2D CONCRETE

GET
TO
KNOW
CONCRETE

GROUP 3

TO: MADAM HAZWANI BINTI RAMLI

Prepared by

Nuraisyah Binti Johari
2020476962

Nurul Hasifa Binti Alias
2020462272

Nur Fadhlin Hana Bt Mohd Hazrul
2020477062

Nurul Aley Aleyana Binti Rasilah
2020840256

Maryam Binti Agus Salim
2020847342

CONTENT

Acknowledgement
Introduction

Definition of P.C Concrete
Uses of P.C Concrete

Types of P.C Concrete
Why P.C Concrete is used in construction?
Precast concrete VS Cast in-situ concrete

Pros & Cons of Precast Concrete
Types of projects that used precast concrete structure

How P.C Concrete is made?
Consideration for Precast Concrete Construction

How does P.C Concrete is trending nowadays?
Conclusion
References

ACKNOWLEDGEMENT

First of all, we would like to express our gratitude to Almighty
Allah to enabling us to complete this Precast Concrete handbook.

We convey our sincere gratitude to our lecturer Pn Hazwani
Ramli, lecturer of Construction Technology II (BQS 452), Centre
of Studies for Quantity Surveying, UiTM Shah Alam. Without her
guidance, this handbook will not exist. Her guidance makes this

handbook completed perfectly.

We also like to thanks to our classmates for spend their times to
help us in the process of preparing this handbook. Last but not
least, lot of thanks are due to those involved in the making of

this handbook either directly or indirectly.

INTRODUCTION

CONCRETE IS THE MOST POPULAR
MATERIAL USED IN

CONSTRUCTION INDUSTRIES
NOWADAYS DUE TO THE

STRENGTH, DURABILITY AND
VERSATILITY THAT CONCRETE

PROVIDED.
THERE ARE SEVERAL TYPES OF
CONCRETE THAT ARE USE FOR
DIFFERENT PURPOSES SUCH AS

ORDINARY CONCRETE,
REINFORCED CONCRETE AND

PRECAST CONCRETE.
THIS HANDBOOK WILL EXPLAIN

THE DETAILS OF PRECAST
CONCRETE.

Definition
Precast concrete is a form of concrete that prepared,
cast and cured off-site using reusable moulds. Elements

can be joined to other elements to form a complete
structure. Typically used for structural components due

to its strength, durability and affordability.

Uses of Precast

Frame Concrete

Structural frame Cross-wall frame
consist slabs, beams consists floor slabs and
and columns. Mainly solid walls. Use mainly
used for offices, car for hotels, schools and

parks and retail hospital.
development

Uses of Precast Concrete

Floor

Mainly used for those
types of floor because
good strength to weight
ratio, fast construction
and economic production.

Can be uCseldaasdading

structural element but
more often used as a
non-structural
decorative façade.

Types of Precast
Concrete

Precast Beam
The ratio of mortar for precast concrete beam
commonly 1:1:2 in construction.

a) RCC beams c) Shell beams
RCC beams used to carry transverse external loads Shell beams can streamline the building programs
that cause by the bending moment, shear forces, and reduce on-site labor with the precast floor
and in some cases torsion across the length. RCC system. The depth of the shell beams possibilities
beams used as supporting the floors, walls, roof within 290mm to 600mm and within 600mm to
and cladding. RCC beams have many sizes such 2400mm of the width.
rectangular, tee shape (T-beam), I-beam, L-beam
and Circular beam. Figure 1 shows the structure
of RCC beams in rectangular shape.

b) Prestressed beams
Prestressed beams are easy to install due to the
less of costs and on-site labor needs although they
are very large than steel-prestressed beams.
Prestressed beams are commonly used in multi-
story buildings and industrial buildings due to the
structure comprises of a wide range of depths
that give a reinforcement for that building.

Type of Precast Concrete

Precast slabs
Precast slab is the most usually used in the construction due to the
precast slab are easy to adopt to the requirements and used as a ledge
for other precast flooring types

a) RCC slabs
The thickness of RCC Slabs within 10 to 50 centimeters commonly used
for the construction of floors and ceilings where the slab that
supported on foundations or sometimes on the subsoil are used for the
construction of the ground floor of a building. The thick of RCC Slabs
mostly install in many domestic and industrial buildings. For the thin of
RCC Slabs, they are often used in high rise buildings and skyscrapers for
exterior paving purpose where they are slung between the steel frames
as forming the floors and ceiling on each level.

b) Prestressed Hollow Core Slabs
The Prestressed Hollow Core Slabs that also known as hollow core plank or
voided slab or simply concrete plank of prestressed concrete are used in
multi-storey buildings such apartment buildings. The hollow core plank
iscommonly used in construction of a building.

