Precast Concrete Construction Research Articles

A Semantic Digital Twin for the Dynamic Scheduling of Industry 4.0-based Production of Precast Concrete Elements

Precast concrete construction enhances project efficiency, sustainability, and durability by leveraging a controlled production environment that ensures high-quality outputs. Still, the sequential nature of off-site production, encompassing casting, curing, and storage of the precast elements, is subject to significant uncertainties, including supply chain variability and environmental factors affecting curing times. Dynamic adjustments to the production schedule are essential for aligning with real-time changes, necessitating a robust framework for real-time data acquisition and analysis. Dynamic Scheduling (DS) is a responsive and adaptive approach that accommodates real-time changes, optimizes the production flow, and minimizes downtime or delays. However, the DS approach demands real-time data to quickly and efficiently respond to unforeseen challenges, which requires acquiring and analyzing production-relevant data throughout the production process. The Digital Twin (DT) emerges in Industry 4.0 (I4.0) as a bridge between physical operations and digital capabilities, enabling a seamless flow of information, for which the Asset Administration Shell (AAS) is a reference implementation. This study introduces a DS framework to optimize precast element production, utilizing a DT for real-time data aggregation across the production system. The framework implements a Semantic DT based on the AAS and the Linked Data approach. It employs Resource Description Framework (RDF) serialization of the AAS and an ontological representation of the production system for data integration. The framework leverages a simulation-based scheduler, which exchanges data with the DT in a Service-oriented Architecture (SoA) using SPARQL, a language for querying and updating graph databases. The approach is evaluated through a proof of concept, demonstrating effective uncertainty management in a dynamic production environment.

BIM for maintenance planning of façades in precast concrete buildings

PurposeThis paper aims to identify the different system approach using Building Information Modelling (BIM) technology that is equipped with decision making processes. Maintenance planning and management are integral components of the construction sector, serving the broader purpose of post-construction activities and processes. However, as Precast Concrete (PC) construction projects increase in scale and complexity, the interconnections among these activities and processes become apparent, leading to planning and performance management challenges. These challenges specifically affect the monitoring of façade components for corrective and preventive maintenance actions.Design/methodology/approachThe concept of maintenance planning for façades, along with the main features of information and communication technology tools and techniques using building information modeling technology, is grounded in the analysis of numerous literature reviews in PC building scenarios.FindingsThis research focuses on an integrated system designed to analyze information and support decision-making in maintenance planning for PC buildings. It is based on robust data collection regarding concrete façades' failures and causes. The system aims to provide appropriate planning decisions and minimize the risk of façade failures throughout the building's lifetime.Originality/valueThe study concludes that implementing a research framework to develop such a system can significantly enhance the effectiveness of maintenance planning for façade design, construction and maintenance operations.

Enhancing the Construction Efficiency of Mid Rise Construction Projects with Partial Precast Construction Technique By IJISRT

The primary success parameter of every construction project is to achieve the better quality products, in the most reasonable time and at an economic cost. Along with the materials the method of construction used in mid rise construction projects contributes mainly for the cost of the project, time duration to complete the project & structural behavior such as stability, durability, quality etc. of these structures. This paper is about understanding the need for creating an awareness about the construction method to be adopted & enhancing the construction efficiency of mid rise construction projects with partial precast concrete construction technique. The study also speaks about the cost, time and quality effectiveness as compared to cast in-situ concrete construction techniques for the mid rise construction projects. The research findings shows that partial precast construction for mid rise construction projects is time and quality effective. Thus, we can achieve the cost effectiveness in partial precast concrete construction if the recommendations made are implemented.

The Most Impactful Changes from ACI 318-14 to ACI 318-19

This paper discusses selected changes from ACI 318- 14 to ACI 318-19 that are likely to have the largest impact on precast concrete design and construction. Some of these changes have proved to be somewhat problematic. These concerns are described, and in a few cases, suggestions are offered that might mitigate some of the negative impact.

Развитие строительства и промышленности строительных материалов в Магаданской области в 1953–1964 гг.

The article is devoted to a comprehensive analysis of the development of the construction industry and construction materials industry in the Magadan Region in 1953–1964. The key areas and results of construction activities, the dynamics of capital investments in construction in various sectors of the economy, the establishment and development of enterprises for the production of wall materials, precast concrete and other construction industry in the region are examined. Particular attention is paid to the analysis of the problems of logistical support for construction, the cost of building materials, and the shortage of certain types of products. The pace and volume of housing and social and cultural construction are considered. Based on a wide range of archival sources, it is concluded that the development of construction and local production of building materials was of great importance for the formation of the Magadan Region as a northern region of the country during the period under review.

