODUCTION
Objectives
• Covers wide ranging topics
• Simple and easy to read approach
• References to easily accessible literature
INTRODUCTION
Target Users
• Engineers in public and private organisations
• Professionals in construction industry
• Decision making officials
• Educators and students
CHAPTERS
1. Precast Concrete in Buildings and Urban Infrastructure
2. Precast Concrete Building Systems An Overview
3. Foundation and Underground Structures
4. Structural Analysis and Design
5. Prestressed Precast Concrete
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CHAPTERS
6. Seismic Design of Precast Structures
7. Materials and Properties
A) Materials and Products)
8. Joints and Connections in Precast Buildings
9. Production, Handling and Erection of Precast Elements
10. Quality Control and Assurance in Precast Products
CHAPTERS
11. Contracts and Taxation
12. Information Technology in Precast Construction
13. Case Studies
A) Precast Building using Precast Hollow Core Slab
Systems
B) Precast Parking Garage
1. (Late) A Ramakrishna B Sivarama Sarma
2. Amlan K Sengupta
3 S R G dhi
AUTHORS 7. V RamachandraManamohan R KalgalM N Ramesh Raj PillaiB Sivarama Sarma
8. K P Jaya
3. S R Gandhi Subhadeep Banerjee
4. K Ramanjaneyulu
5. N Raghavan
6. A Meher PrasadK P Jaya
9. (Late) K Mohan Kumar
10. P Srinivasan
11. N Raghavan
12. Chandrasekar
13. Sthaladipti Saha
CHAPTER 1
Precast Concrete in Buildings and Urban Infrastructure
(Late) A Ramakrishna, B Sivarama SarmaL&T Constructions
CHAPTER 1Precast Concrete in Buildings and Urban Infrastructure
Advantages of Precast Concrete
• Quality
Better control in a factory environment
Suitable during inclement weather
Efficient quality management
Accuracy in dimensions
Possibility of textured finish
Improved durability with adequate
connectionsMock‐up buildingCourtesy: L & T
CHAPTER 1Precast Concrete in Buildings and Urban Infrastructure
Advantages of Precast Concrete
• Time
Rapid construction with robust planning
Use of mechanised ways, such as
extrusion, battery and tilting moulds etc.
Suitable for modular and repetitive
construction
Curing of wall panelsCourtesy: L & T
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CHAPTER 1Precast Concrete in Buildings and Urban Infrastructure
Advantages of Precast Concrete
• Cost
Optimum use of materials
Limited use of temporary supporting
structures, such as scaffolding
Multiple use of form work
Reduction in amount of formwork
Availability of standard shapes
Reduced maintenance leads to
reduced life‐cycle cost Hostel building at IIIT Sri CityCourtesy: Teemage Precast
CHAPTER 1Precast Concrete in Buildings and Urban Infrastructure
Advantages of Precast Concrete
• Miscellaneous
‘Greener’ buildings
Block work and plastering can be avoided
Additional features can be incorporated
conveniently
Thermal and acoustic control
Reduced manual labour
Better safety and environmental conditions
Suitable for laboratory testing of components
Testing of biaxial hollow slab at IIT Madras
CHAPTER 1Precast Concrete in Buildings and Urban Infrastructure
Challenges of Precast Concrete
• High initial costs for setting up factories
• High transportation costs for delivery of precast components
• Erection of components
• Excise duty of precast products
Courtesy: Teemage Precast
CHAPTER 2
Precast Concrete Building Systems ‐ An Overview
Amlan K Sengupta
IIT Madras
CHAPTER 2Precast Concrete Building Systems ‐ An Overview
Wall type Multistoreyed Buildings
Residential building in BangaloreCourtesy: Star Worth Infrastructure & Construction LtdCourtesy: Star Worth Infrastructure & Construction Ltd.
CHAPTER 2Precast Concrete Building Systems ‐ An Overview
Frame type or Dual type Multistoreyed Buildings
Commercial building in HyderabadCourtesy: Aurobindo Realty & Infrastructure Pvt. Ltd.
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CHAPTER 3
Foundation and Underground Structures
S R Gandhi, Subhadeep Banerjee
IIT Madras
CHAPTER 3Foundation and Underground Structures
Advantages of Precast Concrete
• Fast placement of footing or other components
Early backfilling of soil
Curing is not required
Convenient during monsoon Convenient during monsoon
Fluctuating ground water table
• Reduction in size of excavation
• High grade & quality of concrete
Reduction in cover of concrete
• Avoid bentonite slurry for piles
• No necking or bulging of piles Courtesy: Precast India Infrastructure Pvt. Ltd.
CHAPTER 3Foundation and Underground Structures
Shallow Foundations
Column foundationCourtesy: Teemage Precast
Wall foundationSchmersal India Production Facility, Pune
Courtesy: Precast India Infrastructure Pvt. Ltd.
