PREFABRICATED CONCRETE

Prefabrication
It is a construction industry term used to describe assemblies that are manufactured
under factory conditions and then transported to construction sites for
incorporation into building and civil engineering works.
Generally, there are two main types of pre cast concrete elements, mainly precast
reinforced concrete elements and precast prestressed concrete elements

Normal casting process for precast reinforced or prestressed concrete elements

Fabrication process
1. Assembly of mould

Good practices
Check the level and flatness of the
base mould before assembling the
mould for panel casting.
Ensure that the dimensions of
mould are within the specified
tolerances.

Check the squareness of the mould

form.

2. Mould cleaning and

preparation

The mould should be clean and

free from debris and old mortars
using remover or scaling bars.
Form oil or mould release agent
should be applied evenly over the
mould surface.

 Check that the joints and edges of

the mould, bolts, stoppers, tie rods,
side props and rubber seal are
intact and properly secured.

3. Fixing of rebars/ cast in items/

prestressing strands

Check that the rebar size, spacing

and lap length are in accordance
with the drawings.

 Rebars, cast in items, corrugated

sleeve pipes, recesses, lifting
hooks and inserts must be
correctly positioned and properly
secured.

 Use of fabrication rig can help to

ensure the accuracy of rebars
fixing and spacing.

Sufficient number of spacers with

the correct sizes should be
properly placed and secured to
achieve the required concrete
cover during casting.

4. Final inspection before casting

Check and verify that all details

comply with drawings.

 Check the mould fitting conditions

including blockout details.

5. Concreting

Conduct slum test in compliance

with SS 78 to assess the
workability of the concrete mix
before placing the concrete to the
mould.

 The drop height of concrete mix

should not exceed more than 1m.
Proper vibration and compaction
should be carried out in particular,
in more congestion areas.

Spreading and leveling of concrete

surface level after initial set.

Use of power trowel/ float is

recommended for smooth surface
finishes.

6. Curing

Observe adequate curing time and

desired environment.
Concrete cubes should be
subjected to the same curing
conditions as the precast concrete
element.

7. Demoulding

Cube tests should be conducted to

verify the concrete strength of
elements before demoulding.
Loosen and remove all bolts and
pins and end and side mould forms
before lifting.
For prestressed elements, cut
strands before lifting.

8. Final inspection / transfer to

storage yard

Finishing works before delivery to

site

Check the condition of the

finished product

Application of prefabricated concrete as foundation component in buildingsPrecast concrete systems can be used to rapidly construct foundations. The
elements are usually to a bespoke design and cast in a factory environment, giving
assured quality for the finished product. The foundations are often supported by
concrete piles and connected together.
These systems improve productivity, especially in adverse weather conditions, and
reduces the amount of excavation required - particularly advantageous when
dealing with contaminated ground.
1. Precast Abutment
The precast concrete abutment is an L-shaped shallow foundation component,
much like a conventional bridge beam seat. Sections are produced in 3-9
sections and butt-jointed together to form longer abutments. They are designed
for lateral earth pressure against one side and for the load transferred from the
beam and tread combination from the first span.This abutment component will
rest on a bed of compacted stone or an unreinforced cast in place pad (aka "mud
mat") so that load can be transferred uniformly to the in situ soil. These

abutments contain a horizontal reveal positioned to receive the first groove on

the adjacent tread. The beam seat of the abutment has a semi-circle shaped
valley for proper seating of the precast beams.
Shallow foundation component

2. Precast concrete pier system

Precast piers are advantageous to engineers and designers for many reasons.
First, these relatively-light components are easily handled in the field by
laborers or small lifting equipment. Taller piers are achieved by adding risers to
the precast pier. Typically 42'' is a maximum total height for a precast pier.
Second, precast piers allow for fewer disturbances to the sub grade and
surrounding areas than driving deep foundations.
Shallow footing option
Most cost-effective
Stackable components consisting of base, riser(s), and cap
Can stack additional risers up to 3.5' in height above grade before additional
bracing is required.

3. Cast in-place Concrete Shallow Footings

Cast-in-place concrete shallow footings are typically circular or square, and
commonly formed with a Sonotube form. The Sonotube (or equal product) acts
as a stay-in-place form. The advantages associated with concrete piles
(durability & longevity) are realized with this method. Once constructed, the
precast caps are then attached to the top of the pier with a steel dowel and
epoxy connection, allowing proper alignment of the beams via the pin
connectors.
Shallow footing option
Typically more cost-effective than a deep foundation option
Circular or square

Precast foundation walls simplify basement construction, save time and money,
and result in warmer, drier basements. The walls comprise high-strength concrete
panels manufactured off site. Each panel contains solid concrete studs for loadbearing support and a built-in concrete footing. Some panels include rigid
insulation to keep the basement warmer and rebar and polypropylene fibers for
strength. Walls can be customized by project to allow for door and window
openings, steel-beam pockets and brick ledges. Manufacturers offer other
convenience features such as built-in access for wiring and plumbing and wood or
steel nailers for easy drywall installation. Panels range in size from 2 to 12 feet
wide by 8 to 12 feet high to accommodate a variety of basement configurations.
The cost of precast concrete systems is competitive with the cost of other
foundation walls. A precast concrete foundation is best-used to construct a full
basement with consistent sill height; different wall heights slow the process,
minimizing the cost benefit. Installers who aren't familiar with precast concrete
panel assembly will need additional training. Some manufacturers allow only
certified installers to deliver and erect their systems.
Other features and benefits of precast foundation walls include:
Time and labor savings. A typical precast concrete foundation can be
erected in four to five hours, about a sixth of the time needed for a formedconcrete wall. The panels can be erected in cold temperatures, which means
weather delays aren't an issue. And there's no on-site curing timethe walls
can be backfilled as soon as the slab and first-floor joists are in place.
Stronger, lighter, safer walls. Precast concrete panels are manufactured in
temperature-controlled environments, which enables manufacturers to
produce concrete mixes that harden to 5,000 psi. This is stronger than the
2,500-psi concrete in standard poured walls and stronger than concrete
block, yet the precast panels are thinner and of lighter weight. Precast panel
systems also are more resistant to fire, termites, dry rot, and tornado and
hurricane damage than other foundation types.
Better indoor comfort. Because many precast concrete panels are formed
with integral rigid insulation, little or no additional insulation is needed to
achieve a warm basement. Precast panels also are low-maintenance and have
better soundproofing characteristics than other foundation types.
Water-resistant construction. The high-strength, low-water concrete mix
used for precast panels is denser than typical concrete, making it more

water-resistant. This helps keep basements dry without additional

waterproofing. In regions with high rainfall, however, local building codes
may require additional waterproofing.

Ten times stronger than block foundation.

It prevents water infiltration and moisture built up.
They keep houses warmer and drier than conventional foundations while
adding valuable living spaces and increasing resale value.
To enhance strength and durability, they are manufactured with steel
reinforced concrete studs, rigid insulation, a reinforced top and bottom bond
beam with a 2 inch thick concrete facing.
Foundations can often be installed in under five hours using a precast
concrete system.

Manufacturing process

Benefits of Precast Building Components

- Consistency quality through stringent quality control in manufacturing process
- Improve buildability
- Improve construction speed & shorter cycle time
- Safer & more organized construction site environment
- Reduce wastage of materials
- Less labour intensive