Types of Precast Concrete

c) Prestressed solid slabs
The prestressed solid slabs consist of fully customized of concrete
slab. They are used in residential and industrial buildings

d) Double Tee slabs
The double tee slab’s structure is resembling the two of T-beams that
connected side by side. They commonly used for the roofing, parking,
and also for the bridges. The structure consists of one strong bond of
the flange for the horizontal section and two webs (stems) of the
vertical section.

e) Waffle slabs:

A waffle slab (two-ways joists slab) is made by the reinforced
concrete with concrete ribs running in two directions on its
underside. As we know, the waffle slab stronger than flat slab due to
the waffle slab produce greater span with more than 40 feet
compared to flat slab. Of course, by the name of waffle, we can see on
the figure below shows the structure look similar to the waffle shape.
The waffle shape is formed by the reinforcing ribs due to the grid
pattern. Waffle slab currently used in construction of floors and
ceilings in the area that have a greater span and they used just a
smaller number of columns.

Types of Precast Concrete

Precast Foundations c) Combined footing
As the name combined footing,
a) Isolated footings their structure consists of two
Isolated footings comprises either of or more columns close to each
other that supported at the same
reinforced or non-reinforced concrete footing. The combined
material. Thus, they are used in footing used in commercial and
hallow foundations that can carry and
spread concentrated loads, caused for industrial buildings.
example by columns or pillars. They are
commonly used in smaller structures

and residential buildings.

b) Pocket footings d) Precast piles
Pocket footing’s locations are similar As the figure below, prestressed

to isolated foundation which is at concrete that are driven into
shallow foundations but pocket the ground using diesel or

footing is used in the commercial and hydraulic hammer forms the
industrial buildings. precast piles that known as
prefabricated piles. The main
benefit of the precast piles is
the high vertical pile load and

resistance.

Why P.C Concrete is used in
construction?

Safety and security
High level security and capable of preventing damage such as
stray bullets and tornado scale 5 is capable being prevented.

Thermal friendly
Denser and less thermal conductors cause heat not move
around building. It slow to react and easier to heat or cool

compared to outdoor temperature.

Fire resistant
Limit ability of fire to spread between rooms. Strength and

uniformity of this concrete prevents the spread of fire
andprevent further damage

Reduce noise
Very compact and its manufacturing process makes it more
compact and effectively reduces noise. This concrete is able

to reflect and absorb sound.

CASTING WORK PREPARATION WORK SUITABILITY
The element in precast Required to excavate Repeatability and easy to
concrete aremanufactured the land as needed make copies of the same
in a controlled environment
that makes the weather also precast product & get
has no effect to casting the most value

work.

QUALITY CONTROL CONSTRUCTION’S TIME
Quality can be controlled and Total construction time
is less as they are fast
maintained easily also all
concrete must passed strict construction.

testing

Precast Concrete

vs

Cast in-situ Concrete

CASTING WORK PREPARATION WORK SUITABILITY
This work is being done at site that Required excavation and Adapts to any building
make it was making in open environment on - site to be created shape and post tensioning
which make the bad weather will cause a
and place
delay to casting work

CONSTRUCTION’S TIME QUALITY CONTROL
Total construction time is Quality control and maintenance
more due to the element
are being casted on site are difficult and all testing
must be performed on site only

Pros of Precast Concrete
Energy Efficiency
The effect of thermal mass is formed to precast concrete lends itself
to energy efficiency and reduces the heating and cooling peaks and

loads also can make it less costly mechanical systems.

Versatility & Aesthetics
As we know that the structure are prefabricated at a factory in a
controlled environment, the several combinations of colour and texture
can be used due to the customer’s requirement. Precast concrete also
served a smooth finishing which make it more versatile in many ways as a
wide range of shapes, sizes and finishes are available to choose and the

aesthetical value of products are increased.

Durability & Sustainability
The precast concrete is being made from the factory and was strictly
tested to remain the durability. This allow the material to withstand
years of wear and tear and remain as strong as the day it was cured.
Hence, the high density of precast concrete is very durable and sustain

to acid attack, corrosion, reduce surface voids and resists dust.

