Category Archives: Precast Infrastructure & Construction

Precast Structures – How are they used in Construction?

The concept of precast construction includes those buildings that are majorly made of components that are standardized and produced in a factory environment that is usually located away the site of construction. These materials are then transported to the site for assembly. They are manufactured by industrial methods of mass production that can help build a large number of buildings in a short time and at a low cost.  The main features of this construction process are as follows:

  • This includes the use of standardized tools, machinery and other equipment that is usually automated and can produce standard, interchangeable parts and products.
  • The division and specialization of human work force is an essential part of this process.

The entire conventional construction process is restructured to enable the interaction between the design phase and production planning. This helps improve the speed of construction. It is hence important to design buildings that have a regular configuration in plan and elevation.

Precast building systems are known to be more economical when compared to conventional multi-family residential construction.

Depending on the load bearing structure, precast construction systems can be divided into the following categories:

  1. Large panel systems
  2. Frame systems
  3. Slab-column systems with walls

Precast Infrastructure in India

Large panel systems
This refers to the multi-story structures that are composed of large wall and floor concrete panels connected in the vertical and horizontal direction. These panels enclose appropriate spaces for the rooms within a building by forming a box like structure.

Precast frames
Precast frames can be constructed using either linear elements or spatial beam column sub-assemblages. Precast beam column sub-assemblages have the advantage that the connecting faces can be placed away from the critical frame regions. Linear elements are generally preferred because of the difficulties associated with forming

Slab-Column Systems with Shear Walls
These type of systems rely on shear walls to sustain lateral load effects and the slab column structure resists the gravity loads. There are basically two main systems in this category. First, the lift slab system with walls where the load bearing structure consists of precast reinforced concrete columns and slabs.

All the precast structural elements are assembled by means of special joints. Reinforced concrete slabs are poured on the ground in forms one on top of the other. They are lifted from the ground up to the final height by lifting cranes. They are then moved to their final positions. Temporary supports are used to keep them in place until the connection with the columns has been achieved.

Pre-stressed slab column system
This type of precast system is a slab column system that uses horizontal pre-stressing in two orthogonal directions to achieve continuity. The reinforced concrete floor slabs fit the clear span between columns and after erecting the slabs and columns of one story, the columns and floor slabs are pre-stressed. The gap between the slabs is filled with in situ concrete and the tendons become bonded with spans.

The use of precast structures in construction will definitely revolutionize the way the construction industry works.

KEF Infra – Infrastructure Development Company

Infrastructure development plays an integral role in the growth of any economy. We are currently experiencing a revolution in the infrastructure industry and economies need to channelize their efforts in order to become future ready and adapt to the changing trends. Traditional methods of building are no longer sustainable as they are impacted by a lot of project delays due to climate changes, labour availability, and accessibility of material or due to regulatory approvals. These methods are also subject to a number of external factors that impact the build quality and the delivery time. These delays in infrastructure can also impact other sectors such as education and healthcare and reflect on the overall economy at large. In order to bridge this gap, and provide better access to quality infrastructure, KEF Infra has set out to employ more evolved and innovative methods of building technologies.

We understand that technology is the answer when demands and expectations from the infrastructure industry is high. Urban growth and development requires time and cost reducing solutions that only technology and higher skilled workforce can provide. By developing a long term solution, with science, design and technology as the foundation, we are positive that the gap shall be bridged.

Technology, innovation and automation are the main driving forces for progress and at KEF Infra, we offer the most efficient and cost effective building solutions without sacrificing architectural design or site utilization. WE are the pioneers in Offsite Manufacturing and have a state of the art offsite manufacturing facility that ensures that quality is maintained at every stage.

Infrasturcture

Offsite Manufacturing – the building process is taken away from the physical site to a controlled factory environment. There is a great improvement in terms of cost savings, time to deliver and the quality of the final structure.

Precast – this is the process of creating a construction product (a pillar, column or a beam) by casting concrete in a reusable mould. This is then cured in a controlled environment and then transported to the physical site and lifted to place.

