PRECAST COMPONENTS

Faculty: Prof.Reshma Shah

T.A: Rohan Rajput

By:Tirth Ramoliya
UCT21145
 Identify Common Materials For Precast Concrete Moulds

Precast Concrete Moulds Are Made From Steel, Aluminium,

Fiberglass, Plastic (ABS), Rubber, Timber, And Mild Steel, Each
Types of Materials Used for Offering Unique Properties For Different Uses.

Precast Concrete Moulds

Understand The Factors Influencing Material Selection

Choosing The Right Mould Material Depends On Factors Like

Durability, Flexibility, Surface Finish Quality, And Production
Volume Requirements.
ABS PLASTIC PROPERTIES

The Versatility of ABS Plastic Moulds

Acrylonitrile Butadiene Styrene (ABS) plastic is a cornerstone material i precast
concrete mould fabrication due to its excellent balance of properties. It offers a
unique combination of strength, durability, and lightweight characteristics, making it
highly practical for both mould handling and long-term use in demanding industrial
environments. n

• Strength & Lightweight: ABS is remarkably strong, resisting impact and wear, yet
remains lightweight, simplifying mould transportation and setup. ABS Plastic Moulds
• Fast Production: The material's thermoplastic nature allows for rapid
manufacturing processes, making ABS moulds ideal for bulk orders and high-
volume production cycles.
• Chemical Resistance: ABS exhibits good resistance to the chemicals present in
concrete, ensuring a longer lifespan for the moulds and consistent performance.
FLEXIBILITY AND SHORE HARDNESS

Rubber Moulds: Precision and Protection

Rubber moulds are invaluable in precast concrete manufacturing, especially when dealing with intricate designs or delicate elements. Their primary
advantage lies in their exceptional flexibility, which significantly reduces the risk of damage during the demoulding process—a common challenge
with more rigid mould materials.

• Adaptive Flexibility: Rubber's inherent elasticity allows it to conform to

complex shapes and undercuts, ensuring a precise cast every time.

• Damage Reduction: The flexibility facilitates safe demoulding, minimizing

chips, cracks, or surface imperfections on the finished concrete product.

• Shore Hardness Customization: Rubber moulds are available in various Rubber Moulds
shore hardness levels (e.g., Shore A, Shore D), which can be customized to
specific project requirements. A softer shore hardness is ideal for highly
detailed or delicate pieces, while a harder shore hardness offers greater
durability for simpler, higher-volume casts.

• This adaptability makes rubber moulds perfectly suited for projects demanding complex or flexible moulding,
providing a safe and effective method for producing high-quality precast concrete elements with intricate
Rubber Moulds
details.
VERSATILITY AND ELASTICITY

Timber Moulds: Traditional Strength and

Adaptability
Timber, a time-honored material in construction, continues to be a versatile choice for precast concrete moulds. Its
adaptability makes it suitable for a wide array of projects, from custom, one-off designs to larger, repetitive tasks.

• Toughness and Elasticity: Timber possesses natural toughness, strength, and elasticity. This allows it to absorb
impacts and return to its original shape after use, contributing to its durability and resilience for multiple casting
cycles.
• Weight Selection: The choice of timber weight is crucial. Heavy timbers, such as hardwoods, provide
exceptional strength and stability for robust moulds that endure significant pressure. Lighter timbers, like
softwoods, are easier to handle and cut, making them ideal for custom or intricate designs where frequent
modifications are needed.
• Shape Retention: Despite its natural flexibility, timber's elasticity ensures that moulds maintain their precise
dimensions and structural integrity, crucial for consistent concrete element production.
Timber moulds are particularly valuable for their ability to be easily modified or customized on-site, offering a cost-effective solution for diverse moulding
requirements across various project scales.
STRENGTH AND DURABILITY

Steel Moulds: Engineered for Industrial Scale

Steel moulds represent the pinnacle of strength and durability in precast concrete manufacturing, specifically engineered for large-scale industrial
projects. Their robust construction ensures exceptional longevity and consistent performance, making them an indispensable asset for high-volume
concrete production.

