PRECAST CONCRETE SYSTEM

INNOVATIVE STRUCTURE SYSTEMS

FOR MASS HOUSING

1. CAST IN-SITU CONCRETE FORMWORK STRUCTURE SYSTEMS :

- ALUMINUM FORMWORK SYSTEM. ‫القوالب األلومنيوم‬

- TUNNEL FORMWORK SYSTEM. ‫القوالب النفقية‬

2. PRECAST CONCRETE SYSTEM

‫منظومة الوحدات الخرسانية سابقة الصب و التصنيع‬
‫‪PRECAST CONCRETE SYSTEM‬‬
‫منظومة الوحدات الخرسانية سابقة الصب و التصنيع‬
 DEFINITION OF
PRECAST CONCRETE
 DEFINITION OF PRECAST CONCRETE
PRECAST CONCRETE is a construction product manufactured in precast factories by casting
reinforced or prestressed concrete in a reusable mold or formwork which can be speedly cured
by using advanced methods in a controlled environment . Then, finished precast units are stored
till transported by trucks to the construction site and lifted by cranes into required place (tilt-up)
to be assembled together . In contrast, Standard Concrete is casted into site-specific forms /
shuttering and cured on site under weather conditions which cause waste of time and materials
, lower control / quality & more expenses.

PRECAST CONCRETE STANDARD / CAST IN-SITE CONCRETE

 PRECAST CONCRETE
VERSUS
CAST IN SITE CONCRETE
PRECAST CONCRETE VERSUS CAST IN SITE CONCRETE
1. METHOD: Precast concrete is casted & cured in controlled environment in factories while
cast in site concrete is casted & cured at site.
2. CASTING: Precast concrete are casted in advance to save time while cast in site concrete
can not be casted in advance.
3. QUALITY: Precast concrete is casted in a controlled environment in factories under ideal
conditions while cast in site concrete quality depends on skills of labor & weather conditions
4. LABOR: Precast concrete save labor cost as it needs much less number of labors in site but it
must be skilled labor.
5. SPEED OF CONSTRUCTION: Precast concrete can save time of construction up to 50% as it is
the most speedy concrete construction system especially with mass production of
prototype elements. The work can be completed with minimum scaffolding in a very short
time as precast concrete members have very high erection speed. (UP to 1000 M2/Week).
6. CURING CONDITIONS: Precast concrete does not need curing time in site as it was cured in
factory. Curing process in factory can be accelerated to 8 hours only by many treatments
such as warm water, boiling water , steam curing or autoclaving. Curing period not less than
7 days must get complete for cast in site concrete to reach 65% strength before dismantling
shuttering / scaffolding system and proceeding which cause more delay and cost.
7. WEATHER CONDITIONS: No effect of weather on casting precast concrete in controlled
environment at factory while bad weather can delay the casting work and curing time of
concrete in site.
8. COST: Precast concrete increase productivity , economy in cost , reduce time & period of
construction causing early returns of investment. In large scale projects , Precast concrete
slabs are cheaper than relevant with cast in site concrete by about 23% & precast columns
are cheaper than relevant with cast in site concrete by about 21%. Cost is saved by less
number of labor in site and by using precast prestressed concrete which requires less
amount of steel reinforcement. Cast in site concrete is cheaper for only small projects.
PRECAST CONCRETE VERSUS CAST IN SITE CONCRETE
9. STANDARDIZATION & REPETITION: Larger number of each precast unit type reduces cost of
mold/unit. Cast in site concrete is more beneficial in case of limited standardization & repetition
10. HANDLING: Precast units require heavy machineries in site for lifting such as cranes while
cast in site concrete work can be executed without cranes or any other heavy machineries.
11. JOINTS TREATMENT: After fixation of precast concrete units in site , large number of joints
between them is very critical and needs careful attention and treatment while there are few
joints in cast in site concrete which do not need careful attention.
12. RESISTANCE TO EARTHQUAKES / WIND FORCES: Precast concrete units are resistant to
earthquakes, wind forces, fire and explosion like cast in site concrete.
13. CONTRACTORS SKILLS: Precast concrete needs skilled and technical contractor while cast in
site concrete does not need skilled contractors.
14. MATERIAL WASTAGE: It is negligible for precast concrete due to controlled environment in
factories while it is remarkable and increase costs in case of cast in site concrete.
15. REUSE: Precast concrete units can be reused, extended and refitted in other places while
cast in site concrete can not be reused.
16. STORAGE OF MATERIALS: Precast concrete units save storage area in site as their delivery to
site can be arranged with factory when required which is ideal for tight / limited sites while cast
in site concrete needs a big storage area in site with more labor reserved to store necessary
materials such as scaffolding systems, cement, sand, gravel / aggregate, steel bars and bricks.
17. ONSITE CONCRETE TEST: In case of precast units, on site strength test is not needed while
in case of cast in site concrete it is extremely important to check / control quality of concrete.
18. BRICK & PLASTERING WORKS: Not needed for precast concrete units as they have smooth
fair-face surfaces while needed for cast in site concrete with extra cost.
19. ENVIRONMENT: Precast concrete units are environmental friendly due to cleanness /
neatness of site and quietness during installation contrary to cast in site concrete.
 APPLICATIONS OF
PRECAST CONCRETE
 APPLICATIONS OF PRECAST CONCRETE
The term PRECAST CONCRETE is applied to a variety of individual concrete construction
elements / members such as foundations , columns , beams, wall panels , slabs & staircases
which are casted in different forms before being placed in the structure. Furthermore, precast
concrete is applied to other products such as Hardscape elements (Fences , paving blocks for
walkways / pavements finish , Curbs , Flower boxes, Pergolas , Seating furniture , car sheds &
bumpers , Garbage bins ,….) Bridge pillars & girders , Traffic barriers , Sewage network pipes ,
Manholes , Water tanks , railway sleepers and many other products.
 - PRECAST
- FENCES
- PRECAST
- COLUMNS

