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this is the report on the precast technology in const. industry .
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1
sr. no. Particulars Pg no.
1
Introduction to precast concrete
3
2
Types and procedure of precast concrete construction
12
3
Precast technology in residential building
21
4
Case study on the precast technology in Bandra worli
sea link (BWSL)
68
5
Research paper study on the future of precast
technology in law rise building
94
2
Precast technology
Subject: Advanced construction practice
Topic: Precast technology
Prepared by: Hardik Patel (PT101214)
Guided by: Prof. Jyoti Trivedi
Dr. Ganesh Devkar
Date: 7th oct. 2014
3
Precast Concrete
Introduction to precast concrete
Types and procedure of precast concrete construction
Precast technology in residential building
Case study on the precast technology in Bandra worli
sea link (BWSL)
Research paper study on the future of precast
technology in law rise building
Video on manufacturing of precast wall
Video on installation of precast modular pavement
4
Precast Concrete
Precast concrete is a construction
product produced by casting concrete in
a reusable mould or "form" which is then
cured in a controlled environment,
transported to the construction site and
lifted into place. In contrast, standard
concrete is poured into site-specific
forms and cured on site.
5
History
precast paneled buildings were pioneered
in Liverpool England, in 1905
A process was invented by city engineer John
Alexander Brodie.
Between 1917 and 1932, they erected 145
such buildings
6
Why Precast???
Speed to market
Strong image
High quality
Low maintenance
Effective pricing
Safety
Early input
7
Why precast ?? As a
Project Manager Elimination of needs for supports / scaffolding
Elimination of temporary structures
Reduced health and safety risks
Reduction in lorry traffic and traffic management
Easier management of steel procurement
Elimination for long and continuous pouring operations
Significant reduction/elimination of temporary shuttering
Controlled curing of concrete
Improved quality controls performed at the factory
Process not subjected to weather conditions
8
Precast concrete Products
Agricultural Products
Building and Site Amenities
Retaining Walls
Sanitary and Storm water
Utility Structures
Water and Wastewater Products
Transportation and Traffic Related Products
Modular Paving
Marine Products
9
Raw Materials
Portland cement
water
Sand
Gravel
admixtures
For light weight
clay, shale, or slate
pumice and scoria blast furnace
10
Design
The shapes and sizes of most common concrete blocks have been standardized to ensure uniform building construction.
block design, called a split-faced block, includes a rough, stone-like texture on one face of the block instead of a smooth face
we must consider not only the desired shape, but also the manufacturing process required to make that shape
We must consider the utility facility requirements in building during design
11
Procedure for
precast
manufacturing
12
Procedure for precast construction
Production of reinforced cages and main connections
Assembly of moulds
Mix being poured
Compaction of concrete using poker vibrator
Precast concrete being moved to the storage area
Storage of high-quality units in storage area
Transport to site
Erection at site
Finished building
13
Production of reinforced cages and
main connections
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Assembly of moulds
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Mix being poured
16
Compaction of concrete using poker
vibrator
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Precast concrete being moved to the
storage area
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Storage of high-quality units in
storage area
19
Transport to site
20
Erection at site
21
Types of precast construction
Large-panel systems
Frame systems
22
Large-Panel Systems
The designation large-panel system refers to multistory structures composed of large wall and floor concrete panels connected in the vertical and horizontal directions so that the wall panels enclose appropriate spaces for the rooms within a building. These panels form a box-like structure
23
Large panel
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Frame Systems
Precast frames can be constructed using either linear
Elements or spatial beam-column sub assemblages.
Precast beam-column sub assemblages have the advantage that the connecting faces between the sub assemblages can be placed away from the critical frame regions; however, linear elements are generally preferred because of the difficulties associated with forming, handling, and erecting spatial elements.
The use of linear elements generally means placing the connecting faces at
the beam-column junctions.
26
Installation CONSIDERATIONS
All safety issues on site when handling precast elements,
especially so when working within a tight site
The lifting capacity of the crane used
The working boom-radius of the crane
The suitability of construction materials for the purpose of use,
i.e. sealant, grouting, shim plate, propping etc
Co-ordination with the precaster and specialist supplier to achieve the best performance and working method - precaster often provide relevant technical requirements to the contractor during the design development phase to avoid discrepancy
27
Crane Position
28
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Setting Out
1. Surveyor to set cross reference.
2. Transfer grid and mark wall position on slab.
3. Mark 100mm offset line from rear building
edge.
4. Offset wall position by 200 mm.
5. Secure 2x2 timber to the floor at wall edge to guide wall.
30
Setting Out
31
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Wall Positioning
1. The first wall in place has to be the partition wall
at the rear.
2. Mark a line parallel to and 100mm from the
external edge of the wall.
