FALL 2009

PRECAST
CONCRETE
Northeastern University School of Architecture
ARCH G691 Graduate Degree Project Studio
FALL 2009

PRECAST
CONCRETE
Northeastern University School of Architecture
ARCH G691 Graduate Degree Project Studio
TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION
Precast Concrete

TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION

Table of Contents
 INTRODUCTION
DESIGN
INTRODUCTION

Definition of Precast
Organization

1 DESIGN

MANUFACTURE
1.1 Component Relationships
1.2 Slabs
1.3 Beams
1.4 Columns

2 MANUFACTURE

2.1 Plant Logics

2.2 Mixtures
2.3 Reinforcement
2.4 Molds

TRANSPORTX+XASSEMBLY
3 TRANSPORT + ASSEMBLY

3.1 Shipping Logics

3.2 Crane and Site Logics
3.3 Joinery and Detail Connections

Precast Concrete
Introduction
 INTRODUCTION
Approach Scope Conclusions

DESIGN
This book looks at the structural system of In an effort to create an in depth model of the In all we have discovered that precast
precast concrete through a discerning lens. precast system, the content of this book is limited construction is driven by economics and time.
While tons of books exist on the subject, none to structural members. More specifically we have Being a material known for its quick on-site
distill relevant information down for architectural focused on panel construction rather than construction, every step of precast construction
practice. Moreover, we have decided to examine masonry units. Despite this fact, many of the is geared towards improving cost and schedule.
the processes inherent to this building material insights uncovered in the following analysis can Consequently, the system has developed the

MANUFACTURE
instead of creating a survey of precast concrete be applied to the expanded scope of precast reputation of being the low-grade building
use. The chapters are organized by design, construction. material of developers. The content of this book
manufacture, and transport and assembly. We attempts to reconnect the profession with this
are hoping that this approach better unites the undervalued structural system.
architectural design process with the realities of
building construction, revealing the inner logics
and latent opportunities.

TRANSPORTX+XASSEMBLY
Precast Concrete
Design
 Design

INTRODUCTION
1.0 Introduction
1
This chapter focuses on the design of precast components
in a site-less condition. Specifically, the sections are divided
into the parts that make up the structural system: columns,
beams and slabs. Through this investigation, the varying
depths of each piece are diagramed, along with their corre-
sponding spans, that are determined by the number of steel

DESIGN
reinforcement bars. Along with these span graphs, each
piece has a graph that compares the safe service load, when
considering the depth of the piece and the span. In addition,
a typical arrangement of these parts is shown in an axon,
along with standard dimensions and an explanation of the
logic of these sizes and distances.

MANUFACTURE
The standard used to develop these charts assumed no top-
ping on precast components. The logic carried through this
section was due to the fact that not all components have top-
pings and for the sake of clarity and consistency, these addi-
tional variables were not included in the chart. In instances
where more information could be found about toppings, the
section instructs you where to find these calculations.

TRANSPORTX+XASSEMBLY
Precast Concrete
 Design
INTRODUCTION

1 1.0 Component Relationships

DESIGN
MANUFACTURE

10ft typ.

8ft typ.

60ft typ.

30ft typ.
TRANSPORTX+XASSEMBLY

Typical Dimensions The use of 10 foot width double tee members allows
The above diagram illustrates the tyical for only three pieces to be used to make the 30
dimensions of a single bay of parking, and the foot dimension between the columns. If the double
logic behind those measurements. The span tee width were to change to be 8 feet, the distance
of 60ft allows for two rows of 18 foot deep between the two columns could change into 32 feet to
parking, with 24 feet of car circulation space. still accomodate three parking spots, but four double
The space of 30 feet between the columns in tee members are used instead of three. The 8 foot
the lateral direction allows for three adjacent tall dimension of the column allows for the minimum
parking spots of 9 feet, uninterupted by columns. height clearance of the parking garage ceiling.
 Design

INTRODUCTION
1.0 Design Relationships
1

DESIGN
MANUFACTURE
In this particular example, the seams of the double
tee line up with the center of the column, so the

TRANSPORTX+XASSEMBLY
dimension of three 10 foot double tees creates
the 30 foot distance between the columns. If
the beam was rectangular instead of L shaped,
the double tees would rest on top and cause the
floor thickness to be greater. In other causes, the
double tee members don’t have to line up with
the center of the column. The double tees can
continue uninterrupted as long as the legs of the
double tee fall onto a beam.

Precast Concrete
TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION

1 Design
1.1 Components: Slabs
 Design

INTRODUCTION
1.1 Components: Slabs
1

DESIGN
MANUFACTURE
TRANSPORTX+XASSEMBLY
Slabs
These pieces come in four different shapes: double
tees, single tees, solid slab and hollow core slab. The
span of each of these can vary greatly and is only
limited by how much service load is desired. The
width, however, has a much smaller range, and is
determined by the width of the transporting vehicle.
Widths are also determined by how many pieces are
going to be used and the spacing of the columns.

Precast Concrete
 Design
INTRODUCTION

1 1.1 Components: Double Tees

8’-0” wide

Double Tees
These are the most commonly manufactured 12”

depth (in.)
14”
shape of precast slab. They can span longer 16”
18”
distances than a solid slab or hollow core, 20”
and can easily be stacked and transported. 24”
Although they can span a long distance, a large 28”
DESIGN

number of pieces are necessary to complete 32”

a specific width. Also, in order to span a larger 36”
distance, the pieces need to have a greater depth.
MANUFACTURE

Spans and Service Loads

In the diagrams to the right and on the opposite
page, varying depths correspond to span
lengths and capacity to support certain levels Increasing Safe Service Loads
of service load. The deeper the double tee PLEASE NOTE: The load chart on the opposite
component, the higher the constructible span. page represents a double tee with no additional
topping. By adding either a 2 inch or 4 inch
In the lower diagram, each polyline boundary topping of reinforced concrete, the span
TRANSPORTX+XASSEMBLY

designates the possible safe service loads, and safe service loads can greatly increase.
depending on depth of the double tee, and the
span. Typically, the longer the span, the lower This is more commonly used when a member
amount of service load the member is able to needs to be able to support a certain amount
support. Additionally, the higher the number of of service load, but it cannot increase its span.
reinforcement steel bars used in the precast The amount of depth at which the component
member, the higher the capability to hold a increases is very small, so this is a more viable
higher service load. These reinforcement bars option than producing a piece of much greater
also allow the double tees to span farther depth and span. For measurements of safe
distances, but as a result of the spans being serviceable loads when using additional
greater, less service load can be supported. topping, please reference the PCI handbook.
 Design

INTRODUCTION
1.1 Components: Double Tees
1

DESIGN
12 20 30 40 50 60 70 80 90 100 104

span (ft.)

