Precast Flat Panel System
Precast Flat Panel System
Precast Flat Panel System
C o n s t r uction
M aterials
R E I N F O R C E D C O N C R E T E WA L L E L E M E N TS
• The thickness of the load bearing walls is determined by the static calculations
and the minimum allowable depth of the f loor slab which is between 14 and 20
mm. This is also sufficient to fulfill the necessary sound and fire protection
requirements.
D O U B L E WA L L E L E M E N TS
• Thin concrete walls are fitted together with intermediate steel gratings, all
necessary reinforcement is already installed between the walls.
• These double walls are delivered to the site where they are poured with filling
concrete to produce a stable, single layered wall construction element.
SANDWICH ELEMENTS
P O R O U S C O N C R E T E FA Ç A D E E L E M E N T S
• Porous concrete elements can be employed both horizontally and ver tically as
façade elements or a infill panels for frame structures.
• In addition to the bracing functions which panels provide , they also perform
functions relevant to building physics.
C E I L I N G A N D F LO O R S L A B S
• Pre fabricated concrete slab elements are produced as solid, hollow or web
panels. They offer planar structures of reinforced concrete or pre stressed
concrete which act as the par titioning elements for frame or panel
constructions.
UNITISED SLABS
SOLID SLABS
• They are seldom applied for spans exceeding 6m as the necessary thickness
of the slab for larger span would become heav y
H A L LOW S L A B S
• Weigh t redu cti on of u p to 5 0 % are possi bl e u sing h ollow slabs com pared wi th
solid slabs of the same dimensions. Depending upon the production
t e c h n i q u e s , t h e c a v i t i e s a r e o v a l , r o u n d o r r e c t a n g u l a r.
Fine Coarse
water cement Mild steel H.T wire
aggregate aggregate
Measuring cutting
Curing and
detensioning PRODUCTION FLOW CHART
Mould
cleaning Demoulding
Curing in yard
Testing
Dispatch
AARSH MALHOTRA | JASSIMAR WAHI | RAJAT VERMA | 4A
P R E C A S T F L A T P A N E L S Y S T E M
S P E E D TO M A R K E T
Precast, prestressed products provide a long ser vice life that far exceeds
field-placed concrete par tly because members are manufactured in plants
under strictly controlled conditions. The controlled plant environment has
offers easy verification of quality and a dedicated workforce. This means
h i g h - q u a l i t y p r o d u c t c a n b e m a n u f a c t u r e d e v e r y d ay, r e g a r d l e s s o f
w e a t h e r. T h e l o w w a t e r - c e m e n t r a t i o u s e d i n p r e c a s t c o n c r e t e c r e a t e s a
denser product that does not allow penetration of chlorides and other
harmful elements as easily as field -placed concrete.
I N T E G R AT E D P R O J E C T D E L I V E R Y
ENHANCES SAFETY
S U S TA I N A B I L I T Y
P r e c a s t i s p e r f e c t f o r t o d ay ’s f o c u s o n p r e s e r v i n g r e s o u r c e s a n d
p r o t e c t i n g t h e e n v i r o n m e n t t h o u g h s u s t a i n a b l e b u i l d i n g p r a c t i c e s . I t ’s a
perfect Green Building product. Precast reduces overall life cycle
impact on environment compared to other methods as it has lower
wastage and high potential to recycle waste.
O P T I M I Z AT I O N & F L E X I B I L I T Y
I N STA L L AT I O N
• Proper planning and preparatory works shall be required before
the actual installation of precast concrete elements in order to
ensure quality installations. The following items shall be planned
in advance.
Location of Joints
The location of joints between external wall panels should be selected based on careful consideration of the following factors:
• Structural Considerations External wall panels may be load bearing (e.g. side walls of corner
terrace, semi-detached or detached) or non load bearing (e.g. front and rear façade panels).
In selecting panel joint locations, it is important to consider the panel stability (i.e. ability to
resist horizontal loads such as wind pressure or loads specified in the Building Regulations
Fourth Schedule).
• Aesthetics Whilst in general, panel joints are not highly visible, locations should be selected
which minimise any potential impact on the external façade aesthetics. In general, vertical
joints should align for the full height of the building and would preferably be located
symmetrically with respect to adjacent features.