Safe Construction Platform
There is no raw materials have to be stocked in construction site as it is

fabricated in factory. In addition, it also helps in reducing the raw
materials of formworks, workers and props thus it is provide a safe

working platform as there is no air pollution on site.

Uniformity
The concrete components were put together in a plant that casting
the precast concrete using the same moulds of every parts of element

so it is fairly easy to maintain the uniformity among the precast
concrete components.

Cons of Precast Concrete

Transportation Issue
The plant / factory making Precast Concrete can be at a distant
location from the construction site so that the precast members
must be carried using trailers as the precast must be large in size.
In this case, the reduced costs of Precast Concrete is compensated

by the transportation cost.

Installation of Precast Concrete
In using this term of precast concrete, they need a proper care
and precaution in handling this precast concrete.Theinstallation of
precast concrete on site required a large plant and machinery
which is mobile cranes often being used to install the large pieces
of precast concrete. Hence, the cost of installation the precast
concrete required a crane rental which make it much expensive for

installation.

Handling Difficulties
In using this term of precast concrete, they need a proper care
and precaution in handling this precast concrete. Usually, the
precast members are heavy and large which make it difficult to

handle without damage.

Sensitive Connection Works
The connections between structural members should be supervised
and done properly to ensure the strong structural behaviour and
ensuring the intended behaviour of the connection. In addition, if

the connections iswrong connect may lead to water leakage and
failing sound insulation.

Types of

projects that

used Precast
CONCRETE WALLS
Concrete A concrete wall is a most stable wall that support soil and
allowing the ground maintained at different levels. Hence, the
precast concrete is currently used because it is more reliable,

structuredurable and long lasting and the important one is cost-effective
cause used less workers.

BRIDGES
This type of precast concrete structures hasbeen used in
several well-known bridges such as bridges in Japan. In order to
make the bridge more sustain and versatile in shape, the precast

concrete is used due to the environmentally friendly
structures. Precast concrete is used in a variety of bridge

substructures such as columns and caps.

BUILDINGS, PARKING LOTS AND THEIR FOUNDATIONS
Precast concrete is often being used as a construction building

material. The types of building are always used this type of
concrete are single and multi – level parking structures and

home is the ideal building. Precast concrete also is chosen
because it may used to build a variety of architectural styles.

GUTTER
The gutter is to allow the water to flow under a road or any

obstructions. Precast concrete is the best to used in the
gutters as they are reliable and durable. Precast concrete also
is always been used in the culvert’s parts due to the long lasting
product, to ensure a good quality and can installed quickly at a

low cost.

How the Precast

Concret made of

Step 1 Design and engineering:
At the first stage, the designer or design engineer will set the requirements of the precast components. And then,
when the drawings are finished from the engineer, that precast components will be engineered in-house as based on

the engineered design and owner’s specification. Moreover, the engineer will ensure the precast components will
complete with the appropriate steel reinforcement. The suitability of that precast components must include the soil
type in term of surrounding them when they are constructed such the buildings adjacent of them or other structure
and the water table of the area. Then, the drafting team will provide the detail drawings of the precast components
and sent it to the design engineer or owner to get an approval. Subsequently, the drafting teams and engineers will

provide the production drawings then sent it to the factory floor. The production drawings explained the bill of
materials, the dimension of the cutting rebar and ratio for the mortar as mixing of concrete, sand and aggregate.

The factory will use the production drawings as manufacturing that precast concrete.

Step 2 Prepping the reinforcement bar (re-bar) cage:
The re-bar must be cut to the appropriate lengths as based on the bills of materials and continue to bend it and tie
them as together with the hook. The Wagon wheels use as hooked onto rebar and ensure it as the right position in the

structure of the precast components. The rebar must not too close to both side of the walls of the precast
components and match meeting the structural requirements.

Step 3 Prepping the form
Another teams will prep the forms by reviewing the drawings as observing any openings or knockoutsfor the
components structures and placed theinserts into the form (which are removed after the concrete cures) as secured
and embedded that not allow them to move when the concrete is poured. The openings used for the connection of pipe
into the structure and the knockouts which is a thin wall sections that allow the openings to be “knocked out” in the
field as when the subcontractor knows the position if the electrical conduit or communication lines would enter the
vault. After that, the teams will apply a form of oil as allowing the concrete being easy to release from the form
after it’s cured. Finally, the reinforcement bar cage will be lifted by using a crane and positioned it into the form.