MANUFACTURE
heavy manufacturing / 250
heavy storage
240
230
220
210
200
190
safe service loads (psf)

180
garages (trucks /buses) 170
160
library stacks 150
140
light manufacturing /
130
light storage
120
gym /restaurant 110

TRANSPORTX+XASSEMBLY
office 100
90
retail /hotel /
multifamily housing
80
70
garages (cars) 60
one / two family housing 50
40
30

12 20 30 40 50 60 70 80 90 100 104
span (ft.)
Precast Concrete
 Design
INTRODUCTION

1 1.1 Components: Double Tees

10’-0” wide
Double Tees
These are the most commonly manufactured
shape of precast slab. They can span longer
distances than a solid slab or hollow core,

depth (in.)
12”
and can easily be stacked and transported. 16”
Although they can span a long distance, a large
DESIGN

20”
number of pieces are necessary to complete 24”
a specific width. Also, in order to span a larger 28”
distance, the pieces need to have a greater depth. 32”
36”
MANUFACTURE

Spans and Service Loads

In the diagrams to the right and on the opposite
page, varying depths correspond to span
lengths and capacity to support certain levels Increasing Safe Service Loads
of service load. The deeper the double tee PLEASE NOTE: The load chart on the opposite
component, the higher the constructible span. page represents a double tee with no additional
topping. By adding either a 2 inch or 4 inch
In the lower diagram, each polyline boundary topping of reinforced concrete, the span
TRANSPORTX+XASSEMBLY

designates the possible safe service loads, and safe service loads can greatly increase.
depending on depth of the double tee, and the
span. Typically, the longer the span, the lower This is more commonly used when a member
amount of service load the member is able to needs to be able to support a certain amount
support. Additionally, the higher the number of of service load, but it cannot increase its span.
reinforcement steel bars used in the precast The amount of depth at which the component
member, the higher the capability to hold a increases is very small, so this is a more viable
higher service load. These reinforcement bars option than producing a piece of much greater
also allow the double tees to span farther depth and span. For measurements of safe
distances, but as a result of the spans being serviceable loads when using additional
greater, less service load can be supported. topping, please reference the PCI handbook.
 Design

INTRODUCTION
1.1 Components: Double Tees
1

DESIGN
MANUFACTURE
12 20 30 40 50 60 70 80 90
span (ft.)
240
230
220
210
200
190
180
safe service loads (psf)

garages (trucks /buses) 170

160
library stacks 150
140
light manufacturing /
130
light storage
120
gym /restaurant 110

TRANSPORTX+XASSEMBLY
office 100
90
retail /hotel /
multifamily housing
80
70
garages (cars) 60
one / two family housing 50

40
30
20

12 20 30 40 50 60 70 80 90
span (ft.) Precast Concrete
 Design
INTRODUCTION

1 1.1 Components: Double Tees

12’-0” wide
Double Tees
These are the most commonly manufactured
shape of precast slab. They can span longer

depth (in.)
distances than a solid slab or hollow core,
and can easily be stacked and transported.
Although they can span a long distance, a large
DESIGN

number of pieces are necessary to complete

a specific width. Also, in order to span a larger
distance, the pieces need to have a greater depth. 32”
MANUFACTURE

Spans and Service Loads

In the diagrams to the right and on the opposite
page, varying depths correspond to span
lengths and capacity to support certain levels Increasing Safe Service Loads
of service load. The deeper the double tee PLEASE NOTE: The load chart on the opposite
component, the higher the constructible span. page represents a double tee with no additional
topping. By adding either a 2 inch or 4 inch
In the lower diagram, each polyline boundary topping of reinforced concrete, the span
TRANSPORTX+XASSEMBLY

designates the possible safe service loads, and safe service loads can greatly increase.
depending on depth of the double tee, and the
span. Typically, the longer the span, the lower This is more commonly used when a member
amount of service load the member is able to needs to be able to support a certain amount
support. Additionally, the higher the number of of service load, but it cannot increase its span.
reinforcement steel bars used in the precast The amount of depth at which the component
member, the higher the capability to hold a increases is very small, so this is a more viable
higher service load. These reinforcement bars option than producing a piece of much greater
also allow the double tees to span farther depth and span. For measurements of safe
distances, but as a result of the spans being serviceable loads when using additional
greater, less service load can be supported. topping, please reference the PCI handbook.
 Design

INTRODUCTION
1.1 Components: Double Tees
1

DESIGN
MANUFACTURE
12 20 30 40 50 60 70 80 90
span (ft.)

200
190
180
safe service loads (psf)

garages (trucks /buses) 170

160
library stacks 150
140
light manufacturing /
130
light storage
120
gym /restaurant 110
office 100

TRANSPORTX+XASSEMBLY
90
retail /hotel /
multifamily housing
80
70
garages (cars) 60
one / two family housing 50
40
30

12 20 30 40 50 60 70 80 90
span (ft.)

Precast Concrete
 Design
INTRODUCTION

1 1.1 Components: Single Tees

8’-0” wide
Single Tee
Many existing buildings utilize single tees,
however as precast technologies have improved,
manufacturers have realized that double tees

depth (in.)
are easier to produce, easier to transport
because additional bracing is not necessary
DESIGN

to hold them up, and the same distance can

be spanned, with a shallower depth of the
member. In fact, in the newest versions of the 36”
PCI Handbook, single tees are not included.
MANUFACTURE

Spans and Service Loads

In the diagrams to the right and on the opposite
page, varying depths correspond to span
lengths and capacity to support certain levels Increasing Safe Service Loads
of service load. The deeper the single tee PLEASE NOTE: The load chart on the opposite
component, the higher the constructible span. page represents a double tee with no additional
topping. By adding either a 2 inch or 4 inch
In the lower diagram, each polyline boundary topping of reinforced concrete, the span
TRANSPORTX+XASSEMBLY

designates the possible safe service loads, and safe service loads can greatly increase.
depending on depth of the single tee, and the span.
Typically, the longer the span, the lower amount This is more commonly used when a member
of service load the member is able to support. needs to be able to support a certain amount
Additionally, the higher the number of reinforcement of service load, but it cannot increase its span.
steel bars used in the precast member, the higher The amount depth at which the component
the capability to hold a higher service load. These increases is very small, so this is a more viable
reinforcement bars also allow the single tees to option than producing a piece of much greater
span farther distances, but as a result of the spans depth and span. For measurements of safe
being greater, less service load can be supported. serviceable loads when using additional
topping, please reference the PCI handbook.
 Design

INTRODUCTION
1.1 Components: Single Tees
1

DESIGN
MANUFACTURE
12 20 30 40 50 60 70 80 90 100
span (ft.)

190
safe service loads (psf)

180
garages (trucks /buses) 170
160
library stacks 150
140
light manufacturing /
130
light storage
120
gym /restaurant 110
office 100
90
retail /hotel /

TRANSPORTX+XASSEMBLY
multifamily housing
80
70
garages (cars) 60
one / two family housing 50

40

12 20 30 40 50 60 70 80 90 100
span (ft.)