An investigation and design of novel moment-resisting beam-column connections for precast concrete construction

This study investigates the behavior of hybrid beam-column connections with numerous detailing methods to be incorporated into precast concrete moment-resisting frames under simulated reversed cyclic loading, and ultimately develops a design procedure. Seismic performance of moment-resisting precast concrete beam-column connections was investigated through simulated reversed cyclic load tests. In addition, nonlinear finite element analysis (FEA) of typical monolithic and precast concrete connections was carried out using a modified concrete damage plasticity model. Good agreement was achieved between experimental and numerical results, which indicates that the FEA model is capable of capturing failure modes of the investigated precast concrete connections. Simple detailing modifications resulted in major improvements in the performance of connections in terms of load-displacement curves, stiffness, and energy dissipation. Finally, a design procedure was developed for the investigated connections based on failure modes and investigated limit states.

Carbon emission analysis of precast concrete building Construction: A study on component transportation phase using Artificial Neural Network

Off-site construction has been widely adopted for its carbon reduction potential. However, the emissions from its transportation stage are not fully explored. Given the rising prominence of Battery Electric Vehicles (BEVs), this study explores their potential carbon reduction benefits during the transportation of prefabricated components by comparing emissions from Fossil Vehicles (FVs) and BEVs. An Artificial-Neural-Network-based emission model is developed to estimate the carbon emissions of both vehicle types. Specifically, the model collects the real-time carbon emission dynamics across varying external conditions, encompassing diverse transportation constraints, vehicle operational statuses, and road conditions. By employing a supervised learning framework, the transportation carbon emission coefficient of prefabricated components is determined. Comparative analysis reveals that BEVs consistently outperforms FVs, achieving a peak reduction rate of 47.76%. The negative correlation between the reduction rate of BEVs and factors like average speed and load rate underscores BEVs' advantage in urban transportation scenarios, where these factors tend to be low. Hence, the integration of BEVs in the transportation of prefabricated components is advocated. This study provides robust carbon emissions coefficients for BEVs in the transportation of prefabricated components, filling the gap in current estimation methods. These coefficients present a valuable tool for researchers, aiding in the accurate estimation of transportation carbon emissions and fostering the conceptualization of innovative carbon reduction tactics through BEV adoption.

Tensile behaviors and configurations of double-headed bar overlap connections for precast concrete members

The superiorities in construction time, cost, and quality of precast RC structures are accompanied by the challenges in connection, particularly in steel bars connections between RC components. The extensively used steel bar connections for either grouted sleeve splice connection or grouted spiral-confined lap connection requires on-site grouting, which is a concealed construction process with increased the risk of grouting defects, thereby impairing connection reliability. The confined headed bar connection (CHBC) with visible on-site construction has been proposed to address the unseen grouting defects concerns. However, modern structures that use large-diameter or high-strength rebars present higher demands for steel bar connection capacity. For CHBC, it is suggested to use either a long connection length or a large-size head to satisfy the capacity demand. However, the long connection length can increase field wet operation, which is disadvantage in precast concrete construction. The large-size head can help reduce the connection length, but it can cause inconvenience including construction congestion and the increased eccentric bending moment under tension. This paper presents the CHBC with double-head configuration, which can reduce the single head size. The proposed CHBC consists of confinement stirrups and two overlapped headed bars and the stirrup confining the core concrete can also improve the CHBC capacity. Experimental investigation on 21 CHBC specimens has been carried out. The failure modes, bearing capacity, and stirrup strain development have been studied. Effects of the double-head configuration and confinement stirrup ratio have been analyzed through experimental and numerical investigation. Results show that the double-head configuration has a minor impact on the tensile capacity of CHBC while the increase of confined stirrup ratio can improve the tensile capacity of CHBC. Configuration details of size and spacing for stirrup reinforcement in CHBC are proposed. Based on the test results, CHBC tensile capacity prediction method is suggested, which can take the head configuration into account.

