PRECAST CONCRETE AND ITS CONNECTIONS

Abstract
Due to rapid growth in urbanization there is tremendous pressure on industry to
deliver faster construction. In such situation, Pre-cast construction technology becomes a
popular choice. This technology has already addressed several issues like quality, durability and
safety during construction.

This paper presents Need of Precast concrete construction, Its Advantages and
disadvantages. Different joint connections (Beam-Beam, Beam-slab and column-column
connections) and tests conducted to know behaviour and strength of joints in multistory
buildings.

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CHAPTER 1
INTRODUCTION
There is a large shortage of housing for many millions in India and the increase in the
cost of construction is a big problem in overcoming this shortage. It is necessary to
develop a large variety of low cost options for different regions of India such that housing
becomes affordable for an ordinary citizen. The major cost increase in house built with
conventional technology is due to two factors viz.[1]

Increase in basic cost of materials like cement, steel, bricks etc.

Increase in labour costs

To reduce material consumption and to reduce labour component many cost reducing
system and techniques are required. The cost reduction in precast is very essential as it
forms a major part of the construction cost.
In pre-cast, substantial cost reduction is possible by:

Using efficient structural geometry and efficient structural action principles.

Good practice from an early stage in the design and planning process.

In addition, it is also necessary to reduce the cost of other structural components like
walls, foundation, floor, lintels etc. A study on such options will be useful for reducing
cost of construction.

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1.1 PRE-CAST OR PRE- FABRICATED CONSTRUCTION:

In India and other developing countries to accommodate spiraling population,
there is a need to construct more and more houses, and other buildings at a faster speed.
Traditional in-situ construction is too slow to cope-up with this increasing demand. By
pre-fabrication, better quality buildings can be constructed at faster rate.
Most of the European countries and USA have set up efficient concrete industries
with large scale mechanization of pre-cast operation and site erection. The introduction of
large panel and other techniques by these countries has revolutionaries the building
industry and an unprecedented rate of construction has been achieved. The various
advantages and disadvantages of prefabrication are discussed below:
1.1.1 Advantages
1. In pre-fabricated construction shuttering and scaffolding are eliminated to greater
extent. Apart from saving in the cost of shuttering elimination it gives clear space
for other building activities.
2. Pre-cast moulds can be used for a large number of times. As the reuse of mould is
more the cost of mould per precast unit is less.
3. It is easier to produce components with structurally efficient shapes in pre-cast
construction. Hence the consumption of scarce materials like cement and steel
can be reduced.
4. Production can be done independent of the weather condition and hence can be
produced even during rainy season or when the climate is extreme. It is possible
to produce components under close supervision and test them periodically
resulting in better quality and more reliable.
5. By adopting prefab construction work site is reduced to minimum and will be
clean, the construction is speeded up and occupied earlier which means early
return of capital invested.
6. In case of prefab construction as the pre-cast components have undergone most of
the shrinkage before they are used in the construction, stresses due to shrinkage
on the structure are much less compared to in-situ construction.
1.1.2 Disadvantages
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1. To ensure monolithically, free ended condition, more reinforcement is

necessary.
2. In case of handling and erection stresses are excessive, extra reinforcement
may be needed.
3. Special care should be taken while handling and erection to avoid damage
and breaking.
4. Temporary supports may be necessary in some cases. As there is a chance of
leakage through joints between precast components, extra care is necessary to
make them leak proof.
5. Unless adequate quality of reinforcement is provided across the joints
between precast components and in-situ concrete, cracks may develop.
The concept of precast or prefabricated construction includes those buildings,
where the majority of structural components are standardized and produced in plants in a
location away from the building, and then transported to the site for assembly. These
components are manufactured by industrial methods based on mass production in order to
build a large number of buildings in a short time at low cost.
The main features of this construction process are as follows:
1. The division and specialization of the human workforce.
2. The use of tools, machinery, and other equipment, usually automated, in the
production of standard, interchangeable parts and products.
3. Compared to site-cast concrete, precast concrete erection is faster and less
affected by adverse weather conditions.
4. Plant casting allows increased efficiency, high quality control and greater control
on finishes.
This type of construction requires a restructuring of entire conventional
construction process to enable interaction between design phase and production planning
in order to improve and speed up construction.

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Fig. 1.1: Precast plant consisting structure elements

(a)
(b)
Fig 1.2 : (a) Erection of Gypsum reinforced concrete wall panels construction
in IITM-2013, (b) Precast concrete structure at GVP college of Engg,
Vishakhapatnam during ICICPC-2013 conference.