CHAPTER 3Foundation and Underground Structures
Deep Foundations
PilesCourtesy: Industrial Concrete Products Berhad
PilesCourtesy: L & T
CHAPTER 3Foundation and Underground Structures
Miscellaneous Geo‐Structures
Intake wellCourtesy: www.voiceconstruction.net
UnderpassCourtesy: Reinforced Earth India
CHAPTER 3Foundation and Underground Structures
Miscellaneous Geo‐Structures
Reinforced earth wallKanaka Durga Temple, Vijayawada
Courtesy: TenCate Geosynthetics Asia
Tunnel wallChennai Metro Rail Ltd.
Courtesy: L & T
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CHAPTER 4
Structural Analysis and Design
K Ramanjaneyulu
SERC Chennai
CHAPTER 4Structural Analysis and Design
Features of Analysis
• Modelling of Members
Frame elements for the beams and columns
Membrane or shell elements for the wall panels
Plate elements for the slab units and raft foundation
Strut elements for infill walls
CHAPTER 4Structural Analysis and Design
Features of Analysis
• Modelling of Connections
Emulative connections
Rigid joints
Semi‐rigid joints
Gap joints
Mechanical (Jointed) connections
Semi‐rigid joints
Flexible (Pinned) joints
CHAPTER 4Structural Analysis and Design
Deformed Shapes and Bending Moment Diagrams
Under Gravity Loads
Rigid jointed frame
Flexible jointed frame with eccentric beam‐to‐column loadingCourtesy: K. Ramanjaneyulu
CHAPTER 4Structural Analysis and Design
Deformed Shapes and Bending Moment Diagrams
Under Lateral Loads
Rigid jointed frame
Flexible jointed frameCourtesy: K. Ramanjaneyulu
CHAPTER 4Structural Analysis and Design
Types of Analysis for Lateral Loads
• Linear
Static
Equivalent static analysis
Dynamic M d 1 fi ti Dynamic
Response spectrum analysis
Linear time‐history analysis
• Non‐linear
Static
Pushover analysis
Dynamic
Non‐linear time‐history analysis Courtesy: L & T
Multi‐storeyed apartment buildings at Mumbai
Mode 1 configuration
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CHAPTER 5
Prestressed Precast Concrete
N Raghavan
IIT Madras
CHAPTER 5Prestressed Precast Concrete
Advantages of Prestressing
• High span‐to‐depth ratios
Larger spans
Increased column‐free spaces
Reduced member sizes
Lighter self‐weight
Less material consumption
Lower seismic forces
• Uncracked sections under service loads
Reduction of steel corrosion
Increase in stiffness and shear capacity
CHAPTER 5Prestressed Precast Concrete
Long‐line Prestressing Bed
Courtesy: Teemage Precast
CHAPTER 5Prestressed Precast Concrete
Miscellaneous Applications
Folded platesDept. of Ocean Engineering,
IIT Madras
Trusses,Godown at Chennai portCourtesy: L & T
CHAPTER 6
Seismic Design of Precast Structures
A Meher Prasad,
IIT Madras
K P Jaya
Anna University
CHAPTER 6Seismic Design of Precast Structures
Failures in Past Earthquakes
• Inadequate design and detailing of connections
• Inadequate seating and diaphragm action of floors
• Inadequate deformation compatibility between the gravity load
and lateral load resisting systems
• Inadequate separation of non‐structural elements
Bhuj earthquake, 2001
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CHAPTER 6Seismic Design of Precast Structures
Capacity Based Design
• Members to yield at selected locations sequentially before
damage of the connections (specifically, which transmit gravity
loads)loads)
Stiff and strong connections
Ductility of the connected members
Damage in members beyond repair
CHAPTER 6Seismic Design of Precast Structures
Ductile Joint Based Design
• A joint in a connection to yield before damage of the connected
members
Deformable and ductile joints Deformable and ductile joints
Joints can be repaired
Damage in members is limited
CHAPTER 6Seismic Design of Precast Structures
Frames
Emulative connection
Mechanical (Jointed)connection
Schmersal India Production Facility, Pune
Courtesy: Precast India Infrastructures Pvt. Ltd.
CHAPTER 6Seismic Design of Precast Structures
Walls
Emulative Joint
Multi‐storeyed apartment buildings at Mumbai
Courtesy: L & T
CHAPTER 6Seismic Design of Precast Structures
Design based on Energy Dissipation and Self Re‐centering
• Aims to reduce drift and eliminate damage of members
Jointed connections to open‐and‐close (rocking rotation) cyclically
Avoids uncontrolled cracking of concrete Avoids uncontrolled cracking of concrete
Inserted elements of mild steel (external or internal) to dissipate
energy by yielding across the ‘artificial gaps’
Unbonded post‐tensioned tendons to ‘restore’ elastically
CHAPTER 6Seismic Design of Precast Structures
Frames
External energy dissipater
Internal energy dissipater
Internal
restoring
element
Courtesy: S. Pampanin
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CHAPTER 6Seismic Design of Precast Structures
Walls
Courtesy: Sritharan et al.
