concrete early efforts - bmtpc · 2021. 2. 24. · 12.information technology in precast...

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HANDBOOK ON PRECAST CONCRETE FOR BUILDINGS − A PRIMER

Amlan K. Sengupta, PhD, PE

Department of Civil Engineering

Indian Institute of Technology Madras

NAVARITIH 2021School of Planning and Architecture, New Delhi

Building Materials and Technology Promotion Council

EARLY EFFORTS

Courtesy: Hindustan Prefab Ltd. (Estd. 1953)

EARLY EFFORTS

Industrial Buildings (1963)Hindusthan Cables Ltd., Rupnarayanpur

Precast segmental PT girders

Pre‐tensioned purlinsCourtesy: Pinaki Chakraborti

EARLY EFFORTS

Residential Buildings (1964)Heavy Engineering Corporation Ltd., RanchiCourtesy: Pinaki Chakraborti

EARLY EFFORTS

Courtesy: CSIR Structural Engineering Research Centre

Residential apartments (1972‐76)

INDIAN PIONEERS

Baburao G Shirke (1917 – 2010),Padma Shri (2003)

Navi Mumbai

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INDIAN PIONEERS

Shirish Patel (1932),Petit Hall, Mumbai, 1973

INDIAN PIONEERS

A Ramakrishna (1939 – 2014),

Padma Bhushan (2014)

EDRC Building, L & T, Chennai

INDIAN PIONEERS

R SundaramPresident, Structural Engineers World Congress (SEWC)

Kanteerava Indoor Stadium, Bangalore

INTRODUCTION

Objectives

• Covers wide ranging topics

• Simple and easy to read approach

• References to easily accessible literature

INTRODUCTION

Target Users

• Engineers in public and private organisations

• Professionals in construction industry

• Decision making officials

• Educators and students

CHAPTERS

1. Precast Concrete in Buildings and Urban Infrastructure

2. Precast Concrete Building Systems An Overview

3. Foundation and Underground Structures

4. Structural Analysis and Design

5. Prestressed Precast Concrete

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CHAPTERS

6. Seismic Design of Precast Structures

7. Materials and Properties

A) Materials and Products)

8. Joints and Connections in Precast Buildings

9. Production, Handling and Erection of Precast Elements

10. Quality Control and Assurance in Precast Products

CHAPTERS

11. Contracts and Taxation

12. Information Technology in Precast Construction

13. Case Studies

A) Precast Building using Precast Hollow Core Slab

Systems

B) Precast Parking Garage

1. (Late) A Ramakrishna B Sivarama Sarma

2. Amlan K Sengupta

3 S R G dhi

AUTHORS 7. V RamachandraManamohan R KalgalM N Ramesh Raj PillaiB Sivarama Sarma

8. K P Jaya

3. S R Gandhi Subhadeep Banerjee

4. K Ramanjaneyulu

5. N Raghavan

6. A Meher PrasadK P Jaya

9. (Late) K Mohan Kumar

10. P Srinivasan

11. N Raghavan

12. Chandrasekar

13. Sthaladipti Saha

CHAPTER 1

Precast Concrete in Buildings and Urban Infrastructure

(Late) A Ramakrishna, B Sivarama SarmaL&T Constructions

CHAPTER 1Precast Concrete in Buildings and Urban Infrastructure

Advantages of Precast Concrete

• Quality

Better control in a factory environment

Suitable during inclement weather

Efficient quality management

Accuracy in dimensions

Possibility of textured finish

Improved durability with adequate

connectionsMock‐up buildingCourtesy: L & T



• Time

Rapid construction with robust planning

Use of mechanised ways, such as

extrusion, battery and tilting moulds etc.

Suitable for modular and repetitive

construction

Curing of wall panelsCourtesy: L & T

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• Cost

Optimum use of materials

Limited use of temporary supporting

structures, such as scaffolding

Multiple use of form work

Reduction in amount of formwork

Availability of standard shapes

Reduced maintenance leads to

reduced life‐cycle cost Hostel building at IIIT Sri CityCourtesy: Teemage Precast



• Miscellaneous

‘Greener’ buildings

Block work and plastering can be avoided

Additional features can be incorporated

conveniently

Thermal and acoustic control

Reduced manual labour

Better safety and environmental conditions

Suitable for laboratory testing of components

Testing of biaxial hollow slab at IIT Madras


Challenges of Precast Concrete

• High initial costs for setting up factories

• High transportation costs for delivery of precast components

• Erection of components

• Excise duty of precast products

Courtesy: Teemage Precast

CHAPTER 2

Precast Concrete Building Systems ‐ An Overview

Amlan K Sengupta

IIT Madras

CHAPTER 2Precast Concrete Building Systems ‐ An Overview

Wall type Multistoreyed Buildings

Residential building in BangaloreCourtesy: Star Worth Infrastructure & Construction LtdCourtesy: Star Worth Infrastructure & Construction Ltd.