Evaluating the Modified Uncertainty MCMC Approach to Obtain Safety-Quality Index in PC Construction with Current Models

Precast Concrete Construction (PCC) is a famous method in construction industry due to its different advantages. Nevertheless, this method has several discontinuous processes and they can enhance various uncertainty safety-quality issues. In this system, Building Information Modeling (BIM) technique plays a key role in managing of discontinuous processes to improve multidimensional safety and quality. Dimensionless parameters were used to evaluate the modified type of multidimensional BIM index (IMBIM) as the target index using the Modified Fuzzy Analytic Network Process (MFANP) method. In fact, the importance weight of input indices on the target was determined by the MFANP approach. The results of statistical analysis in verification step indicate that MFANP is well compatible with other approaches, so this developed method was considered as a reference point. The modified uncertainty Markov Chain Monte Carlo (MCMC) analysis was used for the validated method to determine the optimal high occurrence rate of IMBIM. The results demonstrate that a high percentage of occurrence frequency for IMBIM is in the range between 0.9 and 0.925. In this range, the mean optimal value of IMBIM as a management measure for multidimensional problems is 0.912. Stakeholders in PCC projects can use the proposed high occurrence range to assess the quality-safety of construction and make appropriate decisions.

Effect of GGBFS slag on CSA-based ternary binder hydration, and concrete performance

Calcium sulfo-aluminate (CSA) cement is an alternative cement that can be beneficial for precast, rapid, and low-temperature concrete construction. But low workability and impractically short setting time of CSA cement, prevent its application in the construction industry. The use of Portland cement (OPC) and ground granulated blast furnace slag (GGBFS) in CSA-based composite binder can provide improved workability, and setting time while maintaining early strength and low carbon footprint. This article studies the hydration process in a composite binder with CSA, GGBFS and OPC to identify the controlling reaction and chemical parameters that can be used to predict the concrete performance during the fresh and hardened state. As SCMs and alternative binders are being used more in construction, the hydration process and compatibility assessment of binders need to have a scientific basis instead of a trial-and-error process.

A state of art review on time, cost and sustainable benefits of modern construction techniques for affordable housing

Purpose This paper aims to identify modern construction techniques for affordable housing, such as prefabrication and interlocking systems, that can save time and cost while also providing long-term sustainable benefits that are desperately needed in today's construction industry. Design/methodology/approach The need for housing is growing worldwide, but traditional construction cannot cater to the demand due to insufficient time. There should be some paradigm shift in the construction industry to supply housing to society. This paper presented a state-of-the-art review of modern construction techniques practiced worldwide and their advantages in affordable housing construction by conducting a systematic literature review and applying the backward snowball technique. The paper reviews modern prefabrication techniques and interlocking systems such as modular construction, formwork systems, light gauge steel/cold form steel construction and sandwich panel construction, which have been globally well practiced. It was understood from the overview that modular construction, including modular steel construction and precast concrete construction, could reduce time and costs efficiently. Further enhancement in the quality was also noticed. Besides, it was observed that light gauge steel construction is a modern phase of steel that eases construction execution efficiently. Modern formwork systems such as Mivan (Aluminium Formwork) have been reported for their minimum construction time, which leads to faster construction than traditional formwork. However, the cost is subjected to the repetitions of the formwork. An interlocking system is an innovative approach to construction that uses bricks made of sustainable materials such as earth that conserve time and cost. Findings The study finds that the prefabrication techniques and interlocking system have a lot of unique attributes that can enable the modern construction sector to flourish. The study summarizes modern construction techniques that can save time and cost, enhancing the sustainability of construction practices, which is the need of the Indian construction industry in particular. Research limitations/implications This study is limited to identifying specific modern construction techniques for time and cost savings, lean concepts and sustainability which are being practiced worldwide. Practical implications Modern formwork systems such as Mivan (Aluminium Formwork) have been reported for their minimum construction time which leads to faster construction than traditional formwork. Social implications The need for housing is growing rapidly all over the world, but traditional construction cannot cater to the need due to insufficient time. There should be some paradigm shift in the construction industry to supply housing to society. Originality/value This study is unique in identifying specific modern construction techniques for time and cost savings, lean concepts and sustainability which are being practiced worldwide.

Applicability of the Modified Nurse-Saul (MNS) maturity function for estimating the effect of temperature on the compressive strength of GGBS concretes

The non-destructive real-time evaluation of compressive strength of concrete is of significant interest to the concrete industry as it can serve as a decision tool for performing critical operations on site. Maturity methods have traditionally been employed for such purpose; however, conventional maturity approaches encompass certain deficiencies. The Modified Nurse-Saul function is an improved maturity function for estimating the compressive strength development of concrete under non-isothermal curing histories. The function relies on a relationship between concrete compressive strength and the Nurse-Saul maturity index and makes use of: (a) an “acceleration” factor and (b) a “temperature efficiency” factor. The method has been previously validated under isothermal and non-isothermal conditions for neat Portland cement concrete mixes. It is however important to assess the applicability of the Modified Nurse-Saul function for concretes with varying levels of GGBS which are known to be more temperature sensitive when compared to Portland cement concretes. The procedures needed to determine the inputs for the Modified Nurse-Saul function for estimating the compressive strength of concrete under isothermal and non-isothermal (adiabatic) conditions are described herein. The predictions/estimates of compressive strength of GGBS concrete were shown to be significantly more accurate than those from the Nurse-Saul and Arrhenius maturity functions, which are the most frequently employed maturity functions in construction despite their known deficiencies/inaccuracies. The Modified Nurse-Saul function encompasses high potential for being used reliably to optimise construction processes relying on real-time strength development evaluation, such as precast concrete and fast-track construction applications.