• Panel Weight The weight of panels will dictate the crane capacity required for installation of
the wall panels. Apart from the disadvantage of higher cost, larger capacity cranes may not be
able to access the site. For typical conditions, a weight limitation of approximately 4 tonnes is
considered likely to be applicable. In general, the panel size should be maximized, leading to
increased speed of construction and reduced number of panel joints to be treated.
• Transport Limitations For transportation purposes, it is necessary to limit one of the panel
dimensions to 3.6m. In general, panel heights will be less than 3.6m and panel length is based
on weight or other considerations. When the required panel height exceeds 3.6m, the length of
panel will be reduced to 3.6m or less. Early planning for site access must be undertaken,
particularly when houses are built along Category 5 road.
• Internal Crack Control To minimise the risk of cracks appearing at the internal face of wall
panel joints, the following considerations are relevant: - If possible, locate panel joints at
internal wall intersections, inside service ducts or wardrobes and at other non-visible locations.
- Avoid panel joints towards midspan of floors, where beam or slab deflections could lead to
joint opening. - Avoid long continuous runs of panels, where accumulated shrinkage could result
in joint cracking.
A DVA N TAG E S
• Saves Construction Time: Precast Concrete construction saves
time, the risk of project delay is also less. The precast
concrete casting can be carried on simultaneously with other
w o r k s o n s i t e s u c h a s e a r t h w o r k , s u r v e y, e t c . a n d t h u s s a v e s
time.
• Qualit y Assurance: The key factors which regulate the qualit y
of construction such as curing, temperature, mix design,
formwork, etc. can be monitored for Precast Concrete. So,
improved quality construction can be performed.
• Usage of Prestressed Concrete: By using pre - stressed precast,
structural materials of high strength and load -bearing
capacity can be achieved, which can result in greater clear
span, reduced size of the cross - section of structural
members, etc.
• Cost-effective: The simplified construction process reduces the
t i m e , i n c r e a s e s t h e p r o d u c t i v i t y, q u a l i t y a n d s a f e t y a n d t h u s
the cost is reduced.
• Durability: Precast Concrete structure has a longer service
time period and minimal maintenance. The high -density
Precast Concrete is more durable to acid attack, corrosion,
impact, reduces surface voids and resists the accumulation of
dust.
• Aesthetics: As the structures are prefabricated in a controlled
factory environment, several combinations of colors and
textures can be used. A wide range of shapes and sizes are
available to choose from with smooth finishing and thus the
aesthetical value of products are increased.
• Safe Construction Platform: No raw materials have to be
stocked in site for Precast Concrete construction. It reduces
the requirement of traditional formworks and props, wastage,
workers, etc. and thus provides a safe working platform.
D I S A DVA N TAG E S
• Tr a n s p o r t a t i o n I s s u e : T h e c o n s t r u c t i o n s i t e c a n b e
at a distant location from the Precast Concrete
plant. In that case, the precast members must be
carried to the site using trailers. In many cases,
the reduced costs of Precast Concrete is
compensated by the transpor tation cost.
• Handling Difficulties: Proper care and precaution
have to be taken for handling precast concrete.
U s u a l l y, p r e c a s t m e m b e r s a r e h e a v y a n d l a r g e
which makes it difficult to handle without damage.
G e n e r a l l y, p o r t a b l e o r t o w e r c r a n e s a r e u s e d t o
handle precast members.
• Modification: Limitation In case of precast
structures, it is difficult to modify the structure.
For example, if a structural wall is to be
dismantled for modification it will impact the
overall stability of the structure.
• Sensitive Connection Works: Assembling of the
precast members is one of the key points for
e n s u r i n g s t r o n g s t r u c t u r a l b e h a v i o r. C o n n e c t i o n s
between several structural members must be
supervised and done properly to ensure the
intended behavior of the connection such as
simple, semi -rigid or rigid connections. Besides
this, faulty connections may lead to water leakage
and fail sound insulation.
A PPL I C AT I O N S
C AS E ST U DY
• The selected building is one among the six similar towers of G+23 storeys, which
is under
• c o n s t r u c t i o n a t B h o i w a d a , M u m b a i b y L a r s e n & To u b r o L i m i t e d . T h i s p r o j e c t i s
under the slum rehabilitation housing scheme. The developers are M/s Omkar
R e a l t o r s , M u m b a i . C u r r e n t l y, t h i s i s t h e t a l l e s t p r e c a s t b u i l d i n g i n I n d i a . T h i s
case study is based on the drawings, design repor t and computational models
presented by L&T Ltd.