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CHAPTER 2
CONNECTIONS
The structural integrity of precast concrete buildings depends mainly on the
connections between the precast structural components. A sequence of particular
construction causes joints in a structure. Connection can be between old and fresh
concrete and can be between two parts of a structure. Construction joints must be so
positioned that the strength of a completed member is not affected. The most suitable
place for a construction joint in a simple structure is where a bending moment is zero or a
shear force is maximum. A construction joint may be at the junction of a rib and slab of a
T-beam or a smaller beam at a short distance from the junction of intersecting beams.
Joints can also be possible where columns at different floors are to be integrated with slab
or beam construction.
In the completed building the structural connections will form an essential part of
the structural system. The structural response will depend on the behaviour and the
characteristics of the connections. The structural layout, the arrangement of stabilizing
units, the design of the structural system and the design and detailing of the connections
must be made consistently and with awareness of the intended structural behaviour. To
achieve a satisfactory design the designer should understand how the connections
influence the flow of forces through a structure under vertical and horizontal loads. The
main purpose of the structural connections is therefore to transfer forces between the
precast elements in order to enable the intended structural interaction when the system is
loaded. Precast concrete building structures are composed of some basic types of
structural systems. These systems can be combined in different ways to obtain an
appropriate and effective structural concept that fulfils the needs of specific buildings.
The most common systems are:
1. Beam to beam connection
2. Beam to column connection
3. Column to column connection
4. Column beam floor connection
5. Floor and roof system
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Fig 2 : Different type of connections column to footing, column to column and column to
beam.

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2.1 Beam to beam connections

The figure shows the composite connections between two identical precast beam
elements. Both the isometric view and the sectional elevation show the two beams with
opposite notches or nibs connected by mechanical fastenings or bolts. Shear stresses at
the nib are reduced by the introduction of the bent bars. In addition, a bar cast in one end
is projected outside to be inserted into the hole left in the other element. The two
elements will achieve a monolithic structure of higher efficiency. A similar method is
adopted by connecting two precast concrete beam elements by means of high tensile bars
as tie rods leaving grooves at the top of the concrete and filling them with a specified
filler.

Fig. 2.1: Beam to beam connection

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2.2 Beam to column connections.

At the bottom a steel bar, as shown on figure 2.2, is welded to a steel plate which
is then welded to a bearing plate on top of the precast column bonded by a steel bar.

Fig.

2.2:
Beam

to

column connection

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Fig. 2.2.1: Showing beams resting on column

Fig. 2.2.2 Configuration of beam and column

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2.3 Column to column connections

Sometimes factory-made column elements are to be connected to make
larger columns of specified lengths. Dowel bars, as shown on fig 2.5, are used to
erect such columns. Injection holes are left to fill in hollow areas with grout.

Fig. 2.3: Column to column connections

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Fig. 2.3.1: Details of column connections

2.4 Floor and roof system

The main purpose of floor and roof systems is to carry vertical load to the vertical
load-resisting structural elements. Besides, precast floors and roofs are often used as
essential parts of the stabilizing system to transfer horizontal loads by diaphragm
action to the stabilizing units. The most common floor systems are hollow-core floors
and double-tee floors, Double-tee units are also used in roof systems. The elements in
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a floor system will not resist loads separately from each other, but a degree of
interaction between adjacent elements is desired. To obtain a transverse distribution
of load effects in case of concentrated loads and prevent uneven vertical
displacements at the longitudinal joints, the floor connections must be designed to
develop shear key action that ensures the interaction between adjacent elements. In
composite floor plate floors precast concrete floor plates are used as formwork for the
cast in-situ part and remain integrated in the composite floor section. Composite
action depends on the shear transfer in the horizontal joint between the precast plate
and the cast in-situ concrete part. There is no requirement for design of longitudinal
joint between the plates as the topping is continuous over the precast joint lines.

