I.

INTRODUCTION
Most people are familiar with concrete. However, many people don’t know that
there are many different types of concrete and application for them. Nowadays, the
construction industry is growing more and more with new techniques. Various
researchers and development programs are held by researchers and national
association to find economic and time-saving techniques anchored as the so-called
alternative construction system being precast concrete and cast-in-place as the most
familiar in use.

A. Definition
Site-cast concrete or the cast-in-place is the most popular construction
technique. Dating back for over hundred years ago, an American inventor, Thomas
Edison, patented the first application of a single-pour cast-in-place concrete house. But
before, it was predominantly used for basement walls. Due to certain structural damage
of materials above, Thomas Edison understood the importance of improving upon the
advancement of cast-in-place concrete for its use beyond basement walls.

Typical process:

1. Formwork preparation- wood or metal to define shape and size

2. Reinforcement placement- steel reinforcement, rebars or mesh
3. Concrete placing or pouring- cast-in-place concrete poured into formwork
4. Curing and hardening- concrete needs time to gain strength
5. Formwork removal- once the concrete achieved its strength

Precast concrete OR prefabricated concrete is poured offsite in specific pre-

made molds. Today, it is one of the most widely used materials in construction
worldwide. Because of its producing methos, there is a more guaranteed
assurance of controlled curing since it is closely monitored. Therefore, precast
concrete provides a higher quality structure.

Typical process: molds preparation; concrete mixing, pouring; and molds removal
II. CAST-IN-PLACE VS. PRE-CAST CONCRETE
Here is an overview table comparing precast concrete to site-cast concrete:

Factor Precast Concrete Site Cast Concrete Winner

Precast Concrete
Uses the best materials Uses the locally
Quality has a better quality
possible available options
No guaranteed
Highly durable due to better durability due to Precast concrete is
Durability
materials used variation in materials more durable

Both are versatile in

Highly versatile due to Versatile in shape but shape but precast
customized size, shape, no option for variation concrete has a
Versatility
finishes, and reinforcement in other elements like better overall
options finishing versatility

Significantly higher strength Limited strength due Precast concrete

Strength due to controlled to environmental has significant edge
manufacturing and added factors and lack of in terms of strength
reinforcements quality reinforcements

Precast concrete is
Cheaper initially but
Costly initially but cost cheaper for large
more expensive
Cost saving overall in large scale constructions
overall for large
constructions whereas site cast is
constructions
cheaper for small
scale construction

High labor Precast concrete is

Human Labor Low labor dependency since dependency since the better choice
Dependency labor is only required for labor is required for since it is
installation concrete making and independent of labor
pouring requirements

Preparation work is Precast concrete

Preparation No preparation work
required for the has lower
Work required, simply buy the
concrete as well as preparation work
panel and install it as it is
the job site requirement

Curing Cured in ideal conditions Cured outdoors

Precast concrete
Conditions with controlled temperature without any control
and humidity over temperature
High quality control due to
 No quality control
constant monitoring over the since constant
Quality Control Precast concrete
entire process monitoring is not
possible at the job site
No installation time
Some installation time is
Installation required since
required since concrete Site cast concrete
Time concrete is poured
slabs need to be fixed in
directly in place
place
Total
Low construction time due to High construction time
Construction Precast concrete
elimination of prep work and due to weeks spent in
Time
curing process concrete curing

Transportation High Low Site cast concrete

Cost

Joints Presence of joints when No joints present Site cast concrete

merging of different panels

Heavy Required for lifting and

Not required Site cast concrete
Machinery installation of panels
Requirement

Earth quality High due to reinforcements

Variable Tie
and Wind and structural elasticity
Resistant

Weather Independent of weather Highly dependent on

Precast concrete
Dependency conditions since curing weather conditions
happens off-site
III. METHODS OF CONSTRUCTION (PRE-CAST)
Concrete is the most widely used construction material in the world. Precast
concrete is a type of concrete that is produced offsite and then transported to the
construction site for installation. This type of construction method offers several
advantages over traditional construction methods, including increased speed of
construction, improved quality control, and reduced labor costs. There are several
methods used in precast concrete construction. Here are some common methods:

1. Precast Slabs - Slabs are one of the most common precast elements used in
construction. They are manufactured in various sizes and shapes according to the
project requirements. Precast slabs can be used for walls, floors, roofs, and other
structural elements. They are typically cast on flat beds or tables and cured in a
controlled environment.

• Flat slab - Flat slab is a reinforced concrete slab supported directly by concrete
columns without the use of beams. The principal features of a flat slab floor are a
flat soffit, simple. formwork and easy construction. A flat slab is a one-way or
twoway system with thickenings in the slab at the columns and load bearing
walls called drop panels.
 • Hollow-core slabs - Hollow-core slabs are precast concrete elements that are
used to create floors, roofs, and ceilings. They are produced with hollow cores
that reduce their weight and increase their strength.