• It is a rectangular building with plan dimensions 45.8m × 19.69m. The total
height is 70m. The appropriate type of precast system for the given height of
building is the wall system, which gives adequate lateral load resistance.
Advantages like fast and repetitive construction, good qualit y and finish due to
factory controlled production, cost competitiveness etc., suppor ted the selection
of the system. The typical f loors have a projection of approximately 1m on t wo
s i d e s w i t h r e s p e c t t o t h e g r o u n d s t o r e y . To a v o i d t h e c o m p l i c a t e d d e t a i l s o f a
precast cantilever suppor ting system at the first floor level, conventional cast -in-
p l a c e c o n s t r u c t i o n w a s a d o p t e d f o r t h e g r o u n d s t o r e y.
• Stuctural Stability
The stability of the structure was considered against the gravity loads, lateral loads
from wind and
ear thquake, and the accidental loads like explosion. The precast design followed an
emulation of cast -inplace system. Inter-connected walls are provided in or thogonal
directions. The wall joints are such that an entire wall acts as an equivalent
monolithic system under lateral loads. The connections between different panels are
w e t c o n n e c t i o n s , a n d a r e a b l e t o t r a n s f e r i n - p l a n e s h e a r, f l e x u r a l t e n s i o n a n d
c o m p r e s s i o n . To i l e t p o d s , w h i c h a r e U - s h a p e d u n i t s , a c t a s s m a l l c o r e u n i t s . T h e
wall-to-floor area ratio is 5.7% for shor ter direction and 2.2% for longer direction.
C AS E ST U DY
• Connections
• Horizontal Joint: A horizontal connection
bet ween panels transfers ver tical stresses
due to gravity loads and any out -of-plane
bending due to eccentricity of the loads.
It also transfers ver tical stresses due to
cantilever action of the wall and
horizontal shear under lateral loads. The
horizontal joint bet ween panels at a f loor
level is made by projecting dowel bars
from the lower panel. They are inser ted
into the dowel tubes provided in the upper
panel and grouted at site using non -
shrink, non-metallic grout. Shear force is
• transmit ted by dowel action of the bars.
Any shear capacity of the grout is
ignored. The dowels are designed to
g e n e r a t e t h e i r t e n s i o n c a p a c i t y. T h e y a r e
placed continuously from the foundation
to the roof. Tie reinforcement overlapped
with U-bars are provided in the slabs for
slab-to-wall connection.
C AS E ST U DY
• Ve r t i c a l J o i n t : T h e v e r t i c a l j o i n t s a r e d e s i g n e d t o t r a n s f e r
shear forces under lateral loads. The joint faces are
indented to provide shear keys(9) for shear transfer with
increasing lateral loads. Beyond cracking of concrete, a
strut-and- tie action is expected to develop. Overlapping
reinforcing loops are provided along with shear keys to take
up the horizontal component of the inclined compressive
strut. A continuous ver tical bar is provided inside the
overlapping loops from the adjacent units. The loops thus
c o u p l e s t h e a dj a c e n t p a n e l s . Fo r s u f f i c i e n t o u t - o f - p l a n e
suppor t, a panel is adequately connected to the
perpendicular panel through overlapping reinforcing loops
w i t h t h e v e r t i c a l b a r. T h e e x t e r i o r w a l l p a n e l s a l o n g t h e
shor ter direction of the building, which constitute the
primary shear walls to resist the lateral forces, are
provided with six shear keys per storey height. In interior
wall joints, reduced number of reinforcement loops are
provided per storey height since the shear demand is less
C AS E ST U DY
• Modelling
T h e a n a l y s i s o f t h e s t r u c t u r e w a s c a r r i e d o u t u s i n g t h e E TA B S s o f t w a r e p a c k a g e . T h e e n t i r e s u p e r s t r u c t u r e w a s
modelled primarily using shell elements. The walls were of shell elements and the slabs of membrane elements. A f loor
was considered as a rigid diaphragm at the respective level, to transfer the lateral forces to walls. The horizontal joints
o f t h e w a l l p a n e l s w e r e i d e a l i s e d t o s i m u l a t e a n e q u i v a l e n t m o n o l i t h i c b e h a v i o u r, i n p r e s e n c e o f t h e c o n t i n u o u s v e r t i c a l
dowel bars. Therefore, the shell elements representing the panels were made continuous at the f loor levels. A few
beams and columns present in the structure were modelled using frame elements
• Integrated Model: In this case, perfect shear transfer was assumed through monolithic behaviour of t wo adjacent
panels connected by the grouted loops. The ver tical joint strip was modelled as a 100mm wide strip of shell element.
