ABT REVIEWER precast elements and becomes a working part
of their structural action.
Precast concrete ● Additional reinforcing can be cast in the
● a construction method using prefabricated topping and in-floor electrical conduits may
reinforced concrete elements – is gaining also be embedded.
popularity worldwide. Initially developed in the ● Alternatively, smooth-topped (pre- topped)
Nordic countries in the 1950s, modular precast slabs are sometimes used, eliminating the
has proven itself one of the fastest, most need for the addition of topping on the
profitable, sustainable, and cost-effective ways construction site
to build.
Precast Concrete Beams, Girders, and Columns
● The concrete is cast in permanent forms made ● Precast concrete beams and girders made in
of steel, concrete, glass-fiber-reinforced several standard shapes The projecting
plastic, or wood panels with smooth overlays. ledgers on L-shaped beams and inverted tees
● The forms may be reused hundreds or provide direct support for precast slab
thousands of times before they have to be elements. They conserve headroom in a
renewed, so formwork costs are low. building by allowing the beam and slab to
● The forms are equipped to pretension the share some of the same structural depth.
reinforcing steel in the precast elements. Precast concrete columns are usually square
Using steel strands with ultimate strengths as or rectangular in section and may be
high as 270,000 to 300,000 psi (1860 to 2070 prestressed or simply reinforced.
MPa), greater structural efficiencies translate
into longer spans, lesser depths, and lower Precast Concrete Wall Panels
weights compared to conventionally reinforced ● Precast concrete panels, either prestressed or
concrete elements. conventionally reinforced, are used as
loadbearing wall panels in many types of
Structural Precast Concrete Elements low-rise and high-rise buildings. Solid panels
● Slabs range from 3 1⁄2 to 10 inches (90 to 250 mm)
● Beams in thickness and can span one or two stories in
● Girders height.
● Columns
● Wall panels PRELIMINARY DESIGN OF PRECAST CONCRETE
STRUCTURES
Precast Concrete Slabs ● Estimate the depth of a precast solid slab at
● The most fully standardized precast concrete 1⁄40 of its span. Depths typically range from 3
elements are those used for making floor and 1⁄2 to 8 inches (90 to 200 mm).
roof slabs ● An 8-inch (200-mm) precast hollow-core slab
● For short spans with minimum slab depths, can span approximately 25 feet (7.6 m), a
solid slabs are appropriate. 10-inch (250-mm) slab 32 feet (9.8 m), and a
○ Solid flat slabs (widths vary) 12-inch (300-mm) slab 40 feet (12 m).
● For longer spans, deeper elements must be ● Estimate the depth of precast concrete double
used, and precast solid slabs, like their tees at 1⁄28 of their span. The most common
sitecast counterparts, become inefficient depths of double tees are 12, 14, 16, 18, 20,
because they contain too much deadweight of 24, and 32 inches (300, 350, 400, 460, 510,
nonworking concrete. 610, and 815 mm). Some manufacturers can
● In hollow-coreslabs (or hollow plank), which provide double tees that are 48 inches (1220
are precast elements suitable for intermediate mm) deep.
spans, internal longitudinal voids replace much ● A precast concrete single tee 36 inches (915
of the nonworking concrete. mm) deep spans approximately 85 feet (926
○ 2', 4', 8' wide (610, 1220, 2440 mm) m) and a 48-inch (1220- mm) tee 105 feet (32
○ (1'–4", 3'–4" some manufacturers) m).