• Single-tee slabs - The name given to a type of precast concrete deck which has
one stiffening rib integrally cast into slab.

• Double-tee slabs - Double-tee slabs are precast concrete elements that are
used to create large floors and roofs. They are produced with a double-tee shape
that provides increased strength and durability.

2. Ribbed floor slab - Introducing voids to the soffit of a slab reduces dead weight
and increases the efficiency of the concrete section. A slightly deeper section is
required but these stiffer floors facilitate longer spans and provision of holes. Economic
in the range 8 to 12m. RIBBED FLOOR SLAB - Ribbed slabs are made up of wide band
beams running between columns with equal depth narrow ribs spanning the orthogonal
direction. A thick top slab completes the system.
3. Waffle slabs - Tend to be deeper than the equivalent ribbed slab. Waffle slabs
have a thin topping slab and narrow ribs spanning in both directions between column
heads and band beams. The column heads or band beams are the same depth as the
ribs.

4. Flat Plate System - One- or two-way system usually supported directly on

columns or loadbearing walls. It is one of the most common forms of construction of
floors in buildings. The principal feature of the flat plate floor is a uniform or near-
uniform thickness with a flat soffit which requires only simple formwork and is easy to
construct.
5. Lift-Slab Construction - A precast method of construction of slab on the ground
and then lifting it to the structure. A type of pre-casting used in building construction
involves casting floor and roof slabs at or near ground level and lifting them to their final
position, hence the name lift-slab construction.

6. Precast Beams and Columns - Beams and columns are another essential
component of precast concrete construction. They are manufactured in various
crosssectional shapes, such as rectangular, T-shaped, or L-shaped. Beams and
columns are cast horizontally or vertically, depending on the design requirements. They
are often reinforced with steel bars or pre-stressing tendons to enhance their strength.

7. Precast Foundation Systems - Precast concrete foundation systems are used

to support the load of a structure and transfer it to the underlying soil. These systems
include precast footings, pile caps, and foundation walls. Precast foundation systems
offer advantages such as reduced construction time, improved quality control, and
enhanced durability.
IV. APPLICATION OF CAST-IN-PLACE AND PRE-CAST BUILDING
CONSTRUCTION

A. CAST-IN-PLACE CONCRETE CONSTRUCTION

1. Uses of Cast in Place Concrete

a) One of the major uses of building roofs is made of generally

cast-in-place concrete.

b) Another use of cast-in-place concrete is In beams, columns:

cast in situ concrete is widely used.

c) Cast-in-place concrete is widely used in different places like

building walls, slabs.

d) Cast in situ concrete is used in building foundations.

e) In beams, columns: cast in situ concrete is widely used.

B. PRE-CAST CONCRETE CONSTRUCTION

1. Uses of Pre-Cast Concrete

a) Use of Precast Concrete in Frames

(1) Structural Frame

This type of frame comprises precast concrete columns

paired with beams, and slabs. It is typically used for retail
developments, car parks, and office buildings.

(2) The Cross-Wall Frame

 This type of frame is made up of solid walls and floor slabs.
You’ll generally find it used for hospitals, schools, and
hotels.

b) Use of Precast Concrete for Floors

This is a very popular way of using precast concrete. More than five
million square meters of precast floor slabs are used in the
construction industry annually. Just to put it into perspective, that’s
equivalent to more than 700 football pitches which makes it a
popular material for the modern construction site.

The main types of precast floor slabs include:

 Plank

 Hollow core

 Beam and a block

 Double tee

c) Use of Precast Concrete in Cladding

Another common application for precast concrete is in the form of

cladding. It can be a structural element in a building, but it is more
often used as a non-structural decorative facade.

The concrete backing will contain ordinary precast concrete

elements. However, the facade will be a special mix. For example,
manufacturers might be producing precast concrete using white
Portland cement. It’s possible to create various forms, colors, and
details.

2. What Are the Most Common Precast Products?

Two of the most common applications for precast concrete manufacturing
products are retaining walls and hardscaping. Precast concrete is used
because it can be formed into stackable, interlocking blocks. These blocks
are extremely stable and provide excellent structure for walls, stairways,
and other applications.