3. Place shim plate @~500 c/c on the floor and
level to wall soffit. Shim plate may also be
placed on Non-shrink mortar bed and allow to
set.
4. Adjust position of the dowel bar.
33
Setting Out
34
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Wall Adjustment
1. Position adjacent walls and plumb wall corners
at 200 mm offset
2. Adjust verticality until within +2 or 2 mm
3. Ensure the four faces of every walls are
adjusted
4. Position string 250 mm from face of walls
5. Walls within the same line are to be adjusted
within same tolerance
6. Ensure air-pocket is fully grouted
36
Wall Adjustment
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Beam Setting Out
1. Cast wall joint.
2. Mark 1 m reference line.
3. Confirm pocket level. Position shim plate to
correct beam soffit level if required.
4. Mark position of beam on floor.
5. Hoist beam in place and check top level.
6. Plumb beam to verify position on floor below.
7. Ensure beam verticality with a spirit level.
8. Wedge beam against pocket and grout the
gap between the beam and the wall.
39
Beam Setting Out
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Slab Setting Out
1. Position the slab temporary supports and
adjust the slab soffit level approximately.
2. Raise the height of the supports about 5 mmabove slab
soffit level
3.Hoist slab in place on top of beam and support.
4.Verify level of every plank soffit at four corners
and center.
5. Adjust level of temporary support accordingly
42
Slab Setting Out
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Staircase
1. Position landing or slab and verify soffit
level at four corners.
2. Adjust level to within tolerance.
3. Position shim plates at staircase support
location to correct level.
4. Verify level difference between pegs on
top and below.
5. Hoist staircase in place.
6. 10mm gap between precast plank andstaircase
44
Staircase
45
46
Installation Requirements
Elements of control
Alignment, Verticality and Levels
Tolerance level
1. For Wall
Vertical deviation +2 mm, -2 mm
Horizontal deviation 0 mm
2. For Beam & Slab
Departure from intended horizontal position, +2 mm or 2 mm
Departure from intended vertical position, +2 mm or 2 mm
47
Connection types
48
49
Columns Connection
50
51
Beam-column connection
52
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Slab-Beam Connection
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CONSTRAINTS SOLUTIONS
! Small road in front of site may not !
allow crane and delivery trailers up to 3.Sm wide to
park.
Use smaller crane and trailers to deliver and
install small
components.
! Crane and trailer are unable negotiate small
turning radius junctions of small roads.
to ! Study the locality and look for at available space
for turning. Have one worker direct traffic while crane
and trailer is turning.
! Diversion of existing services such ! as
lamp-posts, fire hydrants and overhead electrical
cables may be necessary.
! Existing trees and shrubs in front ! of
site require National Parks Board
approval before they can
be removed and later reinstated.
Diversion must be done before installation of precast
components begins.
The consultants must write in to National Parks
Board for approval much earlier before construction
begins.
56
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Cost saving
59
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Time saving
61
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Time comparision
63
Material saving
64
Limitations
Each panel variation (especially openings, bracing inserts and lifting inserts) calls for complex, specialized
engineering design.
It is often more expensive than alternatives (can be offset by reduced construction times, earlier access by following
trades, and simplified finishing and services installation).
Building services (power, water and gas outlets; conduits and pipes) must be accurately cast in and are difficult to add or alter later. This requires detailed planning and layout at design stage when plumbing and electrical trades are not usually involved.
Erection requires specialized equipment and trades.
High level site access required
Panel connection and layout for lateral bracing requires detailed design.
Temporary bracing requires floor and wall inserts that have to be repaired
later.
65
Research paper study
The Future for Precast Concrete in Low-Rise Housing
by. Dr Jacqueline Glass (BA (Hons), Dip Arch, Dip BRS, Phd, CertHE.)
Dr Jacqueline Glass is the British Cement Association Senior Lecturer in the School of Architecture at Oxford Brookes University where she has been carrying out research in concrete construction since 1994. Dr Glass is currently Project Manager of an EPSRC funded research project in innovation in reinforced concrete and has previously contributed to Partners in Technology projects on tilt-up and hybrid concrete construction. Dr Glass is Architectural Consultant to the British Cement Association and the Reinforced Concrete Council and is an active participant on several concrete industry trade associations. She has published widely in both trade journals and scholarly publications and has lectured in the UK and USA on a broad range of concrete related topics.
66
The Future for Precast Concrete in
Low-Rise Housing
This report is about the future use of precast concrete in low-rise housing in the UK. It has been produced in response to a growing level of interest in prefabrication.
focuses on the use of precast concrete, and considers the history of precast concrete in housing
examines the key features of concrete in general, and precast concrete specifically. Fire resistance, thermal mass, acoustic insulation and durability are included together with a discussion of cost and value issues
considerations such as services integration and adaptability are related to the future needs of occupants, and procurement strategies are noted.