● For the longest spans, still deeper elements ● Estimate the depth of precast concrete beams
are required, and double tees and single tees and girders at 1⁄15 of their span for light
eliminate still more nonworking concrete. loadings and 1⁄15 of their span for heavy
○ 8', 10" wide (2440, 3050 mm) loadings. These ratios apply to rectangular,
● For most applications, precast slab elements inverted-tee, and L-shaped beams. The width
are manufactured with a rough top surface. of a beam or girder is usually about one-half of
After they have been erected, a concrete its depth. The projecting ledgers on
topping is poured over them and finished to a inverted-tee and L-shaped beams are usually
flatter, smoother surface. 6 inches (150 mm) wide and 12 inches (300
● The topping, usually 2 inches (50 mm) thick, mm) deep.
bonds during curing to the rough surface of the ● To estimate the size of a precast concrete
column, add up the total roof and floor area
supported by the column. A 10-inch (250-mm) ● Carbon Fiber Reinforcing
column can support up to about 2300 square ○ Carbon fiber reinforcing may be
feet (215 m²) of area, a 12-inch (300-mm) substituted for mild steel reinforcing
column 3000 square feet (280 m²), a 16-inch in precast concrete elements, such
(400-mm) column 5000 square feet (465 m²), as for shear stirrups and temperature
and a 24-inch (600-mm) column 9000 square steel in slabs, single and double tees,
feet (835 m²). and wall panels. Because carbon
● These values may be interpolated to columns fiber does not require protection from
in 2-inch (50-mm) increments. Columns are corrosion, less concrete cover is
usually square. required than for steel reinforcing.
This can result in thinner,
lighterweight reinforced components.
● Concrete
○ Concrete for precast concrete
elements is formulated and
manufactured in the same way as
sitecast concrete. Mixes with 28-day
strengths from 4000 to 6000 psi (28
to 41 MPa) are most common.
● Hollow-Core Slab Production
○ The longitudinal voids in hollow-core
slabs can be formed by a number of
processes. In the extruded process,
Precast concrete beam and girder shapes. The heavier
devices squeeze an extremely dry,
bars near the tops of the beams are mild steel
stiff concrete mix through a moving
reinforcing, and the smaller strands near the bottom are
die, not unlike squeezing toothpaste
high-strength prestressing.
from a toothpaste tube, to produce
the voided shape directly.
AASHTO (American Association of State Highway and
Transportation Officials)
● Column Production
○ Precast concrete columns may be
Assembly Concepts for Precast Concrete Buildings
reinforced with ordinary mild steel or
Three fundamental ways of supporting precast slabs
pretensioned strands. Pretensioned
● On a precast concrete skeleton
columns are often made and shipped
● On precast loadbearing wall panels
in multistory lengths with corbels to
● On a combination of the two
support beams or slabs
Lateral Force Resistance
Joining Precast Concrete Members
● Precast concrete building structures can rely
● frequently used connection details in precast
on any of the lateral force resisting strategies
concrete construction:
previously discussed for steel frame
○ Bolting
construction: that is, shear walls, braced
○ Welding
frames, and moment-resisting frames.
○ Grouting
● Precast concrete elements themselves can be
● A is the familiar anchor bolt.
designed to act as shear walls, or with special
● B is a steel plate welded to a bent rod or strap
attention to the design of the connections
anchor; this weld plate, or embed plate,
between parts, as moment-resisting frames.
furnishes a surface to which steel components
● Lateral force resistance can also be provided
can be welded.
by other systems, such as sitecast concrete
● The steel angle in C has a threaded stud
shear walls or structural steel braced frames.
welded to it so that another component can be
attached by bolting.
Manufacture of Precast Concrete Structural
● D is an adjustable insert of malleable iron that
Elements
is nailed to the formwork through the slots in
● Casting Beds
the ears on either side. A special nut twists
○ Most precast concrete elements are
and locks into the slot to accept a bolt or
produced in permanent forms called
threaded rod from below.
casting beds. Casting beds average
● Images E and F show two different designs of
400 feet (125 m) in length but extend
threaded inserts that are cast into the
800 feet (250 m) or more in some
concrete.
plants.