• Exceptional Strength: Steel moulds are designed to withstand the immense

pressures exerted by wet concrete during casting and the subsequent curing
processes, maintaining their precise shape without deformation.

• Long Service Life: Their inherent resistance to wear, tear, and corrosion—
especially with proper maintenance and surface treatments—guarantees a
prolonged operational life, reducing the need for frequent replacements.

• Mass Production: The stability and rigidity of steel moulds enable highly
efficient mass manufacturing. They are ideal for producing a large number of
identical, high-quality precast elements with minimal deviation.
MILD STEEL CONCRETE MOULDS

The Practical Choice: Mild Steel Moulds

Mild steel moulds are a popular and practical choice in precast concrete production, balancing durability with affordability. Their fabrication from low-carbon
steel makes them highly malleable, allowing for efficient shaping into a wide variety of forms while maintaining robust structural integrity.

Cost-Effective Durable Versatile Forming

Mild steel is more economical than high-grade With proper reinforcement, mild steel moulds Used to shape a broad range of precast
steel, making it ideal for budget-conscious can endure significant casting stresses and components, including beams, columns, slabs,
projects. repeated use. and custom architectural elements.

The malleability of mild steel facilitates easier and quicker fabrication compared to other metals, reducing manufacturing lead times. Reinforcement, often
through welding additional steel profiles, is crucial to enhance their longevity and ensure they withstand the internal pressures of concrete pouring and vibration
without distortion. This combination of attributes makes mild steel moulds an excellent choice for high-volume production environments where both cost-
efficiency and performance are key.
COMMON TYPES OF MOULDS

Overview of Precast Concrete Mould Types

Precast concrete moulds come in various specialized designs, each tailored to produce specific structural elements. Understanding these types is crucial for
optimizing production efficiency and achieving precise architectural and structural requirements.

Panel Moulds For walls, floors, and roofs, allowing for diverse sizes and finishes.

Column Moulds Mainly horizontal casting, featuring movable side platforms for various column dimensions. Vertical moulds are rare and
typically used for round columns.

Beam Moulds System moulds designed for producing multiple beam elements efficiently, often in a continuous process.

Wall Moulds Includes Battery, Vertical Battery, Tilting, and Flat/Table moulds, each offering different casting orientations and efficiencies.

Slab Moulds Variations include prestressed hollow core, prestressed plank, and non-prestressed options for various floor and roof
applications.

Bridge Moulds Highly specialized moulds for casting large, custom bridge components like girders and deck segments.

Custom Moulds Tailored for unique project requirements, offering bespoke solutions for complex or non-standard concrete elements.

Each mould type plays a vital role in the precast concrete ecosystem, enabling manufacturers to meet diverse construction demands with precision and speed.
COMMON TYPES OF MOULDS

Overview of Precast Concrete Mould Types

Panel Moulds Column Moulds Slab Moulds

Bridge Moulds Beam Moulds Staircase Moulds

PANEL MOULDS

Efficiency with Panel Moulds for Walls, Floors, and Roofs

Panel moulds are foundational in precast concrete manufacturing, specifically engineered to produce consistent, high-quality panels for a wide range of structural
applications. Their design facilitates the creation of versatile building components that are critical for modern construction practices.

• Versatile Applications: The panels produced from these moulds are integral to various building elements, serving as robust walls, durable floors, and reliable
roof components. This versatility makes them indispensable for both residential and commercial projects.