Modified BIM Processes Considering Safety–Quality Index for Precast Concrete Construction

Precast concrete construction (PCC) is one of the most innovative and efficient methods in construction, but the separate processes involved in this method are one of its disadvantages. Therefore, the project owners considered quality management of PCC based on the Building information modelling (BIM) technique as a key factor to achieving desired tolerances, combining the separated process, and decreasing errors. This study was conducted to modify BIM processes based on dimensionless indices of PCC. The Fuzzy-decision-making trial and evaluation laboratory (DEMATEL) method was used to obtain the weight of variables. Genetic expression programming (GEP) was then used to estimate the modified BIM index (IMBIM) in the PCC according to other important indicators as input data. The statistical results comparing the predicted and calculated values of IMBIM show that there is a low root-mean-square-error (RMSE) of 0.027, low MAE of 0.019, and high R2 of 0.95 in the testing process. Thus, there is good agreement between the relationship of IMBIM and the calculated values that the proposed algorithm in this study can predict IMBIM with high accuracy. The sensitivity analysis illustrates that the index of system quality (Isq) has the most significant effect on IMBIM in comparison with other indices.

Comparative Analysis of Precast Construction and Conventional Construction of Small-scale Concrete Building in Terms of Cost

Abstract: Building a house is one of the basic needs of humans. To build a house with high durability and low cost, engineer A.N.S. Kulasinghe introduced the pre-cast concrete technology in late 1940’s. According to past studies, National Engineering Research and Development (NERD) Centre precast items are used in housing and other constructions and those details were collected by literature review. Objective of this study is updating the cost effectiveness of pre-cast concrete construction of a small-scale building. Data were collected from the NERD Centre and few pre-stressed concrete yards during the months of June to July 2019 by using face-to-face interviews. After the analysis of obtained data, it was found that there were differences between the costs of items among pre-cast concrete technology and conventional concrete construction technology. Overall cost comparison was done to single story building and two story building separately using cost rates of conventional method and pre-cast method. The outcome of the analysis revealed that, 30% - 38% of cost effectiveness can be obtained using pre-cast methods for single story building and using those methods for two story building, 29% - 32% of cost effectiveness can be gained.

Synergistic Effect and Mechanism of Nano-C-S-H Seed and Calcium Sulfoaluminate Cement on the Early Mechanical Properties of Portland Cement.

The combined utilization of mineral accelerators and nano-seeding materials is a novel method to promote the early strength of cement-based materials. In this paper, the effects of nano-C-S-H seed (NCS) on the early compressive strength of the Portland cement (PC)- calcium sulfoaluminate cement (CSA) binder were investigated. The results showed that NCS and CSA synergistically contributed to the early strength of PC. In detail, a 326.3% increase in the 10 h compressive strength of PC paste was obtained through the addition of NCS (2 wt%) and CSA (5%) in common. This was higher than the sum of the increases observed with the single additions of CSA (157.9%) or NCS (87.6%), with the same above dosage, in PC. Meanwhile, the early strength enhancement effects of NCS and CSA, when used together in PC, lasted longer than the effects of either used alone. Moreover, the synergetic effect mechanism was analyzed by isothermal calorimeter, QXRD, TGA, MIP, and SEM techniques. The calorimetry, XRD, and TGA results demonstrated that the synergistic mechanism was associated with the synergistic promotion effects of CSA and NCS on the hydrates. The fast hydration of CSA produced large amounts of ettringite and also consumed partial free water to promote the performance of the seeding effect of NCS which, simultaneously, further accelerated the precipitation of C-S-H gel and CH. The high alkie environment was also beneficial for the continuous generation of ettringite. In addition, the results of MIP and SEM measurements showed that the micro-filling effect of NCS significantly optimized the pore structure of a PC-CSA blend-hardened paste. Thus, the synergistic strength enhancement effects of CSA and NCS on PC were attributed to the matching of the promotion of hydration generation and the optimization of pore structures in hardening cement paste. The results of this article provide a new approach to achieving the rapid development of the early strength of cementitious materials, with potential applications in precast concrete and low-temperature construction.