Step 4 Mixing and pouring the concrete into the form:
The concrete mixing consists of fine and coarse aggregates, cement, water and admixtures as following the concrete

mix design as specified by the engineer in the factory’s batch plant. The concrete will be approved to poured when
the certified quality control technician will examine under pre-pour inspection the quality of the concrete used as
followings to the drawings. The lab collects sample cylinders of concrete mixture to examine the compressive strength
and verify the quality of the concrete mixture. Once, the mixture of concrete is approved, they will be transported
by using the crane in a dispensing machine to the molds. And then, the required amount of concrete will be poured to
the foam without trapping air voids when the crane is positioned over the mold. After that, the concrete in the form

will be level off when the concrete is settled into the form by the vibrating tables from the plants.

Step 5 Curing the concrete:
The curing process begins after the concrete is poured into the form by placing the tarp over the product overnight
as capturing the production of heat as a part of the hydration process that can speeds up the curing process to reach

the full design strength than in the field.

Step 6 Stripping the forms and inspecting the product:
Once the QC technician confirms that the product is completely reach within 2500 to 3000 psi of strength, the
concrete will be removed out from the form. First, the outer jacket of the mold will be openand the inner core will
be collapse. Moreover, the crane’s hooks will be attaching to the lifting hardware to move the product of precast
components via crate to the post-pour inspection and finishing area. At there, the precast components will be observed
by the QC technician as ensuring the final product matching and following the drawing and ensuring there’s no
damage. Last, the final product will be transported to the yard while waiting for delivery to the project site once

they are passing the final QC inspection.

Consideration for Precast

Concrete Construction

1. Erection Sequence
Precast concrete members must be constructed in a predetermined order. The erection plan is a set of
drawings that is often prepared, if structural integrity and access to connections at a given place are
important. Multiple handling of pieces should be avoided during the erection procedure. Finally, a trial erection
procedure should be considered to rule out any unexpected erection problems.

2. Erection safety
The importance of safety when handling and erecting precast concrete pieces cannot be stressed. As a result,
all machines and equipment used in precast concrete element handling and erection must be kept in good
working order, load tested, and suitable for the specified use.

3. Erection tolerances
When additional standards are specified in the design and specifications, the precast unit shall be erected in
accordance with the tolerances provided by technical specifications.

4. Rigging
Rigging systems for handling and constructing precast parts must be carefully planned. On certain precast
elements, such as beams or flat slabs, it may be necessary to balance loads between lifting points. Slings/cables,
hooks, and shackles are examples of lifting accessories. The forces resulting from all operations involved in the
handling and erection of precast modules should be taken into account while selecting such components. The
sort of rigging system chosen may also be influenced by elevation and flexibility during erection.

5. Temporary bracing
To maintain proper alignment and structural stability until permanent structural connections are established,
precast concrete elements must be properly braced and supported during all phases of erection.

6. Leveling shims
Leveling shims should be made of a long-lasting material with enough strength to support the full design load.
The full construction load of the precast element is carried by the leveling shims, which must provide
sufficient support to prevent movement until the element is embedded into the main structure.

7. Propping
The erection drawings must include all temporary propping requirements. Temporary propping systems should be
designed in compliance with applicable codes. All building loads should be supported completely by temporary
propping.

How does P.C Concrete

is trending nowadays?

In 2020, the precast concrete market
sustained a minimal decline in its demand

due to Covid-19.
However, the increasing cases of Covid-19
required more healthcare and quarantine
building thus the precast concrete demand

has increase.
The global precast concrete market size is
expected to raise from USD 130.6 billion in

2020 to USD 174.1 billion by 2025.

Conclusion

The layout, span length, construction depth, and stability
system are all influenced to a large extent by the precast
concrete construction technique. The majority of structural

members in precast concrete construction are made in
manufacturing plants located away from the construction site.

They are then transported to the project site and erected.
Various connections, such as beam to column connections and
panel to panel connections, have been designed to connect
various types of structural elements. The applied loads are
carried from the superstructure to the foundation in this
technique. Before finalizing the design of a precast concrete

structure, designers should think about the possibilities,
constraints, detailing, manufacturer, transportation, erection,

and durability stages.

REFERENCES

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ay

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products-you-need-know-matt-fee

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