• Design Flexibility: Panel moulds are highly adaptable, capable of being tailored to produce panels of varying sizes, thicknesses, and surface finishes. This
customization allows for diverse architectural and structural requirements to be met with precision, from smooth aesthetic finishes to textured, load-bearing
surfaces.
• Rapid & Consistent Production: A key advantage of panel moulds is their ability to enable quick and uniform production. This efficiency translates into faster
construction timelines and ensures that all panels meet stringent quality standards, reducing on-site labor and material waste.
By utilizing panel moulds, manufacturers can significantly enhance productivity and deliver high-performance precast concrete panels that contribute to the structural integrity and aesthetic
appeal of any building.
COLUMN MOULDS

Column Moulds: Precision in Vertical Elements

Column moulds are specialized tools crucial for shaping precast concrete columns, which are fundamental vertical structural elements. Their design focuses on
precision, stability, and ease of demoulding to ensure high-quality finished products.

1 2 3

Horizontal Casting Formwork Components Rare Vertical Moulds

Most column moulds are designed for horizontal A typical column mould includes a robust While less common, vertical moulds for columns
casting. This orientation simplifies the pouring formwork base, a fixed center platform that defines do exist, primarily used for producing specific
process, allows for better compaction of concrete, one side of the column, and movable side shapes like round columns or when site constraints
and often results in a superior surface finish due to platforms. These movable sides allow for easy necessitate vertical pouring. These require
reduced hydrostatic pressure. adjustment of column dimensions and facilitate specialized lifting and handling equipment.
efficient demoulding.

The meticulous design of column moulds ensures that precast columns are produced with precise dimensions, smooth finishes, and consistent structural integrity, essential for
safe and efficient construction.
 BEAM MOULDS

Adjustable System Moulds

Adjust height and width for flexible Use system moulds to cast multiple
beam dimensions. beams, boosting efficiency.

Durable Beam Moulds: Types and Standard Size

Make moulds to standard
Keep moulds durable,
resistant, and easy to clean. Adjustability dimensions for uniform
quality.

Two-Part Mould Types

Use two-part moulds with clamps for Choose plastic or steel moulds for
easy assembly and casting. lightweight or durable beams.
Wall Moulds
Battery Mould
Set of adjacent, braced moulds for
multiple wall panels in minimal
space; supports vertical concreting
Vertical Battery Mould
of panels and floors.
Produces panels with finishes on
both sides; allows high productivity
in small spaces; panels ready for
stockpiling and transportation in
installation position.
Applications
Used for special architectural walls
such as chajja and lift walls,
enabling customized wall panel
production.
 Bridge Moulds
Design custom Staircase moulds are made
Bridge moulds are
specialized for creating moulds to meet upside down; landing slabs and Custom
may be integrated or
bridge decks, girders,
parapets, and other precast
specific project separate, and the staircase Moulds
bridge elements essential in requirements can be tilted after
production or during on-site
infrastructure projects.
installation.

Use bridge Custom moulds enable the

fabrication of unique Fabricate staircase
moulds for precast elements tailored to
moulds with specific
particular project needs,
various precast offering flexibility in production methods
bridge construction design.

components
 Advantages of Using Precast Concrete Moulds
Versatile for structural uses Save time and budget
These moulds suit load-bearing and Using precast concrete moulds cuts costs and
architectural elements, boosting design speeds up projects by avoiding lengthy on-site
flexibility in projects. casting processes.

Focus workforce on key tasks Ensure consistent quality

Shifting casting off-site lets labor Precast moulds create uniform
focus on installation and concrete parts, keeping high standards
finishing, enhancing overall and lowering defects vs. on-site
project value. casting.

Streamline construction schedules Boost productivity by 50%

Precast components enable parallel According to the National Precast Concrete
workflows, reducing delays and Association, precast moulds reduce project
simplifying on-site project management. time by nearly half.
 Disadvantages / Challenges
Manage detailed manufacturing Control joinery, installation, Employ skilled labor for finishing Handle transportation and large
procedures carefully transportation, and curing processes element logistics

Precast moulds require precise and Effective management of joinery Certain finishing tasks demand Transporting and managing large
complex manufacturing steps to details, installation techniques, experienced workers to achieve the precast pieces can be complicated,
ensure quality and consistency in transportation logistics, and curing desired surface quality and accuracy requiring special equipment and
the final concrete elements. methods is essential to maintain in precast elements. careful planning to avoid damage.
structural integrity and
performance.

