Conveyor Gallries - MM

ECCD – EDRC (MMH - IC )
Precast Concrete Stock
Pile Drain
Objective:
To Study:
1. The general construction practice & procedure adopted for

precast concrete construction
2. The feasibility of precast elements in BMH projects .
To Propose:
Precast concrete elements for stock pile drain construction

Introduction:
Definition: “Precast concrete” is a concrete which has been

prepared for casting, cast & cured in a location which is not its
final destination.
Advantages of Pre-cast concrete:
As it is manufactured off site or at a Facility

a) Are usually in correct size.
b) Saves a lot of time at site.
c) Increased quality of finished work.
d) Saves a lot of space at site; as pre-cast concrete is
usually bought to site when required.
e) Saves money in terms of labour at site, construction
materials at site etc.
Disadvantages of Pre-cast concrete:
a) Lacks design and dimensional flexibility as the

manufacturers may have only fixed shapes and sizes for
moulds.
b) May affect the construction programme as the delivery on
site may not always be on time.
c) May incur addition financial costs due to transportation.
d) Allows for a very small margin for error as the incorrect
dimensions of pre-cast concrete may result in changing
the entire design.
Cost of Precast Concrete Elements:

There are several factors that affect the final cost:
Designers should account following factors

a) Element repetition
b) Size/weight of elements
c) Geometrical shape of element
d) The desired quality of the precast elements
e) The amount of lead-time the precaster has before the
construction start
f) The distance from the precast plant to the building
site
g) Dimensions of the elements.
APPLICATION OF PRECAST CONCRETE:
Building Tunnel Box Culvert
Bridge Retaining Wall Drain

PRECAST CONCRETE MATERIAL

The constituent materials of concrete such as cement,
aggregates, admixtures & steel reinforcement should
satisfy the durability, structural performance and safety
requirements, taking into consideration the environment to
which it will be subjected to.

1. Cement CONTD...
The common types of cement used in concreting

include:
a) Ordinary Portland Cement
b) Sulphate-Resisting Portland Cement
c) Low Heat Portland Cement
Cement selection factors:

 Concrete exposure conditions, whether and special
requirements .
 High alumina cement should not be used as it may
cause substantial loss in concrete strength and durablity
in warm, humid conditions.

CONTD...
2. Aggregates:
Aggregates can be grouped into fine, coarse and

Lightweight categories.
Most commonly used Aggregates :
1. 20mm Size – suitable for beam, column

2. 10mm Size – suitable for closely reinforced
elements.
PRECAST CONCRETE MATERIAL CONTD...

3.Admixtures:
Admixtures selected should have following properties
- should not impair the concrete durability
- should not increase the corrosion of reinforcement.
Admixtures Used
Superplasticisers - Increase the workability
water reducing agents- Reducing the water content in concrete mix
Accelerators - To accelerate the rate of early strength
development
4. Reinforcement:
- Fe 415, Fe 500
- welded wire fabric
Sealant:
Sealant should have following properties to be used in
Precast concrete:
a) Seal the joints between precast elements.
b) It should bond firmly to the concrete.
c) Accommodate panel movements without splitting,
tearing or loss of adhesion.
d) It must be resistant to ultra-violet (UV) light and
other weathering effects.
e) Joints that are subject to frequent and rapid
movement require an elastic sealant.
f) Joints in massive components with high thermal
inertia, should be with an elastoplastic, plastoelastic
or a plastic sealant.
-Polysulphide, Polyurethane and Silicone
Mould Design:
Types of materials used:
 Steel
 Timber/Plywood
 Glass reinforcement concrete
Factors influencing the selection of mould

 Number of usage
 Required Surface finish type
 Quality as well as the Shape complexity
Steel moulds are used in common due to following advantages