Precast Concrete
 Design
INTRODUCTION

1 1.1 Components: Single Tees

10’-0” wide
Single Tee
Many existing buildings utilize single tees,
however as precast technologies have improved,
manufacturers have realized that double tees

depth (in.)
are easier to produce, easier to transport
because additional bracing is not necessary
DESIGN

to hold them up, and the same distance can

be spanned, with a shallower depth of the
member. In fact, in the newest versions of the
PCI Handbook, single tees are not included.

48”
MANUFACTURE

Spans and Service Loads

In the diagrams to the right and on the opposite
page, varying depths correspond to span
lengths and capacity to support certain levels Increasing Safe Service Loads
of service load. The deeper the single tee PLEASE NOTE: The load chart on the opposite
component, the higher the constructible span. page represents a double tee with no additional
topping. By adding either a 2 inch or 4 inch
In the lower diagram, each polyline boundary topping of reinforced concrete, the span
TRANSPORTX+XASSEMBLY

designates the possible safe service loads, and safe service loads can greatly increase.
depending on depth of the single tee, and the span.
Typically, the longer the span, the lower amount This is more commonly used when a member
of service load the member is able to support. needs to be able to support a certain amount
Additionally, the higher the number of reinforcement of service load, but it cannot increase its span.
steel bars used in the precast member, the higher The amount depth at which the component
the capability to hold a higher service load. These increases is very small, so this is a more viable
reinforcement bars also allow the single tees to option than producing a piece of much greater
span farther distances, but as a result of the spans depth and span. For measurements of safe
being greater, less service load can be supported. serviceable loads when using additional
topping, please reference the PCI handbook.
 Design

INTRODUCTION
1.1 Components: Single Tees
1

DESIGN
MANUFACTURE
12 20 30 40 50 60 70 80 90 100 110
span (ft.)

garages (trucks /buses) 170

safe service loads (psf)

160
library stacks 150
140
light manufacturing /
130
light storage
120
gym /restaurant 110
100

TRANSPORTX+XASSEMBLY
office

90
retail /hotel /
multifamily housing
80
70
garages (cars) 60
one / two family housing 50

40

12 20 30 40 50 60 70 80 90 100 110
span (ft.)

Precast Concrete
 Design
INTRODUCTION

1 1.1 Components: Solid Slabs

(width varies)
Solid Slab

depth (in.)
4”
This type of slab can vary in width, but has the 6”
8”
smallest distance it can span. However, it does
have the highest safe service load, especially
at the shortest spans. These components are
also much shallower than the double and single
DESIGN

tees, so this allows for a much larger floor

to ceiling height. In addition, the pieces are
lighter, easily stacked for transportation, and
much more can fit on the transportation vehicle.
MANUFACTURE

Spans and Service Loads

In the diagrams to the right and on the opposite
page, varying depths correspond to span lengths
and capacity to support certain levels of service
load. The deeper the solid slab, the higher the Increasing Safe Service Loads
constructible span. Although the solid slab can- PLEASE NOTE: The load chart on the opposite
not span as far as the single and double tees, it page represents a double tee with no additional
can carry a larger service load. topping. By adding either a 2 inch or 4 inch
topping of reinforced concrete, the span
TRANSPORTX+XASSEMBLY

In the lower diagram, each polyline boundary and safe service loads can greatly increase.
designates the possible safe service loads, de-
pending on depth of the solid slab, and the span. This is more commonly used when a member
Typically, the longer the span, the lower amount needs to be able to support a certain amount
of service load the member is able to support. of service load, but it cannot increase its span.
Additionally, the higher the number of reinforce- The amount depth at which the component
ment steel bars used in the precast member, increases is very small, so this is a more viable
the higher the capability to hold a higher service option than producing a piece of much greater
load. These reinforcement bars also allow the depth and span. For measurements of safe
hollow core to span farther distances, but as a serviceable loads when using additional
result of the spans being greater, less service topping, please reference the PCI handbook.
load can be supported.
 Design

INTRODUCTION
1.1 Components: Solid Slabs
1

12 20 30

span (ft.)

DESIGN
300
290
280
270
260
heavy manufacturing / 250

MANUFACTURE
heavy storage
240
230
safe service loads (psf)

220
210
200
190
180
garages (trucks /buses) 170
160
library stacks 150
140
light manufacturing /
130
light storage
120
gym /restaurant 110
office 100
90
retail /hotel /
80

TRANSPORTX+XASSEMBLY
multifamily housing
70
garages (cars) 60
one / two family housing 50

12 20 30
span (ft.)

Precast Concrete
 Design
INTRODUCTION

1 1.1 Components: Hollow Core Slabs

4’-0” wide
Hollow Core

depth (in.)
This type of slab can vary in width, but has a much 6”
8”
smaller span distance than the double or single 10”
tee. The biggest advantage of this type is the fact 12”

that it weights much less than the tees, and even

less than the solid slab. These components are
DESIGN

also much shallower than the double and single

tees, so this allows for a much larger floor to
ceiling height. In addition, the pieces are lighter,
easily stacked for transportation, and much more
can fit on the transportation vehicle. Through
the hollow core, it is possible to run wiring or
other mechanical equipment through the spaces.
MANUFACTURE

Increasing Safe Service Loads

PLEASE NOTE: The load chart on the opposite
Spans and Service Loads page represents a double tee with no additional
In the diagrams to the right and on the opposite topping. By adding either a 2 inch or 4 inch
page, varying depths correspond to span lengths topping of reinforced concrete, the span and
and capacity to support certain levels of service safe service loads can greatly increase.
load. The deeper the hollow core component,
the higher the constructible span. Although the This is more commonly used when a member
hollow core cannot span as far as the single and needs to be able to support a certain amount of
double tees, it can carry a larger service load. service load, but it cannot increase its span. The
amount depth at which the component increases
TRANSPORTX+XASSEMBLY

In the lower diagram, each polyline boundary is very small, so this is a more viable option than
designates the possible safe service loads, producing a piece of much greater depth and
depending on depth of the hollow core, and the span. For measurements of safe
span. Typically, the longer the span, the lower serviceable loads when using additional
amount of service load the member is able to topping, please reference the PCI handbook.
support. Additionally, the higher the number of
reinforcement steel bars used in the precast Unique to the hollow core, there is a huge
member, the higher the capability to hold a high- variety of shapes, numbers and sizes of holes
er service load. These reinforcement bars also in the various types of hollowcore. These
allow the hollow core to span farther distances, variables affect the depth, reinforcement, span
but as a result of the spans being greater, less and service loads. To explore these possibilities
service load can be supported. please reference the PCI handbook.
 Design

INTRODUCTION
1.1 Components: Hollow Core Slabs
1

12 20 30 40 50

DESIGN
span (ft.)

