PCI 6th Edition

Introduction to Precast
 Presentation Outline

• Material Applications
• Benefits
• Forming and Production Techniques
• Architectural Possibilities
• Engineering Applications
• Connection Introduction
• Building Construction
 Precast and Prestress

• Precast
– Not cast in its
final condition
– Normally mild
reinforcement
 Precast and Prestress

• Precast
• Prestressed
– Reinforced with
strand
– Strand is
stressed prior to
casting
 Precast and Prestress

• Precast
• Prestressed
• Post-tensioned
– Strand is stressed after casting and
curing
 Applications

• Buildings
– Residential
– Office buildings
– Warehouses and
industrial
– Parking structures
– Justice facilities
– Stadiums, arenas
– Bridges
 Applications

• Buildings
– Residential
– Office buildings
– Warehouses and
industrial
– Parking structures
– Justice facilities
– Stadiums, arenas
– Bridges
 Applications

• Buildings
– Residential
– Office buildings
– Distribution
Centers
– Parking structures
– Justice facilities
– Stadiums, arenas
– Bridges
 Applications

• Buildings
– Residential
– Office buildings
– Warehouses and
industrial
– Parking structures
– Justice facilities
– Stadiums, arenas
– Bridges
 Applications

• Buildings
– Residential
– Office buildings
– Warehouses and
industrial
– Parking structures
– Justice facilities
– Stadiums, arenas
– Bridges
 Applications

• Buildings
– Residential
– Office buildings
– Warehouses and
industrial
– Parking structures
– Justice facilities
– Stadiums, arenas
– Bridges
 Applications

• Buildings
– Residential
– Office buildings
– Warehouses and
industrial
– Parking structures
– Justice facilities
– Stadiums, arenas
– Bridges
 Applications

• Other:
– WWT facilities
– Airports
– Marine
– Cold Storage
– Light poles
– RR ties
– Silos
 Benefits of Precast

• Vibration Control • Unlimited Color and

• Shortened Textures
Construction • Produced Under a
Schedule Strict Quality Control
Environment
• Engineering • Long-Term Durability
Assistance Provided
• Penetration Flexibility
• Fire Resistance • Use Flexibility
• Column Free Space
 Forming Techniques

• Variety of
configurations
• Vast flexibility
• Creative structural
and architectural
advantages
• Multiple
colors
 Long Line Forms

• Economic casting
• Form resembles shape
• Used for gray structural
concrete or architectural
concrete
• Typical products
– Double tee
– Inverted tee beam
– L-beam
– Bridge girders
– Spandrels
 Long Line Forms

• Typical long line

– Continuous prestressing
strand for multiple pieces
– Depress depth to
increase capacity
– Stressing method
• Single stressing
• Gang stressing
 Long Line Forms

• Cost benefit due to

– Efficient forming
– Repetitive use
– Reusable bulkheads
– Mass production
 Single form

• Good choice for complex pieces

• Molds can be modified for similar pieces
 Single form

• Mold Modifications
– Easily modified
– Embedded items
– Reveals
– Blockouts
Removal of Blocking Material
 Sawcut pieces

• Hollow Core
• Cast as continuous
piece,
• Cut to fit application
• Cost benefit
– Repetitive design
– No need for bulkheads
– Efficient manufacturing
– Limited embed materials
 Architectural Features

• Textures
– • Color
Ribs
– Based on Aggregate
– Fractured Fin
– Tint
– Acid Etch – Combination
– Sand Blast – Texture
– Retarded
– Inlay Brick • Color and Texture
– Inlay Stone combined
– Mimic Inlay Stone
– Inlay Granite
 Architectural Features

• Geometry
• Liners
• Bullnose
• Reveal
• Quirk Miter
• Mixed finishes
 Finish – Exposed aggregate

• Process
– Paint retarder on form surface
– Cast product
– Cure Product
– Remove and high pressure wash
• Texture controlled by depth of
exposure or “cure prevention”
 Finish – Acid etching

• Process
– High pressure acid
solution
– Sandblasting creates
similar results
• Texture controlled by
depth of etching
 Finish – Sand Blasting

• Process
– High pressure sand or metal shot
• Texture controlled by depth of blasting
 Inlay items

• Brick
• Metal
• Stone
 Backup Mix

• Used to reduce
cost
• Used when back
side is unexposed
to public view.
Backup Mix

Architectural Face Mix

 Engineering Features

• Cantilevers
• Open Space
• Transfer Members
 Connections

• Monolithic • Welded
Emulation – Mimic jointed
– Mimic cast in place structures
structures – Low to moderate
– Used in high seismic seismic risk
risk zones – Quick building
– Wet joint completion
construction
– Precast as formwork
 Haunches

• Steel sections
• Reinforced
concrete
haunches
 Panel to Panel

• Designed to
resist shear
 Panel to Panel

• Designed to
resist tension
 Precast to Foundation

• Precast
connections
can be
customized for
unique
configurations
 Building Erection

• Transportation
• Bracing
• Rigging QuickTime™ and a
Microsoft Video 1 decompressor
are needed to see this picture.

• Piece Erection
Questions?