 Mould can be re-used 50-100 times.
 It gives good surface finish
Beam & Column Drain
Steel Mould
CASTING
Casting Sequence:
•Arrange the form work as per required size & shape.
•Apply oil in formwork surface to avoid the bonding
between formwork and concrete.
•Place the reinforcement cage with required cover.
•Position of insert plate & pipes if required, before
pouring the concrete.
•Pour the concrete in formwork.
•Demould the form work after required time.
CASTING
.
Precast Drain
Curing of Precast Concrete Elements:

Three types of curing is there
Curing Tank Sprinkler Gunny bags

type
Joints and Connection:

Joints and connections must be adequate:
 To transfer the load from precast concrete elements to the

supporting structure or to an adjacent element to form the
structure.
 To meet the design and performance criteria such as strength,
ductility, fire resistance, durability and stability.
The following items should be considered in the design
 Standardise the joints and connection type and details.

 Avoid congestion at joints
 Allow for production and erection tolerances
 Plan for easy assembly and accessibility
Joints and Connection:
Connection Detail Of Precast Drain

Element
Delivery:
Following factors to be considered:
 Planned according to the general erection to minimise

unnecessary site storage and handling.
 It is desirable to transport the precast elements in a manner, it
can be lifted directly for erection or storage without much
change in orientation and sequence.
 To be loaded and delivered with proper supports, frames,
cushioning and tie-downs to prevent in-transit damage.
 Adequate packing or protection to the edges of precast
elements should also be provided to minimise risk of damages
during transit.
Delivery:
Protection measures such as the use of cushion

packing
Lifting & Handling Devices:

 To facilitate the remolding, handling and erection processes
lifting and handling devices are required and placed within the
elements.
 Type, number and location of these temporary lifting and
handling devices play an important role,
 Ensure that the precast elements are not excessively stressed
during lifting operation and before jointing works commenced.
The factors to be considered are as follows.

 Capacity of the lifting and handling devices
 Weight and shape of the precast elements
 Strength of the concrete at the time of lifting
 Position of the opening or cut-out in the precast elements
 Rigging arrangement
 Type of lifting clutch, hook used for handling and installation.
Lifting & Handling Devices:
Different types of devices for lifting operation

and temporary Support
Handling :
Precast Slab Precast Beam
General Hoisting method for Slab & Beam

Storage:
The storage area provided in the yard and job site should be
adequate:
 To permit easy access and handling of the precast elements.
 The area should be relatively level, firm
 It should well drained to avoid any differential ground
settlements which may damage the stored elements.
Precast Slab Precast Drain Precast Wall panels
Stacking method of Precast Elements

Installation:
Proper planning and preparatory works are required before the

actual erection of precast concrete elements to ensure efficient
and quality installation. The following items should be carefully
planned.
 Method and sequence of assembly and erection
 Method of providing temporary supports
 Provision for final structural connections and joint details
 Erection tolerances
 Handling and rigging requirements
Case Study : NLC – Thermal Power

Plant at Tuticorin
Construction of Stock Pile drain by precast concrete:
Project : NLC – Thermal power project at Tuticorin
Structure : Stock Pile Drain
Length : 4000m
Precast Drain Element

NLC Plant Layout: On-Shore
JT12
/B
6A
NV
CO
JT13
CONV 12
A/B
JT14
JT10
JT15 JT 9
JT16 JT21 CONV 23
A/B
CONV
10A/B
SCR
JT20 CONV 23 JT 8 CH
A/B JT 7
JT17
SCR
CONV
8A/B
4 Hoppers JT18
Stock Pile Drain in NLC-Thermal Power Project

Planning the Precast Drain

Section Details
P1
PT1 to PT5
Dimension Details
SL. NO. DRAIN MKD W (mm) D (mm)
1 P1 350 450
2 PT1 350 450
3 PT2 350 550
4 PT3 350 650
5 PT4 350 750
6 PT5 350 870
Typical Arrangement - Precast Drain