CHAPTER 2Precast Concrete Building Systems ‐ An Overview

Frame type or Dual type Multistoreyed Buildings

Commercial building in HyderabadCourtesy: Aurobindo Realty & Infrastructure Pvt. Ltd.

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CHAPTER 3

Foundation and Underground Structures

S R Gandhi, Subhadeep Banerjee

IIT Madras

CHAPTER 3Foundation and Underground Structures


• Fast placement of footing or other components

Early backfilling of soil

Curing is not required

Convenient during monsoon Convenient during monsoon

Fluctuating ground water table

• Reduction in size of excavation

• High grade & quality of concrete

Reduction in cover of concrete

• Avoid bentonite slurry for piles

• No necking or bulging of piles Courtesy: Precast India Infrastructure Pvt. Ltd.


Shallow Foundations

Column foundationCourtesy: Teemage Precast

Wall foundationSchmersal India Production Facility, Pune

Courtesy: Precast India Infrastructure Pvt. Ltd.


Deep Foundations

PilesCourtesy: Industrial Concrete Products Berhad

PilesCourtesy: L & T


Miscellaneous Geo‐Structures

Intake wellCourtesy: www.voiceconstruction.net

UnderpassCourtesy: Reinforced Earth India


Miscellaneous Geo‐Structures

Reinforced earth wallKanaka Durga Temple, Vijayawada

Courtesy: TenCate Geosynthetics Asia

Tunnel wallChennai Metro Rail Ltd.

Courtesy: L & T

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CHAPTER 4

Structural Analysis and Design

K Ramanjaneyulu

SERC Chennai

CHAPTER 4Structural Analysis and Design

Features of Analysis

• Modelling of Members

Frame elements for the beams and columns

Membrane or shell elements for the wall panels

Plate elements for the slab units and raft foundation

Strut elements for infill walls


Features of Analysis

• Modelling of Connections

Emulative connections

Rigid joints

Semi‐rigid joints

Gap joints

Mechanical (Jointed) connections

Semi‐rigid joints

Flexible (Pinned) joints


Deformed Shapes and Bending Moment Diagrams

Under Gravity Loads

Rigid jointed frame

Flexible jointed frame with eccentric beam‐to‐column loadingCourtesy: K. Ramanjaneyulu


Deformed Shapes and Bending Moment Diagrams

Under Lateral Loads

Rigid jointed frame

Flexible jointed frameCourtesy: K. Ramanjaneyulu


Types of Analysis for Lateral Loads

• Linear

Static

Equivalent static analysis

Dynamic M d 1 fi ti Dynamic

Response spectrum analysis

Linear time‐history analysis

• Non‐linear

Static

Pushover analysis

Dynamic

Non‐linear time‐history analysis Courtesy: L & T

Multi‐storeyed apartment buildings at Mumbai

Mode 1 configuration

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CHAPTER 5

Prestressed Precast Concrete

N Raghavan

IIT Madras

CHAPTER 5Prestressed Precast Concrete

Advantages of Prestressing

• High span‐to‐depth ratios

Larger spans

Increased column‐free spaces

Reduced member sizes

Lighter self‐weight

Less material consumption

Lower seismic forces

• Uncracked sections under service loads

Reduction of steel corrosion

Increase in stiffness and shear capacity


Long‐line Prestressing Bed



Miscellaneous Applications

Folded platesDept. of Ocean Engineering,

IIT Madras

Trusses,Godown at Chennai portCourtesy: L & T

CHAPTER 6

Seismic Design of Precast Structures

A Meher Prasad,

IIT Madras

K P Jaya

Anna University

CHAPTER 6Seismic Design of Precast Structures

Failures in Past Earthquakes

• Inadequate design and detailing of connections

• Inadequate seating and diaphragm action of floors

• Inadequate deformation compatibility between the gravity load

and lateral load resisting systems

• Inadequate separation of non‐structural elements

Bhuj earthquake, 2001

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Capacity Based Design

• Members to yield at selected locations sequentially before

damage of the connections (specifically, which transmit gravity

loads)loads)

Stiff and strong connections

Ductility of the connected members

Damage in members beyond repair


Ductile Joint Based Design

• A joint in a connection to yield before damage of the connected

members

Deformable and ductile joints Deformable and ductile joints

Joints can be repaired

Damage in members is limited


Frames

Emulative connection

Mechanical (Jointed)connection

Schmersal India Production Facility, Pune

Courtesy: Precast India Infrastructures Pvt. Ltd.