Modular Construction – this is based on the idea of ‘assemble rather than build’. It brings about a paradigm shift in terms of infrastructure development – especially in the units such as hospitals, hotels and homes.

Above all, these techniques allow for more control over the final product and provide greater efficiency and speed of delivery. It also ensures that the final product is of the highest quality.

These methods are more appealing to the modern age infrastructure because, they are extremely cost effective, agile and sustainable with absolutely no compromise on quality.

The focus is to revolutionize technology and address the real world problems and provide innovative solutions that are sustainable – even in the long run. We believe in being the trends setters, path breakers and change makers to redefine construction!

Why should you use precast concrete for construction?

Rapid urban development requires the help of new technology to go beyond more the traditional building methods. Precast infrastructure is one such technology that provides the means to bring up structures easily, quickly, and conveniently.

Precast technology provides the solution to infrastructural demands. It prefabricates units used in infrastructure development in controlled factory areas situated off-site. Once transported to the construction sites, these units are easy to assemble and fit to complete a structure. Reusable moulds are used to cast concrete off-site.  The concrete is cured and made ready for transportation to sites. What are the advantages of using this prefabricated concrete? Look at some of the benefits of using this material for infrastructural needs.

Precast Infrastructure in India

Less cumbersome
Precast concrete does away with the need to move cumbersome machines and all other raw material needed for making concrete to the site. It reduces the work of mixing, and carrying the mixture manually to be poured into casts prepared manually. Factory made units of concrete are a convenient construction alternative.

Versatility
Precast concrete is used in all types of construction work- for building houses, commercial buildings, infrastructure development projects, and special projects. The units come in both standard shapes and sizes and can also be custom made and designed for a particular structural needs. The range of precast concrete units extends from wall sections, to concrete beams and panels to hollow blocks.

Quality
Concrete units are superior in quality. They are uniform in size, each has the same density and dimension. The standardized product ensures a better finish for the building.

Durability
Concrete produces a tough surface that withstands corrosion for long periods of time. Precast concrete has the added advantage of tighter tolerance levels. The concrete mix made in the factory uses optimum water and is adequately compacted. Problems of curing are avoided with the use of precast concrete. The units are given correct drying time and the process of drying is carried out in a controlled environment to give them maximum strength.

Benefit to the environment
Use of these concrete units benefits the environment by reducing pollution of concrete dust. Natural materials are used to manufacture this concrete to help in controlling environmental damage. The process of production absorbs atmospheric carbon dioxide and cleans the air. During demolition of structures, these units cause less pollution and toxicity in the area. The units are reusable which further helps in environmental conservation.

Variety of finish
The end user gets to choose from a range of finishes according to requirement. There are non skid surfaces, patterned surfaces, and smooth surfaces available. All the surfaces can easily be treated chemically and polished for better appearance.

Using precast concrete for construction work is a smart decision. It is safe, profitable, and durable. Precast infrastructure has rapidly grown in popularity because of its versatility and high quality. Using the blocks and units simplifies the task of constructing buildings.

KEF Infra is a Pioneer of Offsite manufacturing, modular construction company & precast infrastructure in India.

Are precast concrete structures better? How?

It’s a known fact that precast concrete structures produce superior buildings than standard forms of concrete structures. So, what makes Precast Concrete Construction so different than other forms of constructions? After all, the concrete does not know whether it is statically reinforced or pre-tensioned (pre-stressed)! Precast concrete is prepared and cured at a location other than the construction site. But what really distinguishes precast from in-situ is it’s stress and strain response to external (load induced) and internal (autogenously volumetric changes) effects. Precast elements are of a finite size and need to be joined to the other elements of the construction to form a complete structure.

Basically, concrete is a mixture of sand, gravel and other aggregates that are usually bound together by a water based binder. Modifying agents and additives are introduced to improve the characteristics of the concrete.

Precast Concrete Construction

Precast concrete is cast under factory controlled conditions and not erected on site until it is fully hardened. Just like in-situ concrete, precast concrete can be plain, reinforced or pre-stressed concrete.