Invest in high initial mould

fabrication costs
The upfront cost for fabricating
precast moulds is often significant,
impacting budget and project
timelines initially.
Releasing Agents Used
Release agents are applied to the inner surfaces of precast moulds before pouring concrete to prevent sticking, reduce surface defects, and increase mould life.
Common Types of Release Agents:
1.Oil-Based Release Agents
1. Mineral oil or diesel oil blend (traditional, inexpensive but less eco-friendly).
2. Reactive oil-based (react with cement paste to form a thin layer).
2.Water-Based Release Agents
1. Environmentally friendly, easy to apply.
2. Provide a clean, smooth finish.
3.Emulsion-Based Release Agents
1. Mixture of oil and water.
2. Ensure uniform coverage and reduce surface blemishes.
4.Wax-Based Release Agents
1. Durable, good for moulds reused many times.
2. Provide glossy surface finish.
5.Special Chemical Release Agents
1. Contain additives that improve surface finish, minimize air holes, and protect moulds.
Best practice: Select release agent based on mould type (steel, ABS plastic, rubber, etc.) and required surface finish.
Comparison with Conventional Formwork
Aspect Precast Construction Conventional Construction
Speed Faster (factory casting, parallel site work) Slower (on-site casting, curing delays)
Controlled factory environment, uniform Variable quality, depends on site
Quality
quality conditions
Less on-site labor, more skilled factory
Labor More on-site labor, semi-skilled workforce
workers
Higher initial investment, but cost-effective Lower upfront, but higher long-term
Cost
for large projects labor/material cost
Durability High strength, better curing & finish May suffer from inconsistent curing
Safety Safer & less congested sites Higher risks due to more site activities
Flexibility Limited modifications once precast High flexibility for design changes on-site
Procedure
Design
Prepare moulds precisely.

Mix
Formulate strong concrete.

Batching
Measure materials exactly.

Casting
Pour concrete into moulds.

Curing
Harden concrete properly.
 Design and Mould Preparation
Step-by-step process for designing and preparing moulds for precast concrete

Design Precast Elements To Create Reusable Steel Or Fiberglass Ensure Moulds Match Shape And Surface Prepare Moulds With Release

Specifications Moulds Finish Agents And Bracing

Create Detailed Designs That Meet Develop Moulds Made From Verify That The Moulds Accurately Apply Release Agents To Prevent
The Required Dimensions And Durable Materials Like Steel Or Replicate The Desired Shape And Sticking And Add Bracing To
Functional Needs Of The Precast Fiberglass41 That Can Be Used Surface Texture Of The Precast Maintain Mould Stability During
Concrete Elements. Multiple Times For Casting. Elements To Ensure Quality. Casting.
 Concrete Mix Design and
Include essential materials in concrete mix Adjust mix for strength, durability, and Batching
workability
Concrete mix consists of cement, aggregates The concrete mix proportions are tailored to meet Steps 2 & 3: Adjusting and preparing concrete
(sand and gravel), water, and admixtures that specific performance requirements such as mix for optimal performance
modify properties. structural strength, durability, and ease of use.

Ensure consistency through precise Use admixtures to optimize concrete

batching properties
Accurate measuring and mixing in a batching Additives like plasticizers, retarders, and
plant guarantees uniform quality and consistency accelerators enhance workability, control setting
for each batch of concrete. time, and improve overall concrete performance.
 Casting and Curing Processes
Steps 4 & 5: Detailed casting and curing for strong precast concrete

Concrete poured into moulds Use of vibrators to consolidate concrete Curing in controlled environments Proper curing develops strength
and durability
Concrete is poured into moulds Vibrators remove air pockets from Curing takes place in steam chambers Effective curing processes enhance
containing steel bars or mesh concrete to improve density and or water baths to maintain optimal the final strength and durability of
reinforcement to ensure strength. structural integrity. moisture and temperature. precast concrete elements.
 Demoulding and Finishing
Steps 6 & 7: Careful removal and surface treatment of precast elements

Remove precast elements carefully after curing

Ensure the elements are fully cured before gentle demoulding to avoid damage and maintain structural integrity.