290
280
270

MANUFACTURE
260
heavy manufacturing / 250
safe service loads (psf)

heavy storage
240
230
220
210
200
190
180
garages (trucks /buses) 170

160
library stacks 150
140
light manufacturing /
light storage
130
120
gym /restaurant 110
office 100

TRANSPORTX+XASSEMBLY
90
retail /hotel /
multifamily housing 80
70
garages (cars) 60
one / two family housing 50

40

12 20 30 40 50
span (ft.)

Precast Concrete
TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION

1 Design
1.2 Components: Beams
 Design

INTRODUCTION
1.2 Components: Beams
1

DESIGN
MANUFACTURE
TRANSPORTX+XASSEMBLY
Beams
There are three different types of beams: rectan-
gular, L shaped and inverted T. These components
rest on top of the columns and must support the
weight of the slabs that rest on top of them. In each
example, the width stays constant, but the depth
and spans have a very large range. Steel reinforce-
ment is not a variable when calculating safe ser-
vice loads.

Precast Concrete
 Design
INTRODUCTION

1 1.2 Components: Rectangular Beams

12” wide

depth (in.)
16”
20”
24”
28”
DESIGN

32”
36”
MANUFACTURE

Spans and Service Loads Rectangular Beams

In the diagrams to the right and on the This type of beam allows the slab to rest on top of
opposite page, varying depths correspond it, creating larger depth per floor. Because it is of
to span lengths and capacity to support uniform shape, it can be placed anywhere in the
certain levels of service load. The deeper building, whether it resting on the exterior columns
the beam, the higher the constructible span. or the interior columns. Typically these types of
TRANSPORTX+XASSEMBLY

beams do not hold as much load as an L shaped or

In the lower diagram, each polyline boundary inverted T beam, but they are shallower in depth.
designates the possible safe service loads,
depending on depth of the beam, and the span.
Typically, the longer the span, the lower amount
of service load the member is able to support.
The required level of safe service load
is very high, because it is supporting the
weight of the slabs that rest on top of it,
and the weight that the slabs support.
 Design

INTRODUCTION
1.2 Components: Rectangular Beams
1

DESIGN
20 30 40 50

span (ft.)

MANUFACTURE
10,000
9,500
9,000
8,500
8,000
7,500
safe service loads (psf)

7,000
6,500
6,000
5,500
5,000
4,500
4,000
3,500
3,000
2,500
2,000

TRANSPORTX+XASSEMBLY
1,500
1,000

20 30 40 50

span (ft.)

Precast Concrete
 Design
INTRODUCTION

1 1.2 Components: Rectangular Beams

16” wide

depth (in.)
24”
28”
DESIGN

32”
36”
40”
MANUFACTURE

Spans and Service Loads Rectangular Beams

In the diagrams to the right and on the This type of beam allows the slab to rest on top of
opposite page, varying depths correspond it, creating larger depth per floor. Because it is of
to span lengths and capacity to support uniform shape, it can be placed anywhere in the
certain levels of service load. The deeper building, whether it resting on the exterior columns
the beam, the higher the constructible span. or the interior columns. Typically these types of
TRANSPORTX+XASSEMBLY

beams do not hold as much load as an L shaped or

In the lower diagram, each polyline boundary inverted T beam, but they are shallower in depth.
designates the possible safe service loads,
depending on depth of the beam, and the span.
Typically, the longer the span, the lower amount
of service load the member is able to support.
The required level of safe service load
is very high, because it is supporting the
weight of the slabs that rest on top of it,
and the weight that the slabs support.
 Design

INTRODUCTION
1.2 Components: Rectangular Beams
1

DESIGN
20 30 40 50

span (ft.)

MANUFACTURE
10,000
9,500
9,000
8,500
8,000
7,500
safe service loads (psf)

7,000
6,500
6,000
5,500
5,000
4,500
4,000
3,500
3,000
2,500
2,000

TRANSPORTX+XASSEMBLY
1,500
1,000

20 30 40 50

span (ft.)

Precast Concrete
 Design
INTRODUCTION

1 1.2 Components: L Shaped Beams

12” wide

20”
24”
28”
DESIGN

32”
36”
40”
44”
48”
52”
56”
60”
MANUFACTURE

18” wide
depth (in.)

Spans and Service Loads L Shaped Beams

In the diagrams to the right and on the This type of beam allows the slab to rest on
opposite page, varying depths correspond grooves located on one side, causing this type
to span lengths and capacity to support to be best utilized as beam places on the pe-
certain levels of service load. The deeper rimeter of the building. Although this type can
the beam, the higher the constructible span. range to a depth greater than the rectangular
TRANSPORTX+XASSEMBLY

beam, the shape allows for the slab to rest of

In the lower diagram, each polyline boundary the grooves, therefore reducing the thickness
designates the possible safe service loads, of the floor. In addition, this type can support a
depending on depth of the beam, and the span. greater service load than the rectangular beams.
Typically, the longer the span, the lower amount
of service load the member is able to support.
The required level of safe service load
is very high, because it is supporting the
weight of the slabs that rest on top of it,
and the weight that the slabs support.
 Design

INTRODUCTION
1.2 Components: L Shaped Beams
1

DESIGN
MANUFACTURE
20 30 40 50

span (ft.)
10,000
9,500
safe service loads (psf)

9,000
8,500
8,000
7,500
7,000
6,500
6,000
5,500
5,000
4,500

TRANSPORTX+XASSEMBLY
4,000
3,500
3,000
2,500
2,000
1,500
1,000

20 30 40 50

span (ft.)
Precast Concrete
 Design
INTRODUCTION

1 1.2 Components: Inverted T Beams

12” wide

20”
24”
28”
DESIGN

32”
36”
40”
44”
48”
52”
56”
60”
MANUFACTURE

24” wide
depth (in.)

Spans and Service Loads Inverted T Beams

In the diagrams to the right and on the This type of beam allows the slab to rest on
opposite page, varying depths correspond grooves located on both sides, causing this type
to span lengths and capacity to support to be best utilized as an interior beam. Although
certain levels of service load. The deeper this type can range to a depth greater than the
the beam, the higher the constructible span. rectangular beam, the shape allows for the slab to
TRANSPORTX+XASSEMBLY

rest of the grooves, therefore reducing the thick-

In the lower diagram, each polyline boundary ness of the floor. In addition, this type can support
designates the possible safe service loads, a greater service load than the rectangular beams.
depending on depth of the beam, and the span.
Typically, the longer the span, the lower amount
of service load the member is able to support.
The required level of safe service load
is very high, because it is supporting the
weight of the slabs that rest on top of it,
and the weight that the slabs support.
 Design

INTRODUCTION
1.2 Components: Inverted T Beams
1

DESIGN
MANUFACTURE
20 30 40 50

span (ft.)
10,000
9,500
safe service loads (psf)

9,000
8,500
8,000
7,500
7,000
6,500
6,000
5,500
5,000
4,500

TRANSPORTX+XASSEMBLY
4,000
3,500
3,000
2,500
2,000
1,500
1,000

20 30 40 50

span (ft.)
Precast Concrete
TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION

1 Design
1.3 Components: Columns
 Design

INTRODUCTION
1.3 Components: Columns
1

DESIGN
MANUFACTURE
TRANSPORTX+XASSEMBLY
Columns
Although there are a few different types of columns,
this book focuses on square columns, because it is
more commonly used due to the assembly process
being easier than if a round column was used. Col-
umns need to support the largest abount of ser-
vice load because they hold up the beams and the
slabs.