Report also contains an account of the current market success of
other materials in the prefabricated housing sector
67
Conclusions and recommendations
1. The problems of the past can be avoided
2. Low-rise is not high rise
3. Cultural and perceptual views are critical
4. The market potential for precast concrete exists
5. The balance of cost and value needs to be clear
6. Precast means innovation in delivery
7. People need to be convinced
68
Case study on
Precast deck of
BWSL
69
Why precast segmental deck????
Total length : 5.6 kilometres
Width : 2 x 20 meters (66 ft)
Height :126 meters (413 ft)
Longest span :2 x 250 meters (820 ft)
Clearance below :20 meters (66 ft)
The Maritime Board does not allow marine traffic in monsoon
season.
70
Decision for precast segmental
construction
800m long Precast Segmental Approach Bridge on
Bandra Side.
200m long Precast Segmental Approach Bridge between Bandra Cable Stayed Bridge and Worli Cable Stayed Bridge.
1400m Precast Segmental Approach Bridge on Worli
Side.
811m long link to Khan Abdul Ghaffar Khan Road
comprising 510m Precast Segmental Bridge and
310m Cast-in-Situ Bridge.
71
SAGMENT PARAMETERS
a hollow concrete box section with 3 cores
Length:1.5m to 3.1m.
post tensioned
slender and lightweight deck is to reduce the longitudinal
stiffness
pre-casting yard using short line method
A typical 50m span comprises of 15 numbers of precast
segments, a Pier segment and 200mm (nominal) in-situ wet
joints
8 cells to makes all the different types of segments.
centralized pre-casting yard using short line method of casting
Sophisticated software for correct casting curves
A complete construction of a segment takes about a month (20
to 30 days)
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60
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Segment Construction Procedure
survey team sets the bulkhead, the rebar setup
takes place
After rebar setup is done, the concrete is poured in the
formwork
initial tensioning about 30% of its maximum capacity
After strength of about 40Mpa final testing with rest of
the 70% load
Shifted to store at yard
Transported by trailer truck to site
Transported by barge in the sea
Erection by gantry
75
Connection of male-female segment with wet concrete
76
equipments which deployed in
the pre-casting yard
1) Hydraulic Jacks of different capacities
2) Turn Buckles
3) Gantry, for lifting segments
4) Tower Crain
5) Concrete Pumps
6) Cutting and bending machines for rebar of
segments.
77
78
Formwork and rebar setup
79
80
A segment being cast and its conjugate
65
81
Casting Yard
82
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Erection of segment
The precast concrete sections of the deck were launched incrementally between the pillars using a truss system, known as the balanced cantilever method
The two segments are being linked through a male-female joint, in the meanwhile the casted segment is allowed to gain strength and also its curing is done side by side.
The precast sections were then epoxied together and given a certain degree of pre-stress to hold them in place
Once each span had completed and geometrical adjustments made the primary continuous tendons were stressed to the required level.
85
Equipments which deployed in the
erection
Launching Truss: Weighing 1250 tonnes and measuring 112 m in length, it was used for lifting segments each weighing 130 tonnes. This has been fabricated in India.
Flat barge: Size 30x12x2m. Like motor boats, they are driven inside the sea for material transportation.
Self-propelled barge: It is a barge with a machine component and is
used for concrete transportation.
Crawler crane: Capacity ranges from 75-150 tons. It is used for material and heavy lifting activities. 13 barges for concrete
eight steel boats
three tug boats
six smaller passenger boats.
86
The Erection Gantry
87
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Erection of segment
89
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91
Challenge of Ground Stabilisation for Pre-Cast Yard
located on reclaimed land
yard caters to casting, storing and handling of pre-
cast Segments
numbers of segments 2342
The storage capacity of yard 470nos.
Area is limited, the segments stored in three layers.
The bearing capacity of the ground was was very
poor to less than2 T/Sqm.
92
Solution
Excavation of the ground to a depth of ~
2.5Mtrs.
Strengthening the ground using rubble soling
and filling the voids with sand.
The soling thus done was compacted layer by
layer using vibratory rollers.
Total area of the Pre-cast Yard was covered with
a layer of PCC.
RCC Footing done to facilitate storing of
segments.
93
Challenges for project manager
The superstructure of the approach bridges was the heaviest spans in the country to be built with span-by-span method using overhead gantry through a series of vertical and horizontal curves.
Erection of 20000 MT Bandra cable-stayed deck supported on stay cables within a very close tolerance of deviations in plan and elevation.
Navigation and transporting 19 precast segments in 24
hours at different open sea locations was a challenge.
How to move the large truss from the Bandra end of the bridge to the Worli end without having to dismantle the truss which would be too time consuming on such a high profile structure with a strict timescale.