Precast concrete ensures faster construction, enhanced quality control, and lower on-site job requirements than cast in-situ concrete, which is cast and cured on-site.
This guide will help you learn about precast concrete. We will discuss its qualities and uses and explain why it’s one of the most practical construction materials for different types of projects.
How is Precast Concrete Made?
There are several steps to making concrete precast elements:
- Mould Creation: You need a customised mould to produce precast concrete construction materials. The mould may be wood or steel, with wire mesh or rebar to reinforce the structure. Mould makers may also add prestressed cable to the mould to ensure the strength of the precast concrete.
- Concrete Pouring: Once the mould is ready, concrete is mixed and poured into it. The moulds may be tapped or placed on a vibrating platform to distribute the concrete evenly. Tapping also removes air pockets or voids, creating a dense and uniform precast concrete element.
- Curing Process: The moulds are taken to a plant where they sit to cure. The curing process depends on the size of the concrete element, with larger ones taking longer to cure.
- Removal from Mould: After curing, the moulds are removed, and the precast concrete element is thoroughly inspected for quality.
- Transportation to the Jobsite: After passing quality inspection, the precast concrete is transported to the job site, where it will become part of the construction project.
Precast concrete manufacturers like Ozcast Precast can manufacture precast concrete in various sizes and with various complexities. Off-site production allows improved precision, consistent results, and speed in manufacturing.
Types of Precast Concrete Elements
Precast concrete is very durable and strong, so it’s no surprise that it is used in many applications.
- Building Foundations: Strong and reliable precast concrete may be used for the foundations of homes, commercial establishments, and industrial structures. Precast concrete is also moisture-proof, so it will never rot or change shape or strength, even after years of use.
- Parking Structures and Garages: Parking structures and elevated structures should be durable yet economical. Precast concrete can be used as parking columns, traffic barriers, paving slabs, stairs, and more.
- Bridges: Precast concrete is used in various parts of modern bridges, including arches, beams, girders, and deck slabs. Engineers use precast concrete to create structures that blend with the surroundings and with historical structures.
- Culverts: Modern underground tunnels and structures use precast concrete to build wastewater, stormwater drainage, bridges, and more. This material can be easily installed, ensuring quick completion of large-scale projects like these.
- Wastewater Structures: Underground wastewater management structures are mostly made of precast concrete. Workers lay precast concrete pipes, inlets, and catch basins to divert stormwater runoff and prevent flooding efficiently.
- Soundproof Walls: Precast concrete walls act as noise barriers for homes near highways or busy streets. This material has very high sound transmission loss values, thus creating a noise barrier for homes and buildings.
- Retaining Walls: Precast concrete retaining systems, such as segmented retaining walls (SRW), precast modular blocks, crib walls, cantilever walls, and many more, are available for residential or commercial use.
Ozcast Precast specialises in parapets for various infrastructure projects. Parapets act as guard rails to cover rooftop equipment, prevent fires, and reduce wind loads on roofs.
Benefits of Precast Concrete
There are various benefits of using precast concrete:
- High strength and durability: Precast concrete is subjected to strenuous quality inspections to ensure every element is strong and durable, perfect for the project.
- Cost-efficiency: As precast elements are manufactured in a plant, there is a reduced need for manual labour to produce these components on-site. The strict quality control process minimises the possibility of errors, saving time, material, and labour costs.
- Faster construction times: Precast concrete elements can be pre-ordered ahead of time, resulting in faster construction times. Workers also have more time to concentrate on other aspects of the construction, which reduces disruption and contributes to quicker installation times.
- Improved safety: Precast concrete plants have enhanced safety processes for manufacturing concrete elements. They also ensure the safety of the job site and workers when transporting and installing these precast elements.
- Versatility: Precast concrete can be used for a wide range of applications. Precasting concrete allows you to improve its texture, colour, and size, making it a versatile material for various projects.
- Created in a controlled environment: Precast concrete is manufactured off-site in a controlled environment. The weather or climate does not affect the strength of the concrete, as the precast materials are cured consistently in controlled conditions.
Where is Precast Concrete Used?
The sound-proofing and fire-resistant qualities of precast concrete have made it indispensable in various applications:
- Infrastructure (bridges, tunnels, parapets): Precast concrete’s strength, durability, and flexibility make it a great material for constructing bridges, tunnels, and parapets. By using precast concrete elements, infrastructure projects can be completed ahead of time.
- Rail and road projects: Precast concrete is used for sleepers and ballasts on railroad tracks, canals, and road segments. Like bridges and tunnels, using precast components speeds up the construction process.
- Office buildings: Modern buildings in various attractive and functional designs have precast concrete elements.
- Multi-unit housing: Precast concrete is fireproof and very durable, making it an ideal material for building multi-unit housing projects, such as apartments, condominium units, hotels, dormitories, senior living facilities, townhouses, and more.
- Hospitals: Precast materials provide a strong foundation for hospitals and medical centres. These can be used as soundproof walls or retaining walls in medical facilities.
- Educational facilities. School construction is a breeze with precast concrete. There are faster turnaround times, so students don’t need to wait long for a new classroom.
- Commercial or shopping complexes: Precast concrete can be used for the foundation, soundproof walls, and parking spaces. This material can build single or multi-storey retail centres in less time.
Ozcast Precast is the leading supplier of precast concrete in Sydney. We are known for precision, reliability, and innovation and support major construction projects across Australia.
Precast vs Cast In Situ Concrete
Is precast concrete more cost-efficient or consistent than cast in-situ concrete? Let’s compare the two:
Manufacturing Location
Precast concrete is manufactured off-site in a manufacturing or assembly plant, where the environment can be controlled for optimal results. Meanwhile, cast in situ or cast in place is where concrete is poured and cured directly in its final position. For instance, a building’s foundation is cast in situ, as concrete is cast and cured where the foundation is located.
Timeline and Cost
Workers will spend more time and materials setting up cast-in-situ elements, and errors or mistakes can be costly. On the other hand, using precast concrete saves time and materials during construction. These components are subjected to strict quality control, so errors are less likely to occur.
Labour Needs
Using precast concrete significantly reduces labour costs by enhancing the construction process, shifting labour-intensive tasks to manufacturing plants, and reducing the need for skilled workers on site. Construction projects are completed faster with fewer workers on site, resulting in lower overall labour expenses.
Weather Dependency
Cast in-situ components depend on good/fair weather to cure completely; thus, poor weather, storms, or strong winds can greatly affect project completion. Precast concrete is manufactured in controlled environments; therefore, each element is sure to cure or dry completely, providing the best support and use.
Quality and Consistency
Precast concrete is manufactured with precision and high quality. Every element is consistent, ensuring the best results at all times. These materials undergo strict quality control to ensure quality and consistency before they are transported to the job site. Meanwhile, cast in situ may vary in quality and consistency, which can greatly affect the project’s outcome.
Why Choose Ozcast Precast for Your Project?
Ozcast Precast is the name you can trust for infrastructure-grade precast concrete. We specialise in high-performance elements that meet the demands of your large-scale civil or commercial projects.
We offer unmatched quality and consistency. We are ISO accredited and a proud member of the National Precast Association, adhering to the highest standards in safety, performance, and sustainability.
Our team of experts can work on complex precast elements. From intricate architectural details to high-load components, we bring your vision to life. We have years of experience, a strong track record, and the drive to deliver sophisticated precast concrete solutions even under strict deadlines. Contact us today to learn how we can help you with your next project!