Precast Concrete
 Design
INTRODUCTION

1 1.3 Components: Square Column

8”
10”
12”
14”
16”
18”
20”
22”
24”
26”
28”

width (in.)
DESIGN
MANUFACTURE

Heights and Service Loads Square Columns

In the diagrams to the right and on the opposite These members are not categorized by depth and
page, varying column widths correspond span, instead they are measured by width and
to column heights and capacity to support height. Columns have additional extrusions that
certain levels of service load. The wider the act as a shelf to support the beams. The spac-
column, the tallerer the constructible height. ing between columns is determined by the span
TRANSPORTX+XASSEMBLY

of the slabs that rest on top of the beams, and in

In the lower diagram, each polyline boundary the other direction, it is determined by the width
designates the possible safe service loads, of the slabs.
depending on width of the column, and the height.
Typically, the taller the height, the lower amount
of service load the member is able to support.
The required level of safe service load is
very high, because it is supporting the weight
of the beams and slabs that rest on top of it,
and the weight that those members support.
 Design 1

INTRODUCTION
1.3 Components: Square Column

DESIGN
10 20 30 40
height (ft.)
27,000
26,000
25,000
24,000

MANUFACTURE
23,000
22,000
21,000
20,000
19,000
18,000
safe service loads (psf)

17,000
16,000
15,000
14,000
13,000
12,000
11,000
10,000

TRANSPORTX+XASSEMBLY
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000

10 20 30 40
height (ft.) Precast Concrete
Manufacture
 Manufacture

INTRODUCTION
2.0 Introduction
2

Precast concrete can be cast using wet or dry

methods. Wet casting is the typical method used
in precast concrete and therefore the focus of this

DESIGN
chapter. It utilizes workable, fluid mixes of air,
aggregates, cement, pigments, and water. While
there are thousands of mix combinations, the
main variables relevant to precast are compressive
strength and weight.

MANUFACTURE
Tensile strength is determined through reinforcing.
All structural concrete members are reinforced
and most precast shapes are prestressed as
well.

In addition to these design basics, one must

consider a molding strategy. The repition and
economy of materials are huge influences on the
design of custom shapes. Even basic shapes
have some variables like curing time. Once the
product is cured, it is shipped off to the
construction site.

TRANSPORTX+XASSEMBLY
Overall this chapter navigates the logics and
goals of the manufacturing process.

Precast Concrete
 Manufacture
INTRODUCTION

2 2.1 Plant Logics

Location

In looking at the location of precast plants in the

North Eastern corner of the United States, a
couple of trends become apparent. For the most
DESIGN

part plants are evenly spaced out due to price

competition. A manufacturer’s price is always
dependent on how far they are shipping. If
another plant is closer to a job site, their price will
be lower. Within the state of Pennsylvania the
radius of competition for suburban manufacturer’s
MANUFACTURE
MANUFACTURE

is around 50 miles. Once plants enter a city’s

zone of development, this radius of competition
becomes smaller, around 30 miles. Therefore,
the location of precast plants is evenly spaced
and loosely clustered around metropolitian
areas.
TRANSPORTX+XASSEMBLY

Architectural Precast Plant

Structural Precast Plant

Large Metropolitan Area

 2.1 Plant Logics
Manufacture

Precast Concrete
2

TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION

 Manufacture
INTRODUCTION

2 2.1 Plant Logics

Plant Layout + Work Flow

Most plants are layed out using four main

components: a mixing station, steel shop, main
facility, and stock yard. Once a batch is mixed,
DESIGN

trucks or special concrete transporters carry it

through the main facility to the casting beds.
Meanwhile, any reinforcement is constructed in
the steel shop and brought over in cages as
needed. The pieces are cured in the main bay
and then carried out to the stock yard where they
MANUFACTURE
MANUFACTURE

are stamped and stored until delivery to the site.

Concrete Mix Station Steel Shop

The Main Facility

The main facility is organized into a series of

rows that alternate between molds and flex
space. Pouring and moving trucks use this space
to service curing molds. Equipment and products
TRANSPORTX+XASSEMBLY

are transported by overhead skips and rollers

fixed to the casting bed rails. Such equipment
includes: concrete transporters, vibrating sleds,
slip formers, extruders, and cleaning devices.
This use of space allows the largest efficiency of
manufacture.
Main Facility Stock Yard
 2.1 Plant Logics
Manufacture

Precast Concrete
2

TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION

 Manufacture
INTRODUCTION

2 2.1 Plant Logics

Production Sequence

The average plant casts one mold per day. At 7

am the mold is emptied and cleaned. Then the
reinforcing for the next cast is put in place. By
DESIGN

around 2 pm the concrete can be poured in, and

the form vibrated for curing. Curing time can take
up to two days, but is generally shortened through
heating systems.
MANUFACTURE
MANUFACTURE

7 am 2 pm
Demolding Concrete Pouring

Cleaning Vibration
TRANSPORTX+XASSEMBLY

Placing the Reinforcement Curing

 Manufacture

INTRODUCTION
2.1 Plant Logics
2

Curing Systems

Without any external influences a precast

concrete member takes approximately 48 hours
to reach the strength required to remove it from a

DESIGN
mold. This time is quite impractical and a number
of measures have been created to shorten this
time. The fastest curing method is high pressure
steam curing, or autoclaving. However, the cost
of this process is not currently justified by a turn
around time of six hours. Most plants employ

MANUFACTURE
48 Hour thermal tarps and a hydro-thermal system under
Stand Cure the casting form. The form material is very
important in this approach since steel is several
hundred times more conductive than wood.