Its thick ness and stiffness were considered same as that of the adjacent wall panels. In a grouted keyed connection,
Clause 5.3.1 of IS11447: 1985 permits the joints to be modelled monolithic. Clause 8.1 of IS15916: 2010 permits the
prec ast structure to be analysed as monolithic, provided the joints are designed to take the respective forces
• D i s c r e t e g a p m o d e l : I n t h i s m o d e l , n o s h e a r f o r c e w a s a s s u m e d t o t r a n s f e r b e t w e e n t h e w a l l p a n e l s . To i d e a l i s e t h i s
condition, a 20mm gap was provided at the ver tical joint locations. This uncoupled the adjacent walls. The walls were
connected only at the f loor levels by the diaphragm constraints
C AS E ST U DY
Comparative Study of Models
C AS E ST U DY
PREVENTION OF PROGRESSIVE COLLAPSE
T h e Pre c as t s t r u c tu re s a re m o re s e n s i t i ve to p ro g re s s i ve c o l l a p s e a f te r i m p o r t a n t l o c a l d a m ag e.
Fo r t h e s t a b i l i t y o f s t r u c tu re, t h re e d i m e n s i o n a l i n te r a c t i o n s b et we e n s t r u c tu r a l m e m b e r s a re
n e c e s s a r y to p ro du c e a ro b u s t d e s i g n . T h e c o n n e c t i o n s a re n o r m a l ly d e s i g n e d fo r s h e a r a n d
c o m p re s s i o n . B u t i n t h e c as e o f a c c i d e n t a l l o a d i n g l i ke e x p l o s i o n , h i gh te n s i l e s t re s s e s a l o n g w i t h
l a rg e d efo r m at i o n s w i l l o c c u r. To t a ke u p s u c h fo rc e s , t h e c o n n e c t i o n s s h o u l d h ave s u f f i c i e n t
s t re n g t h , c o n t i n u i t y a n d du c t i l i t y. S t re n g t h i s to t a ke u p t h e e x t r a fo rc e s a c t i n g , c o n t i n u i t y to
re d i s t r i b u te t h e l o a d i n g i n c as e o f a c c i d e n t a l c o l l a p s e a n d du c t i l i t y to a c c o m m o d ate l a rg e
d efo r m at i o n s as we l l as fo r e n e rgy d i s s i p at i o n . To t a ke c a re o f t h e s e d e m a n d s , t i e re i n fo rc e m e n t s
i n a l l t h e t h re e d i m e n s i o n s a re a n a b s o lu te n e c e s s i t y ( Cl. 1 6 . 5 , AC I 3 1 8 - 0 8 ) . T h e i n te r n a l t i e s a re
to t a ke u p t h e l ate r a l fo rc e s f ro m s h e a r wa l l a c t i o n .
Pe r i p h e r a l t i e s e n s u re t h e d i a p h r ag m a c t i o n o f t h e s l a b s . Fl o o r to wa l l t i e s t a ke u p t h e h o r iz o n t a l
fo rc e s f ro m a n c h o r ag e o f f l o o r s to t h e i r s u p p o r t a n d ve r t i c a l t i e s e n s u re t h e c a n t i l eve r a c t i o n o f
wa l l s .