Walls

Emulative Joint

Multi‐storeyed apartment buildings at Mumbai

Courtesy: L & T


Design based on Energy Dissipation and Self Re‐centering

• Aims to reduce drift and eliminate damage of members

Jointed connections to open‐and‐close (rocking rotation) cyclically

Avoids uncontrolled cracking of concrete Avoids uncontrolled cracking of concrete

Inserted elements of mild steel (external or internal) to dissipate

energy by yielding across the ‘artificial gaps’

Unbonded post‐tensioned tendons to ‘restore’ elastically


Frames

External energy dissipater

Internal energy dissipater

Internal

restoring

element

Courtesy: S. Pampanin

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Walls

Courtesy: Sritharan et al.

Internal energy dissipater

Internal

restoring

element


Slab Diaphragms

Reinforced topping

Sh t

Chord reinforcement

Precast unitsShear connectors

Composite diaphragm Non‐composite diaphragm


Slab Diaphragms

Hostel building at IIIT Sri City


IT Park Canteen building, Pune

Courtesy: L & T

CHAPTERS 7, 7A

Materials and Properties

V Ramachandra, Manamohan R Kalgal,

UltraTech Cement Ltd.

M N Ramesh,

SAVCOR India Pvt LtdSAVCOR India Pvt. Ltd.

Raj Pillai

Sobha Limited

Materials and ProductsB Sivarama SarmaL&T Constructions

CHAPTERS 7, 7AMaterials, Properties and Products

Materials

• Cement

• Supplementary Cementitious Materials (Mineral admixtures)

• Aggregates: coarse and fine

• Water

• Chemical admixtures

• Reinforcing bars

• Prestressing tendons

• Welded wire mesh

• Fibres Courtesy: Teemage Precast

CHAPTERS 7, 7AMaterials, Properties and Products

Requirements for Precast Concrete

• High early strength

• High durability

• Miscellaneous

High flow mix

Stiff mix

Colour

Texture

Light‐weight

Thermal and acoustic insulation

Fire endurance, etc.Courtesy: Teemage Precast

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CHAPTER 8

Joints and Connections in Precast Buildings

K P Jaya

Anna University

CHAPTER 8Joints and Connections in Precast Buildings

Connections

Slab (S) Beam (B) Column (C) Wall (W)elements elements elements

F: Footing

S–WS–S S–B S–C

elements

B–WB–B B–C

C–FC–C W–FW–W

Facade &

miscellaneous

elements


Connections of Slab Units


Hostel building at IIIT Sri City


Connections

Emulative Mechanical (Jointed)

Courtesy: J&P Building Systems Ltd.


Emulative Connection

• Mimics cast‐in‐place concrete connection

• Based on concreting or grouting (wet connection)g g g ( )

• Expected to be corrosion resistant

• Quality control required at site

• Behaviour expected to be “monolithic”

• Requires inserts of reinforcing bars, dowel bars or equivalent

connectors (eg. studs, looped wire ropes), ducts, etc.


Mechanical Connection

• Mimics structural steel connection

• Based on mechanical components

• Needs protection against seepage and corrosion

• Quality control in tolerance required at machine shop and

casting yard

• Behaviour can be rigid, “semi‐rigid”, flexible or “dissipative”

• Requires inserts of plates, anchor rods, bolts, couplers, steel

sections, etc.

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Connections between Walls

Courtesy: Star Worth Infrastructure & Construction Ltd.Aurobindo Realty & Infrastructure Pvt. Ltd.

Horizontal connection(Elevation)

Vertical connection with U‐bars (Plan)

Vertical connection with looped wire ropes

(Plan)


Connections between Frame Members

Courtesy: Aurobindo Realty & Infrastructure Pvt. Ltd.

Slab to beam(Elevation)

Beam to column (Elevation)

Column to column (Elevation)


Connection Materials

• Couplers

• Looped wire rope in a box

• Headed studs

• Bolts and threaded rods

• Inserts

• Bearing pads

• Miscellaneous connecting elementsCourtesy: Teemage Precast

CHAPTER 9

Production, Handling and Erection of Precast Elements

(Late) K Mohan Kumar,

Ra‐Ni Precast Consulting Services Pvt. Ltd.