14-18 Hour
Tarp + Hydrothermal Heating

TRANSPORTX+XASSEMBLY
6 Hour
Steam Cure Precast Concrete
 Manufacture
INTRODUCTION

2 2.1 Plant Logics

Casting Sequence

Precast plants organize their casting sequence

by what parts are assembled first. Accordingly,
elevator and stair cores are cast first, then
DESIGN

columns, beams, slabs, moving up in level. This

creates the greatest economy of time by allowing Slabs X 12
manufacture and assembly to occur
simultaneously.
MANUFACTURE
MANUFACTURE

Beams X 17

Cores X 2 Columns X 12
TRANSPORTX+XASSEMBLY
 Manufacture

INTRODUCTION
2.1 Plant Logics
2

Week
26 28 30 32 34 36 38 40 42
Mold Fabrication

DESIGN
Panel Fabrication
Slabs X 12 Panel Assembly

Panel Fabrication and Production Schedule

MANUFACTURE
Beams X 17

Columns X 12 Panels X 20

TRANSPORTX+XASSEMBLY
Precast Concrete
 4
3
5 5
3
5
4 4
Manufacture
INTRODUCTION

25 2.2 Mixtures5

The Basics

The basic ingredients of concrete are portland

cement, water, air, and a mix of fine and course
aggregates. Admixtures are often added to alter
DESIGN

the behavior of the concrete mix. Most precast

plants have computer controlled mixing stations
right next to the main facility, making changes
seemless.
MANUFACTURE
MANUFACTURE

1 1
1 Water
2 2
2
1
3 Portland Cement 3
1
3
2
4 Air 4
2
4
3
5 Fine Aggregates 5
3
TRANSPORTX+XASSEMBLY

5 Course Aggregates 4
4
5 5 Concrete Mix Station
 lamron*

Manufacture

INTRODUCTION
1 2.2 Mixtures
2
2
3
Normal Mix 4
High Strength Lightweight
5
The typical concrete mix represents the most High strength concrete has a low water to The proportions of lightweight concrete appear
economical balance of ingredients. The water to cementing material ratio, around .30. The to be the same as normal weight, but the
cementing material ratio is around .70. These increased cement content is what increases the aggregates are up to 50% less dense than those

DESIGN
days most concrete is air entrained to better compressive strength. Both normal and light typically used. Such aggregates include
freeze-thaw conditions, accordingly the mixes weight concrete mixes can be made high
lamexpanded
ron clay and shale.
shown below reflect a higher air content. strength.

50% less dense

htgnerts hgih

MANUFACTURE
1
2
3
1
4
2
5
3
4
5

TRANSPORTX+XASSEMBLY
lamron*
htgnerts hgih
Ingredient Proportions by Volume

1
1 2 Precast Concrete
2 3
3 4
4 5
 Manufacture
INTRODUCTION

2 2.2 Mixtures

15000
Densities + Strengths

As mentioned the strength of a concrete mix is

not dependent on its density. However, there are
stant
slight differences between normal weight and
DESIGN

12000
light weight concrete. The strength of light weight
is always a little less than the typical mix.
Otherwise, the two behave similarly when more
cement is added to increase strength.

9000
MANUFACTURE
MANUFACTURE

Multiple
6000

High White

3000
TRANSPORTX+XASSEMBLY

Density
ocal Single Low Gray

Normal Mix High Strength Light weight

regates Admixtures Pigments Cement
 Manufacture

INTRODUCTION
2.2 Mixtures
2
15000
Economy

From looking at the economic impact of adjusting

mix variables, one starts to wonder whether the
High Better Distant
benefits
12000gained by lightweight concrete are

DESIGN
outweight by the high cost of specific aggregates.
As shown by the chart to the left, the farther an
aggregate has to travel, cost increases. On the
other hand, cement is not as costly, making high
strenth concrete feasible.
9000

MANUFACTURE
Costs

Multiple
6000

High White

3000

TRANSPORTX+XASSEMBLY
Density
Low Worse Local Single Low Gray

Normal Mix High Stren

Uniformity Aggregates Admixtures Pigments Cement

Precast Concrete
 Manufacture
INTRODUCTION

2 2.3 Reinforcement

Types of Reinforcement

There are two basic types of reinforcement used

in precast construction, welded wire reinforcement
and reinforcing bars (rebar). Welded wire is used
DESIGN

for thin shapes like slabs and rebar is formed into

self supporting cages for more three dimensional
shapes.
MANUFACTURE
MANUFACTURE
TRANSPORTX+XASSEMBLY

Reinforcing of Typical Bay

 Manufacture

INTRODUCTION
2.3 Reinforcement
2

Typical Shapes

Flat slabs almost always use welded wire

reinforcement while if double tees get large
enough they sometimes utilize rebar cages and

DESIGN
tensioning cables. Due to the three dimensional
quality of columns and beams, they generally
Flat Slab use rebar cages.

MANUFACTURE
Beam or Column

TRANSPORTX+XASSEMBLY
Double Tee

Precast Concrete
 Manufacture
INTRODUCTION

2 2.3 Reinforcement

Prestressing
24’
It is very common for precast members to be 24’ 24’

prestressed. This type of reinforcement allows for

longer spans and thinner sections than can be
DESIGN

achieved with regular reinforcing. Most slabs,

double tees, and beams are prestressed, but wall

18’
panels and columns vary. Prestressing can be
done before or after the concrete is poured and 18’ 18’
cured. While pretensioning strands are generally
laid flat across the casting bed, post tensioning is
MANUFACTURE
MANUFACTURE

done through a monostrand.

12’ 12’ 12’

Height of Panel

Prestressed 6’ 6’ 6’
TRANSPORTX+XASSEMBLY

Prestressing 3” 6” 9” 12”
Regular Reinforcing Regular Reinforcing Depth

3” 6” 9”
3” 12”
6” 9” 12”
 Manufacture

INTRODUCTION
2.3 Reinforcement
2

DESIGN
Pre Tensioned
Cross Strands Before Pouring

MANUFACTURE
TRANSPORTX+XASSEMBLY
Post Tensioned
Monostrand After Curing

Precast Concrete
 Manufacture
INTRODUCTION

2 2.4 Molds

Mold Design

Understanding and applying the concepts behind

mold design can really help make a project
economical. With precast systems the number of
DESIGN

uses per mold really counts towards justifying the

manufacturing plant strategy.

Total Mold
MANUFACTURE
MANUFACTURE

Basic Mold Types

There are an infinite number of possible mold

designs, but by looking at the envelope molds one Conventional Mold
can start to discern workable types. As
demonstrated to the right, mold approaches can
be broken down into four basic types. There are
total molds, conventional molds, back forming
molds, and molds with haunches. Simple
conventional are the most preferred. They utilize
a basic design that can be altered with removeable
TRANSPORTX+XASSEMBLY

bulkheads. While the total mold appears to be the Back Mold

most simplistic, it only yields one shape. Particle

settling and extra cost make back forming molds
uncommon. Haunches can be a reductive
approach to this design strategy.

Haunch Mold
 Manufacture

INTRODUCTION
2.4 Molds
2

Typical Shapes

Shapes typically cast for precast construction

have standard mold forms. These forms are
always constructed out of steel because of the

DESIGN
high reuse rate. The beds can last as long as 20
years, while a custom bed only lasts at most 100
casts.
Double Tee
Compact shapes, beams and hollow core slabs,
can all be cast on conventional casting beds.