The process becomes more ‘buildable’
With precast structures, the entire process becomes easy and more ‘buildable’. This is because, the construction sequence becomes more sensible and each part is pre-built to exactly fit into place. The overall construction is safe and    there is a sense of stability too. Further, skilled labor is used for the construction of buildings using precast concrete and hence the overall quality of work is superior.

Simply more cost effective
With precast structures, the building component cost per – structural capacity is comparable to other materials and the overall cost of construction including transport, fixing finishing, maintenance and repair are competitive. There is lowest standard deviation and hence quality and final finish is assured. This method uses factory engineered concrete and hence destructive load testing and non-destructive load testing assurances are given.

Fast to erect
The precast concrete manufacturing takes some time – even several weeks. But, once ready, it greatly speeds up the on-site construction work. Clear heights, floor zones and other statistics are accurately built and it greatly speeds up the entire process.

Above all, the intrinsic qualities of an industrial product, manufactured in a controlled environment with accurate methods are bound to be superior to standard concrete mixed onsite. In a factory controlled environment, advanced quality control methods are used and hence the final finish is far better than standard concrete mix. Well, the dimensional accuracy, properties of the hardened concrete and reinforcement can all be checked before inclusion in the structure and hence the final product is more robust.

On a final note, factory made products are independent of the weather conditions on the site and are processed separately from the construction work on site. That’s why they have fewer external dependencies and external factors that negatively impact their quality.

In a world where the need for speed and quality is a never ending quest, precast concrete adds real value to a construction project and offers just the right solution for building sustainable – futuristic structures!

Most Common Uses Of Precast Structures In Construction

Good quality control, speedy construction and economy are some of the factors that make precast constructions a very popular choice. With the growing development and expansion of towns and cities, there is an increasing need for faster construction timelines without any compromise on quality and any impact on the costs too. Precast construction is one method which can be trusted and has uniform quality. Concrete is cast into a reusable mould and then cured under factory controlled environment, and transported to the construction site to be assembled with the other elements.

Precast concrete is used extensively in building structures such as floors, roofs and claddings. Some form the basic elements of a building and some are used for aesthetic appeal and decorative purposes. Here are some of the most common uses of precast structures in construction.

Precast Companies in India

Use of precast concrete in frames

There are two main types of precast concrete building frames. The structural frame consists of slabs, beams and columns. These structural frames can be used to assemble entire offices, car parks as well as retail developments. The cross wall frame consists of floor slabs and solid walls. It is used for hotels, schools and hospitals.

Use of precast concrete for floors

Floors could be of different types such as a plank, hollow core, beam and block or double tee. Using the precast technology for floor construction ensures that the quality of each slab is maintained and the construction is fast. There is standardized cross section and the strength to weight ratio is exactly maintained. Since it is precast in a quality controlled environment, the finishing is good and surfaces look neat.

Use of precast concrete in cladding

Precast concrete cladding is used as a structural element. It can also be used as a non structural decorative façade. In this method, the backing concrete is made from an ordinary mix and the façade consists of a special mix. A great variety of forms and details can be casted and used for decoration. Some of the decorative precast application includes bridge beams, double Ts, hollow core slabs, pipe or culverts, foundation walls or architectural panels etc. Sometimes precast parts are used for aesthetic appeal too. Some examples are countertops, sinks and bathtubs, decorative rock features, decorative window sills, accent strips, statuary or paving stones etc.

The main advantage of the use of precast elements in this type of construction is its repeatability. It is very easy to make many copies of the same product. It is a very efficient way of creating exactly same elements from a mould and using them where repeated designs in a construction are necessary. When you use precast, you can control the quality of the final product by ensuring that each piece is built with great care and is perfect before it is transported to the construction site. The curing of the precast elements is also done in a factory by heating the precast parts and this greatly increases the strength of the structure.

KEF Infra is a leading Precast Construction Companies in India. Precast / Precast Concrete is the process of creating a construction product.