PRE CAST

FLAT
PANEL
SYSTEM

Submitted by Prerana Ratan 2IG17AT011

Sahana Shirke 2IG17AT014
Shubangi nimbalakar 2IG17AT018
PRECAST FLAT PANEL SYSTEM

A precast flat panel (PFP) system is a construction technique that

provides an alternative to traditional site-based construction.

Precast flat panel system components are mass produced off-site,

that are transported to the site and then combined and fitted
together. Panels can include elements, such
as doors, windows and floor units. They can also include features
such as decorative wall finishes, fitted insulation and so on. Some
types can be used as load bearing panels in cross wall
construction applications.

Precast flat panel systems can reduce on-site waste and

ongoing maintenance, but they can be difficult to transport and
handle. Using the precast flat panel construction technique may
shorten construction project completion times.
CONSTRUCTION ELEMENTS
REINFORCED CONCRETE WALL ELEMENTS
• Reinforced concrete wall elements are the characteristics features of both large
panel and cross wall construction methods; they can be used as either
loadbearing or non loadbearing or non loadbearing building elements.

• The thickness of the load bearing walls is determined by the static calculations
and the minimum allowable depth of the floor slab which is between 14 and 20
mm. This is also sufficient to fulfill the necessary sound and fire protection
requirements.

DOUBLE WALL ELEMENTS.

• Thin concrete walls are fitted together with intermediate steel gratings, all
necessary reinforcement is already installed between the walls.

• These double walls are delivered to the site where they are poured with filling
concrete to produce a stable, single layered wall construction element.
SANDWICH ELEMENTS
• Reinforced Sandwich panels are manufactured in plants for use as external walling.

• They consist of three layers: load bearing, insulating and facing.

POROUS CONCRETE ELEMENTS

• Porous or aerated , concrete elements belong to the class of lightweight

concrete that provide great stability with minimal weight. porous concrete
units are used as wall, slab and roof elements.as load bearing elements.

• As load bearing members, they are produced in heights of up to 350mm,

widths of up 150 mm and thicknesses of up to 37.5mm.Slabs and roof
panels of porous concrete have maximum dimensions of 800 mm in length
and 75mm in width. If they are to be subjected to bending loads, load
bearing, porous concrete elements are stabilized with additional corrosion
protected reinforcing steel.

POROUS CONCRETE FAÇADE ELEMENTS

• Porous concrete elements can be employed both horizontally and vertically
as façade elements or a infill panels for frame structures.

• In addition to the bracing functions which panels provide , they also

perform functions relevant to building physics.
CEILING AND FLOOR SLABS

• Pre fabricated concrete slab elements are produced as solid, hollow or web
panels. They offer planar structures of reinforced concrete or pre stressed
concrete which act as the partitioning elements for frame or panel
constructions.

• These elements are predominantly responsible for the absorption of

bending moments, and transfer both vertical and horizontal loads.

UNITISED SLABS

• The elements are manufactured in widths of up to 3m and consists of a

prefabricated slab measuring approximately 5mm with exposed steel
reinforcing anchors.

• These reinforcements act as the connecting elements between the

prefabricated element
SOLID SLABS

• Solid slabs can rest on wall edges in a linear manner or be point-loaded on

columns.

• They are seldom applied for spans exceeding 6m as the necessary thickness
of the slab for larger span would become heavy

HOLLOW SLABS
• Elements constructed of hollow reinforced concrete panels are highly
economical for large spans because they make it possible to economize on
concrete .

• Weight reduction of up to 50% are possible using hollow slabs compared

with solid slabs of the same dimensions. Depending upon the production
techniques, the cavities are oval, round or rectangular.
PRODUCTION FLOW CHART

Fine Coarse
water cement Mild steel H.T wire
aggregate aggregate

Measuring cutting

Mixing bending threading

Mould oiling binding stressing

Filling concrete

Mould fitting Compacting

Curing and
detensioning
Mould
cleaning Demoulding

Curing in yard
Testing
Dispatch
INSTALLATION

• Proper planning and preparatory works shall be required before the actual installation of precast concrete elements in
order to ensure quality installations. The following items shall be planned in advance.