Clean and prep moulds for next use

Thoroughly clean moulds after demoulding to remove residues and prepare them for subsequent casting cycles.

Apply finishing treatments to surfaces

Finishing may include surface treatments like polishing and coatings to enhance both aesthetic appeal and functional quality.

Ensure aesthetic and functional quality

Finishing processes help achieve the desired look and performance standards for precast concrete elements.
Time Cycle For Precast Element

Time Cycle For

Precast Element

Curing (accelerated Total cycle time:

Mould preparation + Rebar placement +
Concrete pouring + steam curing): 8–12 Demoulding & typically 24 hours per
cleaning + release embedment setting:
vibration: 1–2 hours. hours (vs. 28 days in finishing: 1–2 hours. element (1
agent: 1–2 hours. 2–3 hours.
conventional). element/day/mould).
 Transportation and Site Installation
Step-by-step process for safely transporting and installing precast elements

Use specialized vehicles for Employ handling equipment for On-site erection with cranes and lifting Plan carefully to ensure safety and
transporting precast elements loading and unloading tools efficiency

Transporting precast concrete Loading and unloading precast Cranes and lifting tools are essential on-site Detailed planning is necessary to
requires specialized vehicles elements involve specific handling to erect precast elements accurately and coordinate transportation and
designed to safely carry heavy and equipment to ensure secure and safely, facilitating proper assembly of the installation activities, minimizing
large elements to the construction efficient movement during these structure. risks and optimizing workflow on-
site without damage. critical stages. site.
Joinery Details

Example of column-to-column connections Example Beam-to-Column Connection

• Metal bearing plates and embedded anchor bolts are • Beams are set on bearing pads on the column
cast into the ends of the columns. corbels.
• After the columns are mechanically joined, the • Steel angles are welded to metal plates cast
connection is grouted to provide full bearing between into the beams and columns and the joint is
elements and protect the metal components from fire and grouted solid
corrosion.
 Joinery Details

Example Slab-to-Beam Connection

Site cast Concrete Toppings over Precast Slabs
• Hollow core slabs are set on bearing pads on precast beams.
• Greater floor strength and stiffness
• Steel reinforcing bars are in inserted into the slab keyways to span
• Greater fire resistance
the joint.
• Greater acoustic isolation
• The joint is grouted solid.
• Allow easy integration of electrical services into floor system
• The slab may remain untopped as shown, or topped with several
• Create a smoother, flatter floor surface
inches of cast in place concrete.
Joinery Details

Examples of floor-to-floor connection

Joinery Details
Floor-to-beam connection

Floor-to-beam connection

Column-to-beam connection
Joinery Details

Staircase connection
On Site Pictures
Equipment Used
Formwork
Batching Rebar
Formwork and moulds shape
Concrete batching plants Rebar machines cut, bend, and concrete elements; release
ensure precise mixing and tie steel bars to required shapes, agents prevent sticking, and
weighing of raw materials, essential for structural support bracing ensures stability during
forming the foundation for in precast elements. casting.
quality precast elements.

Curing
Vibrators
Finishing Curing systems such as steam
Concrete vibrators remove air
Finishing tools like trowels and chambers accelerate concrete
bubbles and compact concrete
grinders smooth and refine hardening, enhancing strength
within moulds, improving
concrete surfaces after casting, and durability in controlled
strength and surface finish of
preparing them for curing. settings.
elements.

