CONSTRUCTION

TECHNOLOGY
UNIT 2 CONSTRUCTION PRACTICE
MANUFACTURING OF PRECAST COMPONENT FORMS

DESIGNING:
Before fabrication drawings of individual elements to be prepared
and detailed with the following instructions:
1.Project location and reference number of elements, and their locations with
respect to the building layout and elevation.
2.Dimentions of elements, centre of gravity, weight and concrete volume.
3.Locations of all reinforcing steel, cast in items for connection, lifting, and bracing.
4.Locations of embedded items such as service conduits, block outs, and recesses as
well as openings.
5.Jointing and interfacing details between elements.
6.Watertightness details at joints.
7.Architectural details and treatments where applicable.
8. Development of concrete strength for initial lifting from the moulds, and
handling at different stages including on site and during transport
MANUFACTURING OF PRECAST COMPONENT FORMS

NORMAL CASTING PROCESS FOR PRECAST REINFORCED OR PRESTRESSED

CONCRETE ELEMENTS:
FABRICATION PROCESS:
Assembly of mould:
1.Check the level and flatness of the base mould before assembling the mould for
panel casting.
2.Ensure that the dimention of the mould are within the specified tolerence.
3.Check the squareness of the mould forms.
MANUFACTURING OF PRECAST COMPONENT FORMS

MOULD FRICTION OR SUCTION;

Friction or suction to the mould can significantly increase the force
required to lift or release the element from the mould. Care should be taken to
ensure this does not overload lifting devices or inserts or exceed the concrete
strength at the time of lifting. Vibration of moulds, or lifting from one corner to
break suction gradually can sometimes reduce the lifting force required. Proper
application of a suitable release agent prior to casting will assist the demoulding
process. Pre-tensioned elements slide in their mould when the prestress is released
which can cause them to wedge in the mould. If excessive forces are required for
the initial release from the mould, the possibility and effects of sudden release need
to be considered. The sudden release of strain energy can cause high impact loads
and unpredictable sudden movements. Particular care should be taken if the lifting
force applied exceeds the weight of the precast element by more than 10%.
TILTING MOULDS AND VERTICAL MOULDS:
Thin, lightly reinforced panels are often cast in
vertical moulds, or in horizontal moulds that are tilted to vertical before the panel is
lifted. Panels cast in this way should be stored, transported and handled near
vertical at all times. If laid flat, these panels could be damaged by their self weight
alone.
General hoisting method for columns