Connection Detail
Base Slab Connection Details

Connection Detail
Side Wall Connection Details

Installation Procedure:
a) With reference to the drawing co-ordinates, excavation
should be made with proper slope, working space and
required depth as stated in the excavation drawing.
b) Proper line marking should be done and 75mm/100mm
P.C.C/ 50mm-100mm sand should be laid all around as per
NIT specification.
c) Each element should be numbered properly based on
depth and orientation to be aligned. Lifting should be done
based on their numberings.
d) Each precast drain elements has four hooks. There precast
drain elements are lifted using suitable capacity cranes and
placed over the markings.
Installation Procedure:
a) Hooks capacity should be properly calculated using self-

weight of the precast element and erection load.
b) While placing the elements, to avoid edge distortion,
proper grouting should be provided.
c) Water sealants should be provided on the inner side of the
precast elements at joints.
d) All the elements are placed using above mentioned
procedure. Then screed concrete is laid to obtain the
required slope for whole length.
e) Backfilling should be done properly without disturbing the
position of already placed precast elements.
Conclusion:
a) One of the most obvious benefits of utilizing precast drain
elements is the dramatically shortened construction time.
(Approximately not less than 50%)
b) Moulds are repeatedly used in this construction, so the
cost of mould & labour for shuttering work is saved.
c) Before erection of precast drain, the element parameters
has to be fully inspected & should be checked, so the that
quality of precast will be better than cast-in-situ type
construction.
d) There are some design limitations associated with the use
of precast elements because of the size limitations
connected with the transportation and handling of them.
e) Precast concrete construction requires skilled labour for
the connection of precast element.
PRECAST - SCOPE FOR DEVELOPMENT
• Cable Gallery Foundation
• Stacker cum Reclaimer
• Self-Compacting Concrete
• Accelerated curing
Thanking You

Conveyor Gallries - MM

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Conveyor Gallries - MM

Uploaded by

Copyright:

Available Formats

ECCD – EDRC (MMH - IC )

Precast Concrete Stock

1. The general construction practice & procedure adopted for

2. The feasibility of precast elements in BMH projects .

Precast concrete elements for stock pile drain construction

Definition: “Precast concrete” is a concrete which has been

Advantages of Pre-cast concrete:

As it is manufactured off site or at a Facility

Disadvantages of Pre-cast concrete:

a) Lacks design and dimensional flexibility as the

Cost of Precast Concrete Elements:

Designers should account following factors

APPLICATION OF PRECAST CONCRETE:

Building Tunnel Box Culvert

Bridge Retaining Wall Drain

PRECAST CONCRETE MATERIAL

PRECAST CONCRETE MATERIAL

The common types of cement used in concreting

Cement selection factors:

PRECAST CONCRETE MATERIAL

Aggregates can be grouped into fine, coarse and

Most commonly used Aggregates :

1. 20mm Size – suitable for beam, column

PRECAST CONCRETE MATERIAL CONTD...

Factors influencing the selection of mould

Steel moulds are used in common due to following advantages

Beam & Column Drain

Curing of Precast Concrete Elements:

Curing Tank Sprinkler Gunny bags

Joints and Connection:

 To transfer the load from precast concrete elements to the

The following items should be considered in the design

 Standardise the joints and connection type and details.

Joints and Connection:

Connection Detail Of Precast Drain

Following factors to be considered:

 Planned according to the general erection to minimise

Protection measures such as the use of cushion

Lifting & Handling Devices:

The factors to be considered are as follows.

Lifting & Handling Devices:

Different types of devices for lifting operation

General Hoisting method for Slab & Beam

Precast Slab Precast Drain Precast Wall panels

Stacking method of Precast Elements

Proper planning and preparatory works are required before the

Case Study : NLC – Thermal Power

Construction of Stock Pile drain by precast concrete:

Project : NLC – Thermal power project at Tuticorin

Structure : Stock Pile Drain

Precast Drain Element

Stock Pile Drain in NLC-Thermal Power Project

Planning the Precast Drain

Typical Arrangement - Precast Drain

Base Slab Connection Details

Side Wall Connection Details

a) Hooks capacity should be properly calculated using self-

You might also like