• Method of sequence of assembly and installation, Pre cast elements should be indentified based on their location
number and tagged.

• Method of providing temporary support elements should be supported temporarily before these get stabilized.
Generally structural members with adjustable ends shall be used for securing the panels. Shims should be used adjust
the panels to ensure dimensional correctness.

• Installations tolerances Installation tolerances should be based on design considerations should be clearly indicated.

• Handling and rigging requirements elements should be checked for handling stresses before lifting and the cranes
should have sufficient capacity to handle the precast panels. At least 10% impact should be considered while calculating
the lifting capacity of the crane.

• At site locations, panels shall be first unloaded and stacked or directly lifted by the crane. The element shall then be
installed on the site and supported by temporary jacks. The cranes shall be released for next lifting once the temporary
supports are in place. Shims shall be used to carefully align the element before grouting. The panels shall be grouted
after the final adjustments are done.
 ADVANTAGES
• Saves Construction Time: Precast Concrete construction saves time, the risk of project delay is also less. The precast
concrete casting can be carried on simultaneously with other works on site such as earthwork, survey, etc. and thus
saves time.
• Quality Assurance: The key factors which regulate the quality of construction such as curing, temperature, mix design,
formwork, etc. can be monitored for Precast Concrete. So, improved quality construction can be performed.
• Usage of Prestressed Concrete: By using pre-stressed precast, structural materials of high strength and load-bearing
capacity can be achieved, which can result in greater clear span, reduced size of the cross-section of structural
members, etc.
• Cost-effective: The simplified construction process reduces the time, increases the productivity, quality and safety
and thus the cost is reduced.
• Durability: Precast Concrete structure has a longer service time period and minimal maintenance. The high-density
Precast Concrete is more durable to acid attack, corrosion, impact, reduces surface voids and resists the
accumulation of dust.
• Aesthetics: As the structures are prefabricated in a controlled factory environment, several combinations of colors
and textures can be used. A wide range of shapes and sizes are available to choose from with smooth finishing and
thus the aesthetical value of products are increased.
• Safe Construction Platform: No raw materials have to be stocked in site for Precast Concrete construction. It reduces
the requirement of traditional formworks and props, wastage, workers, etc. and thus provides a safe working
platform.
 DISADVANTAGES
1.Transportation Issue: The construction site can be at a distant location from the Precast Concrete plant. In that
case, the precast members must be carried to the site using trailers. In many cases, the reduced costs of Precast
Concrete is compensated by the transportation cost.
2.Handling Difficulties: Proper care and precaution have to be taken for handling precast concrete. Usually, precast
members are heavy and large which makes it difficult to handle without damage. Generally, portable or tower
cranes are used to handle precast members.
3.Modification: Limitation In case of precast structures, it is difficult to modify the structure. For example, if a
structural wall is to be dismantled for modification it will impact the overall stability of the structure.
4.Sensitive Connection Works: Assembling of the precast members is one of the key points for ensuring strong
structural behavior. Connections between several structural members must be supervised and done properly to
ensure the intended behavior of the connection such as simple, semi-rigid or rigid connections. Besides this, faulty
connections may lead to water leakage and fail sound insulation.
APPLICATIONS
• Precast panels have been used on virtually every type of building, including schools, office buildings, apartment
buildings, townhouses, condominiums, hotels, motels, dormitories, and single-family homes.
• Pre cast architectural panels are also used to clad all or part of a building façade or free standing walls used for
landscaping, soundproofing and security walls.
• Conventional moulds Ribbed slabs, beams, window panels, box. type units and special elements.
• Battery moulds.
• Interior wall panels, shell elements, roof. Façade panels and floor slabs.