MANUFACTURE
The tailored shape is achieved through a
slipformer or extruder. These machines set the
shape and

Flat Slab

Slipformer

Beam

TRANSPORTX+XASSEMBLY
Piles

Precast Concrete
 Manufacture
INTRODUCTION

2 2.4 Molds

Master Mold Concept

The master mold strategy is the number one rule

of mold design. Born from the basic modified
mold, a master mold is a manufacturers main tool
DESIGN

for gaming costs. Through simple, inexpensive

modifications one mold can be used to generate
a number of shapes. With all precast design, the
economics of each modification should be con-
sidered. In the example shown to the right, one
mold designed with two removeable bulkheads is
MANUFACTURE
MANUFACTURE

used to create an assortment of six shapes.

Mold Configurations
TRANSPORTX+XASSEMBLY

Cast, with side variations Resultant Shapes 1

 2,3
1

4,5
2
2.4 Molds
Manufacture

Precast Concrete
2

6
3

TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION

 Manufacture
INTRODUCTION

2 2.4 Molds

Adjustable Molds

Adjustable molds are more expensive, but under

certain circumstances they can make precasting
a reasonable choice. They can be constructed of
DESIGN

wood or steel and are fixed into position by

clamps or laminatation. Due to the high reuse
factor of steel, it is a more logical candidate for
adjustable molds. As with most precast 3
2
methodology, it is more effecient to cast one
shape as much as possible before reconfiguring
MANUFACTURE
MANUFACTURE

the mold for further use.

4
6
5
TRANSPORTX+XASSEMBLY

8 7

1. Mold Face 5. Wood Block

2. Wood Side Rail 6. Wood End Gate
3. Adjustable Clamps 7. Wood Wedges
4. Casting Deck 8. Wood Wedge Rail
 Manufacture

INTRODUCTION
2.4 Molds
2

( $f )
2 U = Mold Cost per Sq Ft Materials + Economy

Everytime a mold is used, its cost efficiency

increases. However, wood molds can only be
used 25-30 times, and steel 50-100. This

DESIGN
obsolescence provides an opportunity to create
a new part when a new mold is needed
anyways.

MANUFACTURE
Cost per Sq Ft

TRANSPORTX+XASSEMBLY
Wood
Uses
Steel

Precast Concrete
Transport + Assembly
 Transport + Assembly

INTRODUCTION
3.0 Introduction
3

Some of structural precast concrete’s greatest

advantages become apparent during its transpor-
tation and assembly sequences.

After the pieces have been manufactured accord-

DESIGN
ing to their order of assembly, they are trans-
ported and assembled while other members are
being cast in the plant. Large pieces of the build-
ing, in some cases even whole spaces, can be
transported in one trip by several trucks and
assembled expeditiously in much the same man-

MANUFACTURE
ner as structural steel. There are also much fewer
details to fastened and connected by builders dur-
ing the process, so the construction can be much
faster and more predictable. Unlike site-cast con-
crete, construction phases can occur during poor
weather conditions. Because the concrete has
already cured, little damage will be incurred.

This section will detail the transport of precast by

trucking, the logic of its movements on site, and
the joinery and detailing that secures the pieces
together and stabilize them through the finishing

TRANSPORTX+XASSEMBLY
process and lifecycle of the building. While an
inventive architect can create a wide variety of
parts, connections, and details using precast
methods, this section will focus on the simpler
and more commonly used techniques.

Precast Concrete
 Transport + Assembly
INTRODUCTION

3 3.1 Shipping Logics

13’6” o.a.
height max gross vehicle weight: 80,000 lbs
DESIGN

standard load ≈ 8’6” allowable overhang: 15 ft or 1/3 of

total bed length
MANUFACTURE

oversized load ≈ 14’

Highway Regulation General Cost Note

Height and width are determined by federal hghway regulation. Length of trailer is unregulated by highway, but is While shipping costs vary, in most cases
subject to manufacturer standards. they tend to be cheaper than costs for weld-
ing crews. The fewer welds you make, the
cheaper it will be. In order to make fewer
welds, you must make larger pieces. In
Average Single Vehicle Transportation Costs*: general the larger and fewer pieces, the
better.
TRANSPORTX+XASSEMBLY

$6.99 /mile Standard Load Size

$11.29 /mile Oversized (Permit) Load Size

*Figures are derived from a Pittsfield-Hartford trip carrying 91 pieces over 78 loads on flatbed trucks. 36 of these
were permit loads, and the permit cost for transporting an oversized load in the state of Massachusetts (2009,
$350). Transportation and permitting costs will fluctuate based on state and current market prices.
 Transport + Assembly

INTRODUCTION
3.1 Shipping Logics
3

8’6”
load
Decks
height
The various deck sizes for carrying precast loads are
usually chosen to facilitate carrying either long loads
effienctly, in which case the flatdeck would be most

DESIGN
logical, or taller loads, at which point the choice comes
to efficiency versus heigh requirement of individual
60’ standard bed length members.

FLATDECK TRAILER Flatdeck Trailers beds sit 60” above the ground.

Stepdeck Trailers sit 40' above the ground.

Double-Drop Trailers sit as low as 20” above the

10’2” ground.

MANUFACTURE
load
height

43’ standard bed length

STEPDECK TRAILER

11’10”

TRANSPORTX+XASSEMBLY
load
height

30’ standard bed length

DOUBLE-DROP TRAILER

Precast Concrete
 3 Transport + Assembly
3.1 Shipping Logics

Attachments for Movement

During manufacter, attachments are imbedded to
allow for loops or hooks to be attached to the tops
of the concrete members. These allow for cranes to
lift the pieces into place on site and can be removed
after installation before the finishing and grouting
takes place. After detaching the loops and carrying
apparatus, attention must be paid to make sure
that the material left does not become corrosive or
detract from material stability.

(A) Imbedded in concrete

(B) For crane to attach to, can be removed after
installation.

A
TRANSPORTX+XASSEMBLY
 Transport + Assembly

INTRODUCTION
3.1 Shipping Logics
3

DESIGN
A

MANUFACTURE
B

Carrying Precast

TRANSPORTX+XASSEMBLY
Above, loads must be stacked on trucks in particular ways.

Beams (A) and other horizontal members can overhang truckbeds because of their tensioning and intended load
distribution.

Slabs can be stacked on top of each other, which may also facilitate an easier installation from the truck bed.

Vertical members (C) such as columns and panels must be kept upright to maintain their structural integrity. Here a
stepdeck truck is used to allow a taller panel to be carried.

Precast Concrete
 3 Transport + Assembly
INTRODUCTION

3.2 Crane and Site Logics

DESIGN
MANUFACTURE

Crawler Crane Tower Crane Derrick

Widest range of applications and sizes. Can range from Used to move pieces in a stable manner around site The derrick can range from small single units to large
small trucks outfitted with cranes to larg units that can and for raising members. Used primarily in steel con- derrick systems consisting of multiple cranes. They are
TRANSPORTX+XASSEMBLY

rival tower cranes in height. Have the most manuever- struction as well as pre-cast concrete. meant to lift vertically in an efficient manner and do not
ability but also the most intense operation. Unlike tower Range: 290 ft max have much range.
crane, range and height of movement are inversely Weight Lift: 19 ton max Typical application: installation of heavy precast panels,
proportional. Range will decrease with added height of Height Lift: 270 ft especially in facade construction, movement of large
the crane. members and sections for road construction
Range: 280 ft max
Weight Lift: 250 ton max
Height Lift: 260 ft
 Transport + Assembly 3

INTRODUCTION
3.2 Crane and Site Logics

generic street a generic street a

DESIGN
crawler
building

derrick
foundation

MANUFACTURE
generic street c

tower crane

offloading

freight truck

generic street b

TRANSPORTX+XASSEMBLY
Transport and Site Logic
Each type of transport has a specific logic on site that
aids in the assembly of precast buildings.