● Prestressing and Reinforcing Steel
● The sheet steel dovetail slot in G is used with have a moderately high load-carrying
special anchor straps as shown to tie masonry capacity.
facings to a sitecast concrete frame or wall. ● Fastener S typifies devices whose perforated
● The device shown in H is simply a dovetailed metal plates adhere securely with a
wood nailer strip cast into the concrete, mastic-type adhesive to surfaces of concrete
suitable only for simple, very low-stress or masonry. The fastener shown in the image
connections because the wood may absorb has a thin sheet metal spike, over which a
moisture, swell, and crack the concrete, or dry panel of foam plastic insulation can be
out, shrink, and become loose. impaled. The tip of the spike is then bent
● Fastening systems A–F are heavy-duty across the face of the insulation panel to hold
devices that are available in capacities it in place.
sufficient to anchor heavy building
components and machinery.
● Images I–P depict fastening devices that are
inserted in holes drilled into the cured
concrete.
● Image I shows the steel post of a railing
anchored into an oversized hole in a concrete
slab using grout or epoxy; this device is also
used to fasten bolts to concrete and can carry
heavy loads if properly designed and installed.
● J is a plastic sleeve, K a wood or fiber plug,
and L a lead sleeve; all three are inserted into
drilled holes and expand to grip the sides of
the hole when a screw is driven into them.
● M is a similar type of metal sleeve but has a
special nail that expands the sleeve as it is
driven.
● N is a special bolt with a steel sleeve over a
tapered shank at the inner end. The sleeve
catches against the concrete as the bolt is
driven into the hole and is expanded by the
taper as the bolt is tightened.
● O is a special screw and P is a special nail,
both designed to grip tightly when inserted into
drilled holes of the correct diameter.
● Devices J–P are light- to medium-duty
fasteners, with the exception of L and N, which ● In some cases, precast slab elements,
can carry rather heavy loads. especially solid slabs, require temporary
● The devices shown in Q and R are driven shoring at midspan to help support the weight
anchors. of the topping until it has cured.
● Q is the familiar concrete nail or masonry nail, ● For construction economy, smooth-topped
made of hardened steel. If driven through a precast slab elements are sometimes used
strip of wood with a few blows of a heavy without topping.
hammer or inserted with a nail gun, it will ● At roofs, unevenness in the precast elements
penetrate concrete just enough to provide is readily bridged by rigid thermal insulation
some shear resistance for furring strips and placed on top.
sleepers, but it has a tendency to loosen, ● Untopped slabs may also be used for floors
particularly if driven with too many blows. that will be finished with a pad and carpet and
● Shown in R are three examples of for parking garages.
powder-driven (often called powder-actuated) ● Posttensioning can be used to combine
fasteners, which are driven into steel or precast elements into even larger ones on the
concrete by an exploding cartridge of site. This is done to assemble precast
gunpowder. concrete box segments into very long, deep
○ The first fastener is a simple pin used girders for bridges and to create tall shear
for attaching wood or sheet metal walls from story-high precast panels in
components to a wall or slab. multi-story buildings.
○ The middle one is threaded to accept
a nut. The eye on the fastener to the Composite Precast/Sitecast Concrete Construction
right allows a wire, such as a hanger ● In filigree precast concrete, relatively thin
wire for a suspended ceiling, to be precast elements that are either conventionally
attached. Powder-driven fasteners reinforced or prestressed are used as the
are rapidly installed, economical, and formwork for sitecasting of beams and slabs.
Once the process is complete, composite
structural action between the sitecast concrete
and precast units results in a unified,
structurally efficient system. Because the
precast units remain in place as part of the
finished system, formwork costs are much less
in comparison to conventional sitecast
concrete construction methods
The Construction Process
● The construction process for precast concrete
framing is much like that for steel framing.
Precast Concrete and the Building Codes
● Precast concrete is noncombustible and can
be used in any building code construction, as
long as it meets necessary fire resistance
rating requirements
○ Slab elements are readily available in
1- and 2-hour fire resistance ratings
○ beams and columns in ratings
ranging from 1 to 4 hours.
● The fire resistance ratings of precast concrete
slab elements may be increased by increasing
the topping thickness or adding a topping
where none was otherwise required.
● Solid and hollow-core slabs may achieve
ratings as high as 3 hours by this means.
Single and double tees require the addition of
applied fire-proofing material to achieve a fire
resistance rating higher than 2 hours.