Internal energy dissipater
Internal
restoring
element
CHAPTER 6Seismic Design of Precast Structures
Slab Diaphragms
Reinforced topping
Sh t
Chord reinforcement
Precast unitsShear connectors
Composite diaphragm Non‐composite diaphragm
CHAPTER 6Seismic Design of Precast Structures
Slab Diaphragms
Hostel building at IIIT Sri City
Courtesy: Teemage Precast
IT Park Canteen building, Pune
Courtesy: L & T
CHAPTERS 7, 7A
Materials and Properties
V Ramachandra, Manamohan R Kalgal,
UltraTech Cement Ltd.
M N Ramesh,
SAVCOR India Pvt LtdSAVCOR India Pvt. Ltd.
Raj Pillai
Sobha Limited
Materials and ProductsB Sivarama SarmaL&T Constructions
CHAPTERS 7, 7AMaterials, Properties and Products
Materials
• Cement
• Supplementary Cementitious Materials (Mineral admixtures)
• Aggregates: coarse and fine
• Water
• Chemical admixtures
• Reinforcing bars
• Prestressing tendons
• Welded wire mesh
• Fibres Courtesy: Teemage Precast
CHAPTERS 7, 7AMaterials, Properties and Products
Requirements for Precast Concrete
• High early strength
• High durability
• Miscellaneous
High flow mix
Stiff mix
Colour
Texture
Light‐weight
Thermal and acoustic insulation
Fire endurance, etc.Courtesy: Teemage Precast
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CHAPTER 8
Joints and Connections in Precast Buildings
K P Jaya
Anna University
CHAPTER 8Joints and Connections in Precast Buildings
Connections
Slab (S) Beam (B) Column (C) Wall (W)elements elements elements
F: Footing
S–WS–S S–B S–C
elements
B–WB–B B–C
C–FC–C W–FW–W
Facade &
miscellaneous
elements
CHAPTER 8Joints and Connections in Precast Buildings
Connections of Slab Units
Courtesy: Teemage Precast
Hostel building at IIIT Sri City
CHAPTER 8Joints and Connections in Precast Buildings
Connections
Emulative Mechanical (Jointed)
Courtesy: J&P Building Systems Ltd.
CHAPTER 8Joints and Connections in Precast Buildings
Emulative Connection
• Mimics cast‐in‐place concrete connection
• Based on concreting or grouting (wet connection)g g g ( )
• Expected to be corrosion resistant
• Quality control required at site
• Behaviour expected to be “monolithic”
• Requires inserts of reinforcing bars, dowel bars or equivalent
connectors (eg. studs, looped wire ropes), ducts, etc.
CHAPTER 8Joints and Connections in Precast Buildings
Mechanical Connection
• Mimics structural steel connection
• Based on mechanical components
• Needs protection against seepage and corrosion
• Quality control in tolerance required at machine shop and
casting yard
• Behaviour can be rigid, “semi‐rigid”, flexible or “dissipative”
• Requires inserts of plates, anchor rods, bolts, couplers, steel
sections, etc.
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CHAPTER 8Joints and Connections in Precast Buildings
Connections between Walls
Courtesy: Star Worth Infrastructure & Construction Ltd.Aurobindo Realty & Infrastructure Pvt. Ltd.
Horizontal connection(Elevation)
Vertical connection with U‐bars (Plan)
Vertical connection with looped wire ropes
(Plan)
CHAPTER 8Joints and Connections in Precast Buildings
Connections between Frame Members
Courtesy: Aurobindo Realty & Infrastructure Pvt. Ltd.
Slab to beam(Elevation)
Beam to column (Elevation)
Column to column (Elevation)
CHAPTER 8Joints and Connections in Precast Buildings
Connection Materials
• Couplers
• Looped wire rope in a box
• Headed studs
• Bolts and threaded rods
• Inserts
• Bearing pads
• Miscellaneous connecting elementsCourtesy: Teemage Precast
CHAPTER 9
Production, Handling and Erection of Precast Elements
(Late) K Mohan Kumar,
Ra‐Ni Precast Consulting Services Pvt. Ltd.