Fig. 2.4: Hallow slab connection

2.5 Aspect of design connections.
There are several ways to obtain tensile capacity in connections. Considering the
safety aspect only, the order of preference is as follows:
1) Bolting
2) Grouting reinforcing bars at the site
3) Embedding reinforcing bars in epoxy or polyester at the site
4) Welding
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The use of bolts is a simple way to establish a safe connection, but it generally
puts strict requirements on the tolerances. The bolts can be threaded rods or regular bolts.
Grouting at the site will to some extent depend upon the weather to be successful.
Generally the requirements on tolerances are not severe. When the result from a casting
operation is successful, a very sound connection is established. It also provides fire and
corrosion protection for the steel details.
Mix proportions, aggregate size and casting procedures will vary with the size,
location and orientation of the operation. Patches permanently exposed will often not be
acceptable. Anchoring the grout to relatively large steel surfaces is a problem that is often
overlooked. Large elements such as steel haunches can be wrapped with mesh or wire.
For recessed plates and similar elements headed studs or wiggled refractory anchors can
be welded to plate to provide anchorage for the grout. Gluing with epoxy or polyester is
very dependent upon weather conditions to be successful, especially temperature. Also
the workmanship is of great importance to secure a satisfactory result, like the mixing of
the ingredients and the preparatory cleaning and drying of the contact surfaces. Some
types of glued connections also put some requirements on tolerances. Most types of glue
loose most of their strength when heated to about 80 0C.
Welded connections will in most cases fit without any problems, but the quality of
the weld is totally dependent upon the skill of the welder. When welding outdoors the
welder must have extensive knowledge about what kind of electrodes to use under
different weather conditions on different material qualities, and of treatment of the
electrodes and materials prior to welding. Also the actual work may be difficult and
laborious to perform; like when fixing a small plate with only ladder access, with heavy
cables and no place to put the clamp. The heat generated when welding may also damage
the quality of the concrete close to the weld. Welded connections will in many cases have
to be fire protected.

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CHAPTER 3
Tests carried out:Beam-column connection:Types of Connections

1. Monolithic Specimen (ML):- The monolithic reinforced concrete test specimen

(ML) was designed according to IS: 456-2000 and detailed according to
IS:13920-1993.
2. Precast connection using Tie Rod (PC-TR):- The main connecting elements were
tie rod and steel plates. The beams are connected to the column using tie rods and
are supported on concrete corbels as shown[2]

FIG 3

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RESULTS
Various observations were made from the experimental investigations and are presented
in the following sections. The parameters considered for the present study are Ultimate
Load and Moment Carrying Capacity.
Table 1 Comparison of Experimental Yield and Ultimate Loads of the Specimens
Sl.no

1
2

specimen

Experimental
Yield
load(kn)
Upward
Downward
direction direction
8.8
9.40
6.5
8.62

ML
PC-TR

Experimental
load(kn)
Upward
direction
11.29
7.62

ultimate
Downward
direction
11.75
10.77

Table 2 Comparison of Experimental Ultimate Moment Carrying Capacity of the

Specimens
Sl.no

specimen

1
2

ML
PC-TR

Experimental Ultimate moment(kn-m)

Upward direction
Downward direction
6.21
6.47
4.19
5.92

Column slab connection

All the test units had 275mm x 300mm columns and 275mm deep x 200mm wide beams,
with different slab parameters as given in Table 3. The values of concrete compressive
strength at 28 day are listed in Table.[4]
Table 3
Unit description

Slab 1

Slab 2

Slab 3

Slab thickness(mm)
Reinforcement
fc'

50
6@250m
m c/c
39.02

50
6@165m
m c/c
37.06

63
6@200m
m c/c
38.38

fcu

44.82

43.93

43.33

28-day
strength(mpa
)

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FIG 4 :-Crack patterns in the beam-column intersection zone and slab

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CHAPTER 4
Discussions and Observations
The construction of precast elements is easy simple and economical. The main
advantage of precast construction is time saving. This type of construction is lighter in
weight and provides better sound and thermal insulation to the buildings. It also ensures
rapid construction and eliminates the use of shuttering which are essentially required to
support slabs and beams in the conventional type of construction.
There is a general concern regarding the seismic performance of precast
construction. It is noticed that large panel construction performs better than frame system.
However, in areas of high seismic risk, structures must be designed to respond safely to
the dynamic forces imparted into the structure. Innovations in joint design are improving
the connection systems in precast concrete structures and making them increasingly
suitable for use in such areas. Connections should be carefully designed where the impact
or dynamic forces are much higher.
It is concluded that special Code provisions are required for seismic performance
of connections in precast concrete construction. More experimental studies are required
for a full scale precast concrete structure to understand the strength, deformation,
ductility, dissipation and damage of the structure. [3]

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REFERENCES
1. Mathur, G.C. (1993), Low Cost Housing in Developing Countries, Oxford & IBH
Publishing Co. Pvt. Ltd., New Delhi.
2. Behaviour of precast beam-column tie-rod Connection ,R. Vidjeapriya1 and K.P.
Jaya2
3. Seismic Safety of Joints in Precast Buildings A State-of-theart Literature Review
Ravikanth Chittiprolu & Ramancharla Pradeep Kumar Earthquake Engineering
Research Centre, IIIT Hyderabad.
4. Saddam m, Ahmedi, Umarani Gunasekaran, A Parametric Study of R.C Slab in
Beam-Column Connection Under Cyclic Loading.
5. Code of practice for precast concrete construction (2003).

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