C AS E ST U DY
S U M M A RY
• T h e c as e s tu dy p rov i d e d s o m e i n fo r m at i o n o n t h e d e s i g n a n d m o d e l l i n g as p e c t s o f a wa l l t y p e
p re c as t b u i l d i n g . T h e m o d e l l i n g o f ve r t i c a l j o i n t s was d o n e w i t h t wo e x t re m e c o n d i t i o n s , s i n c e
t h e re i s n o p ro p e r gu i d e l i n e s to m o d e l t h e j o i n t s m o re e c o n o m i c a l ly by c o n s i d e r i n g t h e a c tu a l
s h e a r t r a n s fe r. T h e c o n c lu s i o n s d r aw n f ro m t h e c as e s tu dy o n a p re c as t wa l l p a n e l s ys te m
b u i l d i n g a re as fo l l ow s .
• T h e e m u l at i ve m o n o l i t h i c wa l l s ys te m s e e m s to b e a d e q u ate i n m o d e r ate s e i s m i c z o n e s . T h e
p rov i s i o n s o f t i e re i n fo rc e m e n t s , re i n fo rc e d s h e a r keys a n d d owe l b a r s p rov i d e t h e re q u i re d
s t r u c tu r a l i n te g r i t y fo r t h e p re c as t s ys te m .
• T h e m o d e l l i n g o f ve r t i c a l j o i n t s w i t h o u t c o n s i d e r i n g t h e s h e a r t r a n s fe r t h ro u gh t h e s h e a r keys ,
re i n fo rc e d w i t h s h e a r l i n k s , l e a d to a c o n s e r vat i ve d e s i g n . N o n - l i n e a r s h e a r s p r i n g s c a n b e
i n c o r p o r ate d i n t h e m o d e l to g et m o re re a l i s t i c wa l l fo rc e s . T h i s w i l l l e a d to a m o re e c o n o m i c a l
design.
C AS E ST U DY
To avo i d p ro g re s s i ve c o l l a p s e, t h e s t r u c tu re s h o u l d b e s u f f i c i e n t ly ro b u s t a n d re du n d a n t .
I d e n t i f i c at i o n a n d p ro p e r d e s i g n o f t h e key e l e m e n t s i n t h e s t r u c tu re i s n e c e s s a r y to avo i d
p ro g re s s i ve c o l l a p s e. Ac c o rd i n g to Cl au s e 2 . 6 o f B S 8 1 1 0 - 2 : 1 9 8 5 , a key e l e m e n t a n d i t s
c o n n e c t i o n s s h o u l d b e d e s i g n e d fo r a n u l t i m ate d e s i g n l o a d o f 3 4 k N / m 2 f ro m a n y d i re c t i o n ,
w i t h o u t c o n s i d e r i n g a n y p a r t i a l s a fet y f a c to r. A s p e r Cl au s e 4 . 7 o f I S 1 1 4 4 7 : 1 9 8 5 , t h e m i n i m u m
a re a fo r t i e re i n fo rc e m e n t s s h o u l d n ot b e l e s s t h a n 4 c m 2
.
Re c o m m e n d at i o n s i n t h e s e c o d e s we re fo l l owe d to f i n d t h e d e s i g n l o a d a n d t h e re q u i re d a m o u n t o f
t i e re i n fo rc e m e n t s . H e re, t i e re i n fo rc e m e n t s we re p rov i d e d h o r iz o n t a l ly, b ot h i n te r n a l ly a n d
p e r i p h e r a l ly. T h e re i n fo rc e m e n t at t h e s h e a r key l o c at i o n s p rov i d e t h e h o r iz o n t a l t y i n g a n d t h at at
t h e j o i n t re g i o n s g i ve s t h e n e c e s s a r y ve r t i c a l t y i n g ef fe c t . T h e h o r iz o n t a l t i e s p rov i d e a c a n t i l eve r
a c t i o n to h o l d t h e d a m ag e d p a r t s . T h e ve r t i c a l t i e s h e l p to s u s p e n d t h e l owe r d a m ag e d e l e m e n t s
to t h e i n t a c t u p p e r p o r t i o n s . T h e h o r iz o n t a l a n d p e r i p h e r a l t i e s ys te m s p rov i d e a c ate n a r y a c t i o n to
b r i d g e t h e d a m ag e d p o r t i o n . T h e wa l l - to - s l a b t i e s h e l p to s u s p e n d t h e d e b r i s , a n d p reve n t t h e
d a m ag e d f l o o r f ro m f a l l i n g d ow n o n to t h e i n t a c t l owe r p o r t i o n s