B Sivarama Sarma
L&T Construction
CHAPTER 9
Production, Handling and Erection of Precast Elements
Moulds
• Column
• Beam
• Wall
‒ Flat
‒ Vertical
Battery
‒ Tilting
• Slab
• Stairs
• Miscellaneous
Flat wall mouldsCourtesy: Teemage Precast
CHAPTER 9
Production, Handling and Erection of Precast Elements
Prestressing
Beds/Benches
• Hollow core slabs• Hollow‐core slabs
• Solid planks
• Beams
• PilesBed for hollow‐core slabs
Courtesy: Teemage Precast
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CHAPTER 9
Production, Handling and Erection of Precast Elements
Production Flow‐chart
Railway sleepersCourtesy: Patil Rail Infrasturcture Pvt. Ltd.
CHAPTER 9
Production, Handling and Erection of Precast Elements
Curing, Demoulding and Storage
Bridge girdersCourtesy: Airport Authority of India
CHAPTER 9
Production, Handling and Erection of Precast ElementsTransportation, Handling and
Erection
Wall elementsCourtesy: Teemage Precast
CHAPTER 9
Production, Handling and Erection of Precast Elements
Lifting and Installation
Staircase
Slab
Balcony
Courtesy: Ra‐Ni Precast
CHAPTER 10
Quality Control and Assurance in Precast Products
P S i iP Srinivasan,
CSIR‒SERC Chennai
B Sivarama Sarma
L&T Construction
CHAPTER 10
Quality Control and Assurance in Precast Products
Relevant Codes
• IS 15916: 2010 (reaffirmed 2019), Building Design and Erection using Prefabricated Concrete ‒ Code of Practice
• IS 15917: 2010 (reaffirmed 2019), Building Design and Erection using Mixed/Composite Construction ‒ Code of Practice
• IS/ISO 9001: 2015, Quality Management Systems ‒ Requirements
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CHAPTER 10
Quality Control and Assurance in Precast Products
Quality Control on Materials, Processes and Products
CHAPTER 10
Quality Control and Assurance in Precast Products
Testing of Finished Products
Railway sleepersCourtesy: Patil Rail Infrasturcture Pvt. Ltd.
Hollow‐core slab unitsCourtesy: Teemage Precast
CHAPTER 11Contracts and Taxation
N Raghavan
IIT Madras
CHAPTER 11Contracts and Taxation
Types of Contract
• Item rate contract
• Lump sum or Design and build contract• Lump sum or Design‐and‐build contract
‒ Turn‐key contract
‒ Engineering Procurement and Construction (EPC) contract
• Cost‐plus contract
CHAPTER 11Contracts and Taxation
Types of Contract (based on concepts of Lean Construction)
• Target Value Design
• Integrated Project Delivery• Integrated Project Delivery
• Alliance Contracting
CHAPTER 11Contracts and Taxation
General Indian Taxation Structure
Excise duty is levied on precast products manufactured outside the site.
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CHAPTER 11Contracts and Taxation
Aspects related to Precast Concrete Construction
• Conditions of Contract
‒ Land requirement
‒ Quality and warranty
‒ Billing stages
• Special Technical Specifications
‒ Structural design with tolerances
‒ Production
‒ Handling, transportation and erection
• Taxation
‒ Typical scenarios
CHAPTER 12Information Technology in Precast Construction
L. Chandrasekar
Trimble Solutions India Pvt Ltd
CHAPTER 12Information Technology in Precast Construction
Building Information Modelling (BIM)
• Suitable for mechanised construction of precast components
• Collaborative and integrated project management from• Collaborative and integrated project management from conceptual design to construction
‒ Tendering quantities and bidding
‒ Constructability assessment and cost estimation
‒ Detailing and integrated manufacturing
‒ Progress visualisation of delivery and erection
• Reduction of wastage leading to lean construction
CHAPTER 12Information Technology in Precast Construction
Integration with Analysis and Design Applications
• Coordination and visualisation of‒Models‒ Drawings‒ Reports
• Change management
CHAPTER 13Cast Studies
Sthaladipti Saha
L&T Constructions
CHAPTER 13Cast Studies
Features
• Framed building with shears walls
• Moment resisting frames with precast beams and columns• Moment resisting frames with precast beams and columns,designed for gravity loads
• Floors made of hollow core slab units
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CHAPTER 13Cast Study 1
Canteen Building in Pune
During construction After completion of project
CHAPTER 13Cast Study 1
Canteen Building in Pune
Beams
Columns
Hollow‐core slab units
CHAPTER 13Cast Study 2
Vehicular Parking Garage in Chennai
After completion of project
CHAPTER 13Cast Study 2
Vehicular Parking Garage in Chennai
Erection of wall units
CLOSURE
Handbook
• Source of compiled information
• Explanatory notes and illustrations
• Lists of references• Lists of references
Publisher
Indian Concrete Institute
www.indianconcreteinstitute.org