- SHOP
- DRAWING
- PRECAST
- WALL PANEL

- PRECAST
- FOUNDATIONS
SEQUENCE OF HANDLING AND INSTALLING
PRECAST CONCRETE FENCE

1 2 3

4 5 6
 PRECAST CONCRETE HARDSCAPE ELEMENTS
- PERGOLAS
- FLOWER BOXES

- SECURITY CAR BARRIERS - GARBAGE BINS - SEATING BENCHES

 - BRIDGES PILLARS &
GIRDERS

- MANHOLES - TRAFFIC BARRIERS - CAR BUMPERS

 WHEN PRECAST CONCRETE SYSTEM IS SUITABLE ?
- TYPE AND SIZE OF BUILDING : It is ideal for Big /Large projects with repetitive standardization
and modulation such as mass housing , hotels , universities , office buildings & industrial
buildings.
- SITE LIMITED AREA : If area of site is limited for storage of materials necessary for standard
concrete casting such as cement , steel bars , shuttering & scaffoldings.
- TIME FRAME : If the time frame of project is limited as it is much faster than ALL conventional
and even rapid modular concrete construction systems with higher quality and curing control.
- LOCATION OF FACTORY FROM SITE : Transportation cost for precast units is a critical financial
factor which is severely affected by the distance between precast factory and site.
 ADVANTAGES &
DISADVANTAGES
OF PRECAST CONCRETE
 ADVANTAGES OF PRECAST CONCRETE SYSTEM
1. QUALITY CONTROL : The concrete of superior quality is produced as it is possible to have
better technical control on the production and advanced curing methods of concrete in
factory due to managed environment.
2. ACCURACY : The formworks / molds employed for producing the precast units are of steel
with exact dimension in all directions. These molds are durable and can be used several times.
3. FINISH : The precast wall panels may be given the desired shape and a variety of architectural
external textures / finishes with accuracy. (Finished plaster , brick , stone , marble , ceramic ,….).
4. TIGHT SITES : Suitable for tight construction sites as no storage space required for materials
and shuttering / scaffolding systems.
 ADVANTAGES OF PRECAST CONCRETE SYSTEM
5. FLEXIBILITY: The precast structures can be dismantled if needed and suitably used elsewhere.
6. ECONOMY:
- The labor required in the manufacturing process of the precast units can easily be trained.
- The transport and storage of various components of concrete for cast in site work are
eliminated when precast members are adopted.
- When precast structures are to be installed, it is evident that the amount of scaffolding ,
formwork and labor in site is considerably reduced to the minimum compared by all other
conventional and even innovative modular structure systems.
- Precast is well-executed which may reduce the dimensions and number of structural members.
- Smooth surfaces of fair-face concrete elements leads to cancel plaster work and enables to
reduce external and internal wall finishes if needed.
7. SPEED : (UP TO 1000 M2 / Week)
- It is the most speedy concrete construction system especially with mass production of
prototype elements, the work can be completed in a very short time as precast members have
very high erection speed.
- Precast concrete system can shorten the time schedule of building construction up to 50% .
8. SAFETY: High resistance to fire, explosion and earthquakes due to stiffness, strength and
elasticity of reinforced concrete precast units.
9. ENVIRONMENTAL FRIENDLY : Clean site due to less
waste of materials. Quiet installation with minimum noise.
 DISADVANTAGES OF PRECAST CONCRETE SYSTEM
1. CAMBER : It can provides camber in beam and slab. ‫تقوس‬
2. RESTRICTIONS: Panel size is restricted, this concrete cannot be used for two-way structural
techniques. Load of any precast unit must not exceed 40 tons.
3. ERROR MARGIN: The very low margin for error during erection in site.
4. STANDARDIZATION: The economics of scale demand regular-sized buildings with mass
production of prototype repetitive elements.
5. HANDLING: If not properly handled, the precast units may be damaged during transport or
storage at site or lifting to their place at structure.
6. TRANSPORTATION: The economy achieved in precast construction is partially balanced by
the amount to be spent in transport and handling of precast members. Therefore, It
becomes necessary to locate the precast factory at such a place that transport and handling
charges are brought down to the minimum possible extent.
7. JOINTS TREATMENT: It becomes quite difficult to produce satisfactory joints between the
precast members . They are sometimes costly and complicated.
8. MACHINERY COST: Precast units are very heavy elements . Therefore, It is necessary to
arrange for rent / purchase of special heavy equipment for lifting and moving of the precast
units such as cranes which increase the construction expenses.
9. LABOR COST: On-site precast units handling and application requires highly skilled
workmanship but with much less number of labor than conventional structure systems.
10. COLLAPSE: Bad load distribution during erection can sometimes cause collapse of units
11. DESIGN FLEXIBILITY: No flexibility for modifications / eliminations of any internal concrete
openings , bearing wall panels and MEP extensions.
12. Lake of local specialist contractors and precast factories leads to increase transportation cost
13. Lake of knowledge for investors , owners and consultants about precast concrete benefits
and advantages.
 - JOINTS TREATMENT OF SLAB PANELS