The site is commonly allocated so that multiple trucks

can move and deliver pieces simultaneously as well as
to allow for crawler movement.

Precast Concrete
TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION
3
3.3 Joinery and Details
Transport + Assembly
 Transport + Assembly

INTRODUCTION
3.3 Joinery and Details
3

DESIGN
MANUFACTURE
TRANSPORTX+XASSEMBLY
Assembly Sequence

This urban condition has a grade that requires the trucking ramp to be built within the foundation walls at the edges of
the site. Here (far left), you can see multiple loads of materials delivered by truck and ordered by their use and placement
order. The crane then lifts these members into their corresponding location with the aid of workers on site (left and above).

Precast Concrete
 3 Transport + Assembly
3.3 Joinery and Details

Key of Details and Joints

TRANSPORTX+XASSEMBLY
Horizontal to Horizontal Transfer 3.34 Transport + Assembly

INTRODUCTION
Beam to Beam Connections
3.3 Joinery and Details
3

Horizontal to Horizontal Transfer 3.35

Slab to Beam Connections

DESIGN
MANUFACTURE
Horizontal to Vertical Transfer 3.33
Beam to Column Connections

TRANSPORTX+XASSEMBLY
Vertical to Vertical Transfer 3.32
Foundation to Column/Panel, Column/Panel to Column/Panel Connections

Precast Concrete
 Transport + Assembly
INTRODUCTION

3 3.31 Joinery and Details

From the Ground Up:

The pieces are manufactured, transported, and

assembled in an ascending order from the ground
up. The pieces are then welded to each other
DESIGN

through steel plates embedded in each piece.

This ensures for seismic stability and to create a
more rigid lateral bracing. However, the pieces C
abide by much the same stacking logic of building
blocks and the primary component holding them
together, in the standard applications, is gravity.
MANUFACTURE

To create habitable space, the columns and

beams create a framework (A) which allows the
B
floor slabs (B) to sit inside. There are allowances
within this frame for the next level of columns and
beams (C) to adhere to and rest in. The attach-
ment of corresponding members is intrinsic to
each piece of the framework. Each course of
frame work allows for the easy assembly of the
next level of framework as well as the addition of
floor levels and non structural panelling within the A
frame to create habitable space.
TRANSPORTX+XASSEMBLY

Of course, as any child with building blocks will

quickly learn from wind and the occasional bully,
gravity alone will not do. The holding properties of
gravity must be aided by fastening and attach-
ments in order to ensure the stability and longev-
ity of a structure.
 Transport + Assembly

INTRODUCTION
3.31 Joinery and Details
3

While they appear to be independent members resting

on each other, each piece is connected via steel aper-
tures to corresponding members for greater stability.

In this drawing, you can see the beams linked together

by steel chords that connect through holes pre-drilled
or cast in the vertical column (A). There are welds that
occur at steel plates imbedded in the beam and column

DESIGN
where the plates are linked by a steel angle welded
between the two members (B). After the welds are C
complete, the steel chords are grouted over (C).

MANUFACTURE
B

Detail Key

TRANSPORTX+XASSEMBLY
1. Precast concrete
2. Grout
3. Steel Contact Weld
4. Grouted Steel Tension Connection

Steel contacts are welded together on site to fi-

nally bond the pre-cast members. these contacts are
imbedded during the manufacturing process pre-cast
elements. Contacts imbedded in foundation are done
during the site casting process.

Precast Concrete
 Transport + Assembly
INTRODUCTION

3 3.32 Joinery and Details

Vertical to Foundation Transfer

Foundation to Column, Foundation to Panel Connections
DESIGN
MANUFACTURE

welded and bolted welded plate cast- in anchor grouted dowel

Vertical to Vertical Transfer

Column/Panel to Column/Panel Connections
TRANSPORTX+XASSEMBLY

bolted and welded welded plate

 Transport + Assembly

INTRODUCTION
3.33 Joinery and Details
3

DESIGN
MANUFACTURE
Horizontal to Vertical Transfer
Beam to Column/Panel Connections

TRANSPORTX+XASSEMBLY
Precast Concrete
 Transport + Assembly
INTRODUCTION

3 3.34 Joinery and Details

DESIGN
MANUFACTURE

Horizontal to Vertical Transfer Horizontal to Horizontal Transfer

Slab to Column/Panel Connections Beam to Beam Connections
TRANSPORTX+XASSEMBLY
 Transport + Assembly

INTRODUCTION
3.35 Joinery and Details
3

DESIGN
these connections can be varriated to include rectangular beams, t- beams, notch
details in slabs and different slab types

MANUFACTURE
Horizontal to Horizontal Transfer
Slab to Beam Connections

TRANSPORTX+XASSEMBLY
Precast Concrete
TRANSPORTX+XASSEMBLY MANUFACTURE DESIGN INTRODUCTION
 INTRODUCTION
Sources

Allen, Edward, and Joseph Iano. The Architect’s

Studio Companion. Hoboken, NJ: John Wiley
and Sons, 2002

DESIGN
American Institute of Architects. Architectural
Graphic Standards. Hoboken, NJ: John Wiley
and Sons, 2007

Breen, Timothy. Personal Interview. 28 Oct.

MANUFACTURE
2009.

Bruggeling, A.S.G. Prefabrication with Concrete.

1st ed. Taylor & Francis, 1991. Print.

Kind-Barkauskas, Friedbert et al. Concrete

Construction Manual (Construction Manuals.
1st ed. Birkhäuser Basel, 2002. Print.

Martin, Leslie D., and Christopher J. Perry. PCI

Design Handbook: Precast and Prestressed
Concrete, Sixth Edition, 2004. 6th ed. Precast/

TRANSPORTX+XASSEMBLY
Prestressed Concrete Institute, 2004. Print.

Morris, A. E. J. Precast concrete in architecture.

1st ed. Whitney Library of Design, 1978. Print.

Precast Concrete
PRECAST CONCRETE

ARCH G691 GRADUATE DEGREE

PROJECT STUDIO

FALL 2009

This publication has been prepared as

part of a five week graduate thesis studio
assignment in the Northeastern University
School of Architecture for the Fall 2009
Architecture G691 course. Other publications
in this series include urban retail, office, and
parking garage typologies, all produced
by graduate students in the Northeastern
University architecture program.