Erection
Testing Transport
Site cranes and lifting gear
Quality testing instruments Flatbeds and tilt-bed trucks position and install precast units
verify concrete properties and transport precast elements from safely and accurately during
standards compliance, ensuring the plant to construction sites construction phases.
precast product reliability. efficiently and securely.
Equipment Used
Delivery
Concrete pumps and chutes
transport concrete efficiently
from mixers to moulds,
ensuring continuous flow and
reducing delays.

Handling
Cranes and forklifts move
heavy precast components
safely within the plant and for
loading onto transport vehicles.
Precast Concrete Components in India
Types of Precast Concrete Components
Precast concrete products in India include structurally and architecturally relevant components, such as:
•Beam, columns, slabs, and wall panels designed for residential, commercial, and infrastructure use
•Boundary walls, lintel beams, earth pit chambers for site development and utilities
•Manholes, RCC pipes, U-drains, trenches, and cable covers for drainage and underground infrastructure
•Paver blocks, kerbstones, and retaining wall blocks for landscaping, traffic management, and soil support
•Staircases, facades, and partition walls for customized architectural needs
•Specialized components like street light pole foundations, weight blocks for solar panels, noise barrier elements, and prestressed slabs for roads and
pavements
Precast Concrete Components in India

Precast Cladding Wall Precast Wall Precast Trenches

Precast Columns Precast Toilet Pods Precast Beams

Precast Concrete Components in India

Precast Water Tanks Precast 90mm walls

Precast Boundary Walls Precast Slabs

Applications of Precast Concrete in Indian
Infrastructure Flyovers
Indian flyovers use precast bridges to speed construction and boost durability.

Efficiency RRTS
Precast tech ensures faster, quality construction Delhi’s RRTS uses precast segments for viaducts
across sectors. and stations, ensuring quality.

Modular Pods Metro Tunnels

Modular pods enable rapid construction by Precast lining rings provide structural support
quick on-site assembly. and speed tunnel builds.

Structures Utilities
Box culverts, walls, and noise barriers are precast for Precast pipes, manholes, and channels improve installation
strength and quick setup. speed and reliability.
Quality Assurance
Producing precast concrete in Factories perform
Off-Site Production
a factory ensures uniform inspections and testing to
quality every time. keep high standards and cut Benefits of Precast
defects.

Faster Build Concrete

Less Disrupt
Off-site production allows
Off-site work cuts noise and
parallel work, speeding up
dust, improving site
the project schedule.
conditions.

Custom
Cost Save
Special moulds enable
Better resource use in
custom shapes and finishes
factories lowers waste and
in the factory.
overall costs.

Flexible
Off-site production offers
flexible scheduling and unit
storage.
Leading Indian Precast Manufacturers
1.Teemage Precast IN (Chennai) - Focuses on cost-effective, high-quality precast building services with modern manufacturing facilities.
2.Pacific Precast (Pune) - Specializes in precast concrete solutions for construction and infrastructure projects using advanced technologies.
3.Precision Precast Solutions (PPS) Pvt Ltd - Offers structural precast concrete consultancy and solutions, including hollow core slabs and band
beams.
4.Concretech Infra Solutions - Provides prestressed and precast concrete solutions, including compound walls and cottages, ensuring adherence to
local codes.
5.Strongplus India Private Limited - Manufactures precast concrete building components with innovative solutions, having completed over 500
projects worldwide.
6.BRHC Concrete Industries (Faridabad) - Focuses on manufacturing a wide range of precast concrete products with emphasis on quality and
sustainability.
7.Arto Precast (Bengaluru) - Delivers innovative and customized precast concrete solutions prioritizing durability, aesthetics, and sustainability.
8.Illuminati Solutions Pvt LTD (Mumbai) - Technology-driven precast concrete solutions aimed at improving speed and quality, especially for
low-cost housing.
9.CC Precast Solutions Pvt Ltd - A leader in Prestressed Precast Concrete Pavement in India, known for cost-effective and environmentally
friendly precast roads.
10.BRHC Pipe Industries (Faridabad) - Manufacturer specializing in precast concrete products with technical proficiency and quality standards.
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THANK YOU