- USE OF CRANES FOR LIFTING

PRECAST ELEMENTS INCREASE COST

BAD LOAD DISTRIBUTION CAN SOMETIMES

CAUSE COLLAPSE OF MEMBERS
ELEMENTS/MEMBERS
OF PRECAST CONCRETE
 ELEMENTS OF PRECAST CONCRETE SYSTEM
1. PRECAST FOOTINGS / FOUNDATIONS: Concentric footings, Eccentric footings. In case of
heavy foundations with big dimensions or rough foundation ‫ لبشة‬, it is recommended to cast
foundations in site as precast alternative will highly increase transportation cost.
2. PRECAST COLUMNS: For precast concrete buildings up to ground + 4 floors, each column can
be continuous for the total height of the building. There are 2 types of columns :
Type I - Continuous column: A multi-storey column up to 15 Meters without / with haunch or
corbel.
Type II - Discontinuous Column: A single storey column.
3. PRECAST/PRESTRESSED WALL PANELS: Precast concrete Load-bearing and Non-load bearing
wall panels serve as a stabilizer, stairs and shafts are carried in the form of walls or boxes. They
can be finished by Grey Cement, White cement used in colored concrete, sandblasted concrete
and a big variety of external wall cladding finishes ( Brick , Stone , Ceramic , Marble ,….).
Continuous
Column

PRECAST
FOUNDATION
(Pocket) Non-load bearing
PRECAST WALL
PANEL
TYPES OF PRECAST COLUMNS
 TYPES OF PRECAST WALL PANELS
1. NON-LOAD BEARING WALL PANELS

Non-load bearing
PRECAST WALL
PANEL
Non-load
bearing
WALL PANELS

Load-bearing
WALL PANEL

Crane

Truck 2. LOAD-BEARING WALL PANELS

 ELEMENTS OF PRECAST CONCRETE SYSTEM
4. PRECAST/PRESTRESSED BEAMS: There are 2 types of beams :
- Continuous Beam: It is connected to discontinuous single storey columns.
- Discontinuous beam: It is connected to continuous multi-storey columns.
Beam shapes: Rectangular, Ledge, Inverted/Bulb T, I ,Box.
5.PRECAST/PRESTRESSED SLABS: There are 5 types of TYPES
Slabs (with R.C. Topping 5cm thick.) :
OF
I Beam Box Bulb
Beam Tee SLABS
- Solid slabs. H.C.S.
- Hollow-Core slabs.(H.C.S.) Solid Slab
- Single and Double Tee slabs.
- I girders of span exceeding 30 M. Inverted Ledge Rectangular Hollow
Tee Beam L Beam Beam Core Slab
6. PRECAST STAIRCASES.
SHAPES OF
BEAMS Double
Tee Slab

Cast in-site
R.C. TOPPING 5 CM
TYPES OF PRECAST / PRESTRESSED BEAMS
 TYPES OF PRECAST / PRESTRESSED SLABS
(With cast in-site R.C. Topping 5 cm Thick.)
R.C. Topping 5cm

HOLLOW CORE SLABS

R.C. Topping 5cm

HOLLOW CORE SLABS DOUBLE TEE SLABS

R.C. Topping 5cm

SOLID SLABS

DOUBLE TEE SLABS SOLID SLABS

SLABS TOPPING with cast in-site R.C. LAYER 5 CM thick.
1 2

Precast Slabs Steel Mesh

Cast in-site
R.C. TOPPING
5 CM Thick.