Other common uses of precast concrete include:

 Foundations

 Pocket footings and Combined footings

 Precast piles

 RCC beams and Prestressed concrete beams and Shell beams

 Various types of slabs

 Load-bearing and non-load-bearing walls

C. FEATURED BUILDING EMPLOYING CAST-IN-PLACE AND PRE-
CAST METHODS OF CONSTRUCTION

1. THE SYDNEY OPERA HOUSE

The Sydney Opera House is a great architectural work of the 20th century
and is renowned as Jørn Utzon’s masterwork. This has been
acknowledged by many experts in the field, and also the public, both
nationally and internationally. Jørn Utzon’s exceptional creativity and
response to the competition brief, and Sydney’s harbour setting has given
us the Sydney Opera House we have today – its conceptual arrangement,
its powerfully expressive structure with spectacular white tiled shells
supported on the solid podium and broadwalk, as a man-made headland
at the end of Bennelong Point. Together, these elements determine the
Sydney Opera House’s visual character and its primary significance.
These values are best demonstrated through an understanding of the way
Utzon worked and via specific characteristics of the Sydney Opera House.

a) Story of the Sydney Opera House's Construction

Today, it would be hard to imagine Sydney without the iconic

silhouette of the Opera House. But, like any good drama, the story
of this world-renowned venue is one of highs and lows, moments of
innovation and of disaster.

In
1955
an

international design competition was launched by NSW Premier

Joseph Cahill, calling for a venue suitable for operas, ballets, and
concerts to be sited at Bennelong Point. A total of 233 entries,
representing architects from 32 countries, were received.
The winning design, announced in 1957, was by Danish architect
Jørn Utzon. According to legend, the design was first rejected,
before being rescued by Finnish-American architect Eero Saarinen.

The plan was to build the complex structure in three stages: first the
concrete base, then the curved 'shell' roof, and finally the interior
and theatre machinery. The construction of the building would
eventually end up spanning 14 years, from 1959 to 1973.

Construction commenced on 2 March 1959, but Utzon had not

actually finished his designs, and major questions about the
building's structural integrity remained unanswered. By 23 January
1961, work was running nearly a year behind schedule.

Work on the concrete base was finally completed in February 1963.

But it was soon discovered that corners cut earlier in the
construction meant that the foundations couldn't support the weight
of the roof, and had to be rebuilt.

The 'shell' roof of the building was central to Utzon's design, but the
engineers actually tasked with constructing the concrete panels
struggled to find an acceptable solution. From 1957 to 1963, the
design team ruled out at least 12 different options.

The construction process was notable for being one of the first to
use computers to model the complex forces that the shells would
be placed under. Data was collected at the end of each day and fed
into the computer that would calculate the result overnight.

From a distance, the shells appears to be pure white and smooth,

but they are actually made of 1,056,006 individual glossy white and
matte cream tiles, arranged in a subtle chevron pattern.
On 6 April 1962, it was estimated that the Opera House would be
completed between August 1964 and March 1965. By 1966, with
the building still incomplete, the project had cost A$22.9 million.

That same year Utzon resigned and Lothar Cremer, the project's
acoustic specialist, reported that the hall would only be able to seat
2000, rather than the 3000 expected. In addition, the stage
designer Martin Carr criticised almost every single aspect of the
design.

The building was completed in 1973, having cost A$102 million.

The original cost and scheduling estimates in 1957 projected a cost
of A$7 million and completion date of January 1963. In reality, the
project was completed ten years late and 1,357% over budget.

The Sydney Opera House was formally opened by Queen

Elizabeth II on 20 October 1973. Utzon was not invited to the
ceremony, nor was his name mentioned. The opening was
televised and included fireworks and a performance of Beethoven's
Symphony No. 9.

In the late 1990s, the Opera House reconciled with Utzon and he
was appointed as a design consultant for future work. In 2003,
Utzon recieved the Pritzker Architecture Prize, one of the highest
awards in the field.

b) Building Features
 Although the roof structures of the Sydney Opera House are
commonly referred to as "shells", they are in fact not shells in a
strictly structural sense, but are instead precast concrete panels
supported by precast concrete ribs. The shells are covered in a
subtle chevron pattern with 1,056,006 glossy white- and matte-
cream-coloured Swedish-made tiles from Hoganas AB, a factory
that generally produced stoneware tiles for the paper-mill industry.

Apart from the tile of the shells and the glass curtain walls of the
foyer spaces, the buildings exterior is largely clad with aggregate
panels composed of pink granite quarried at Tarana. Significant
interior surface treatments also include off-form concrete,
Australian white birch plywood supplied from Wauchope in northern
New South Wales, and brush box glulam.

REFERENCES:

Google. (n.d.). The surprising story of the Sydney Opera House’s construction - google
arts & culture. Google. https://artsandculture.google.com/story/the-surprising-story-
of-the-sydney-opera-house-39-s-construction/CAVhiDXG4On-xA?hl=en

Gundaraniya, N. (2022, January 29). What is cast-in-situ concrete: Cast in place

concrete advantages and disadvantages: Concrete casting techniques.
CivilJungle. https://civiljungle.com/cast-in-situ-concrete/

Kommana, G. (n.d.). Methods of precast concrete constructions.

https://www.linkedin.com/pulse/methods-precast-concrete-constructions-goshant-
kommana
Premier Precast. (2023, January 8). Uses of precast concrete.
https://premierprecast.com/precast-concrete-applications/