B Sivarama Sarma

L&T Construction

CHAPTER 9


Moulds

• Column

• Beam

• Wall

‒ Flat

‒ Vertical

Battery

‒ Tilting

• Slab

• Stairs

• Miscellaneous

Flat wall mouldsCourtesy: Teemage Precast

CHAPTER 9


Prestressing

Beds/Benches

• Hollow core slabs• Hollow‐core slabs

• Solid planks

• Beams

• PilesBed for hollow‐core slabs


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CHAPTER 9


Production Flow‐chart

Railway sleepersCourtesy: Patil Rail Infrasturcture Pvt. Ltd.

CHAPTER 9


Curing, Demoulding and Storage

Bridge girdersCourtesy: Airport Authority of India

CHAPTER 9

Production, Handling and Erection of Precast ElementsTransportation, Handling and

Erection

Wall elementsCourtesy: Teemage Precast

CHAPTER 9


Lifting and Installation

Staircase

Slab

Balcony

Courtesy: Ra‐Ni Precast

CHAPTER 10

Quality Control and Assurance in Precast Products

P S i iP Srinivasan,

CSIR‒SERC Chennai

B Sivarama Sarma

L&T Construction

CHAPTER 10


Relevant Codes

• IS 15916: 2010 (reaffirmed 2019), Building Design and Erection using Prefabricated Concrete ‒ Code of Practice

• IS 15917: 2010 (reaffirmed 2019), Building Design and Erection using Mixed/Composite Construction ‒ Code of Practice

• IS/ISO 9001: 2015, Quality Management Systems ‒ Requirements

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CHAPTER 10


Quality Control on Materials, Processes and Products

CHAPTER 10


Testing of Finished Products

Railway sleepersCourtesy: Patil Rail Infrasturcture Pvt. Ltd.

Hollow‐core slab unitsCourtesy: Teemage Precast

CHAPTER 11Contracts and Taxation

N Raghavan

IIT Madras


Types of Contract

• Item rate contract

• Lump sum or Design and build contract• Lump sum or Design‐and‐build contract

‒ Turn‐key contract

‒ Engineering Procurement and Construction (EPC) contract

• Cost‐plus contract


Types of Contract (based on concepts of Lean Construction)

• Target Value Design

• Integrated Project Delivery• Integrated Project Delivery

• Alliance Contracting


General Indian Taxation Structure

Excise duty is levied on precast products manufactured outside the site.

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Aspects related to Precast Concrete Construction

• Conditions of Contract

‒ Land requirement

‒ Quality and warranty

‒ Billing stages

• Special Technical Specifications

‒ Structural design with tolerances

‒ Production

‒ Handling, transportation and erection

• Taxation

‒ Typical scenarios

CHAPTER 12Information Technology in Precast Construction

L. Chandrasekar

Trimble Solutions India Pvt Ltd


Building Information Modelling (BIM)

• Suitable for mechanised construction of precast components

• Collaborative and integrated project management from• Collaborative and integrated project management from conceptual design to construction

‒ Tendering quantities and bidding

‒ Constructability assessment and cost estimation

‒ Detailing and integrated manufacturing

‒ Progress visualisation of delivery and erection

• Reduction of wastage leading to lean construction


Integration with Analysis and Design Applications

• Coordination and visualisation of‒Models‒ Drawings‒ Reports

• Change management

CHAPTER 13Cast Studies

Sthaladipti Saha

L&T Constructions

CHAPTER 13Cast Studies

Features

• Framed building with shears walls

• Moment resisting frames with precast beams and columns• Moment resisting frames with precast beams and columns,designed for gravity loads

• Floors made of hollow core slab units

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CHAPTER 13Cast Study 1

Canteen Building in Pune

During construction After completion of project


Canteen Building in Pune

Beams

Columns

Hollow‐core slab units


Vehicular Parking Garage in Chennai

After completion of project


Vehicular Parking Garage in Chennai

Erection of wall units

CLOSURE

Handbook

• Source of compiled information

• Explanatory notes and illustrations

• Lists of references• Lists of references

Publisher

Indian Concrete Institute

www.indianconcreteinstitute.org

concrete early efforts - bmtpc · 2021. 2. 24. · 12.information technology in precast...

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