Assessment of Musculoskeletal Pain and Physical Demands Using a Wearable Smartwatch Heart Monitor among Precast Concrete Construction Workers: A Field Case Study

This study aimed to quantify musculoskeletal symptoms/pain and characterize the physical demands at work and outside of work among precast concrete workers. Direct heart rate (HR) measurements and self-reported activity levels were used to estimate the physical demands. A total of 27 precast construction workers participated in a survey, and 21 wore a HR monitor smart watch for seven days. The HR data were parsed in minutes associated with occupational and nonoccupational physical activity. Correlation analysis and multivariate regression models were conducted to assess the associations between direct measured physical activity with self-reported physical activity, body mass index (BMI), years of work, smoking, and Borg ratings of perceived exertion (RPE). Approximately half of the participants experienced musculoskeletal symptoms in the last seven days and moderate functional limitations in carrying out activities of daily living (ADLs). The regression model revealed a positive relationship between direct measured moderate occupational physical activity (OPA) and the Borg RPE. Furthermore, an inverse association was found with BMI, smoking status, and years of work. The workers accrued a median of 415 min of moderate OPA per week. The findings showed a high amount of moderate OPA minutes per week and musculoskeletal issues among the precast concrete workers.

Fillet welding of skewed reinforcing steel to steel plate

Connecting or anchoring reinforcing steel to structural steel plate or shapes using fillet welds is a common detail in precast concrete construction. However, there is currently no guidance on the effects of skewing the reinforcing bar with respect to the plate. This paper reports findings from a study of the effects of a skewed reinforcing bar on both the effective weld area and the overall connection strength. Thirty-two samples of reinforcing bars welded to steel plates at various skew angles were fabricated and tested in tension to failure. These results were compared with an analysis based on the instantaneous center of rotation method presented in the American Welding Society’s Structural Welding Code—Steel (AWS D1.1-20). Recommendations are presented to revise the Structural Welding Code—Reinforcing Bars (AWS D1.4) to account for the effect of skewed reinforcing bars welded to structural steel plate or shapes.

The new ACI code for the design of GFRP reinforced concrete

The American Concrete Institute has published ACI 440.11-22, Building Code Requirements for Structural Concrete Reinforced with Glass Fiber-Reinforced Polymer (GFRP) Bars—Code and Commentary. This new code was developed by an American National Standards Institute–approved consensus process and addresses structural systems, members, and connections, including cast-in-place, precast, nonprestressed, and composite concrete construction. ACI 440.11-22 is the first comprehensive building code covering the use of nonmetallic, GFRP reinforcing bars in structural concrete applications. This article provides background on this new code and discusses potential uses for precast concrete components and structures.

Effects of Tuff Powder on the Hydration Properties of Cement-Based Materials under High Temperature

In some instances, traditional mineral admixtures, such as fly ash and slag, have been insufficient, and tuff powder (TP) has been used as an alternate replacement. However, the mechanisms of the hydration of tuff powder have rarely been studied, which has restricted its application; therefore, this paper studied the hydration mechanisms of a cement–TP composite under different temperatures. In this study, the influence of TP on the hydration properties of cement-based materials under different curing temperatures was investigated by a compressive strength test, X-ray diffraction (XRD), and thermogravimetric and differential thermal analysis (TG–DTA). Our results showed that a high curing temperature effectively promoted the hydration of Portland cement and the pozzolanic reaction degree of TP and improved the mechanical and microstructural properties of cement-based materials. The high temperature was most conducive to the early development of strength. Additionally, different water-to-binder ratios showed different effects on the contribution coefficients of high curing temperatures. The effects of a high temperature on the pozzolanic reaction of TP may lead to greater Ca(OH)2 consumption during hydration. This research provides a new way to improve the reaction activity of TP and lays a theoretical foundation for applying TP to precast concrete products, mass concrete, or concrete construction in hot seasons.

Bayonne Bridge, USA: raising the roadway

The Port Authority of New York and New Jersey's Bayonne Bridge crosses the entrance to the ports of Newark and Elizabeth, NJ, USA. The longest steel truss arch span in the world when it opened in 1931, the bridge was designed by Othmar Ammann. To maintain the economic vitality of the ports, the original 46 m navigational clearance needed to be raised to 65.5 m in order to accommodate mega container ships passing through the newly widened Panama Canal. Precast concrete segmental construction was used along with an innovative staged construction approach to avoid long-term bridge closures and to expedite the construction schedule. The new navigational clearance was attained in 2017 and project completion occurred in mid-2019.