PRE-CAST TECHNOLOGY

Usage of Pre-Stressed Precast Hollow Core Wall

& Slab in Green Field Project
the Mega projects in Power, Steel, Fertilizer, Coal,

to GCW contractor to put concrete on various levels of floor &

Warehousing etc., it becomes very essential that

hand over the floors to different teams for further works. Often

a proper solution to construction is found out which can give

this needs a great coordination and yet all Project Managers

advantage on the 3Ms of the project i.e reduce manpower,

were under pressure to deliver and due to movement of unskilled

Reduce waste of material, Reduce cost. This is where Precast

labours, the area also becomes unsafe.

ith the current Govts focus on Fast tracking of

comes in to picture.

Then all the steel beams & columns were erected and given

Hollow core Pre-stressed Precast presents a unique model of

working and is perfectly feasible in the most economic way to avoid
or minimise the cast-in-situ works on the project site. This will also
help the project managers to pre plan & do works in parallel, even
if site has not been fully acquired & work on casting of floors can
commence in parallel with area grading and foundation in a project.
This can save a minimum of 30% construction time.
There is a need to change the mindset of the designers
to adopt the proven technology which is available and use it
innovatively. Another typical
example is of large warehouse
sheds in that the perimeter
Out Door Plant

Today, in any green field project, the greatest challenge to

wall (which is currently

made up of bricks and RCC

the engineers & project managers is to manage time. Delay and

bands) could be replaced with

hurdle often arises due to non availability of site and sequencing

precast walls. This is very

of cast-in-situ concrete limits the construction time flexibility of

cost effective and fast to

the construction manager.

implement. Quality of work

For example in early times, a power plant used to take 48

improves as the product is

Perimeter walls in Factory Shed,

Ware Houses

months to build & mostly all activity from fabrication to Civil

produced from factory setup.

works was done on site. To cut on time, trend of prefabricated

How to Do This in Green Field Projects

structures started in which steel was prefabricated in shop and

brought to site when foundations are ready & erected.

- Plan from the design stage

- Make the design Precast friendly
- Prepare tenders keeping in provision Prestressed Precast
hollow core. For walls & slabs
- Set aside a space in plant for the precast yard & factory of
about 15 Acres
- Issue the slabs to the contractor on area basis free of cost just
like issue of steel
Operation of the plant can be done by manufacturer of the
machine.

Spancrete Hollowcore Advantages

Long Span Slabs Ideal for Podium Parks, Covering Over Nallahas, etc

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- Fast, safe erection with minimal crews.

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PRE-CAST TECHNOLOGY
tamping and troweling mechanisms result in smooth, flat surfaces
which can be carpeted or tiled directly with minimal preparation.
Unmatched dimensional specifications within +1.5mm / .063in,
the highest standards in the industry.

Advantages of Building with Precast, Prestressed

Concrete
Architects, engineers, general contractors, developers and
owners have been specifying Spancrete precast products for
Spancrete 4 wide (1.2 m) Hollow Core Slabs

- Install in excess of 1000m /10,000 ft per day on steel

2

beam, precast, masonry or poured structures.

more than 69 years. These time-honoured architectural and

structural precast components combine to form strong, longlasting fixtures in our everyday lives. Every member involved in
the construction project benefits from the many advantages of

- All year construction.

using precast building products.

- Once in place, Spancrete hollowcore slabs provide a secure

Precast Offers Design Versatility

deck that allows other trades to begin working.

- Each slabs smooth surface can be carpeted or tiled directly
with minimal preparation.
- Slabs can be lifted and installed directly from delivery

Versatility is synonymous with precast. The selection of

structural and architectural precast concrete products offers
aesthetically pleasing yet economical solutions for many types
of construction projects. Precast concrete offers a variety of
surface finishes and textures. Choose ribbed, raked, broomed,

vehicles.
- Horizontal or vertical hollowcore wall panel capabilities.
- Hollowcore spans can be up to 20m/65ft, the worlds longest.

sandblasted or exposed aggregate finishes. Colour and reveals are

available, enhancing the architectural treatment choices. Precast
wall panels are not only ideal for new construction projects, but

- Fire ratings of up to 4 hours.

can be matched to existing structures for additions. Precast

- Offers reductions in sound transmission, for a quiet

concrete components can easily be designed to accommodate

future growth. Interiors can be reconfigured simply and quickly

environment.
- Significant energy savings are achieved with Spancrete
Insulated Hollowcore wall panels.

for the changing needs of the building. Precast products can

span over long areas, resulting in large, open interiors without
obstructions or expensive support structures.

- Fast Turnaround
- Compared to site-cast concrete, precast concrete erection is
faster and less affected by adverse weather conditions.
- Plant casting allows increased efficiency, high quality control
and greater control on finishes.
In addition to the above other advantages are:
Highest Production
Rates: The Spancrete
machine produces at a
rate of 2.5+m/8+ ft.per
minute, resulting in
1200+m2/12,000+ft2 per
8 hour shift.
Most Accurate
Tolerances: The Spancrete
Machines hydraulic

100

Spancrete Floor Slabs Used on Various

Structural Elements / Frames

Spancrete Vertical and Horizontal Wall Panels

(Insulated and Non-insulated)

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PRE-CAST TECHNOLOGY
Beauty

peak heating and cooling loads, and sculpted shapes facilitate the

Nothing combines beauty with versatility, economy, and

efficiency like precast concrete. With all the choices of decorative

design of shading devices for window areas. Precast components

can be cast with insulation attached during manufacturing

finishes, wall panels combine a custom architectural exterior with

process, to increase the structures R-factor.

a durable interior surface to create an attractive, long-lasting

Long Term Cost Savings

building. The pattern, texture, and color variations are practically

Low maintenance costs and insurance premiums, coupled

unlimited, from exposed aggregate finishes to thin brick patterns.

with greater occupant satisfaction and higher resale values, are

Durability

demonstrated benefits of building with precast. The durability of

Durability is the one quality that allows precast, prestressed

precast, prestressed concrete components means that buildings

concrete to outlast competing materials. With its durable

last longer and look better over the years.

design, Precast is exceptionally resistant to impact, corrosion,

Occupant Satisfaction

weathering, and abrasion, rendering it virtually maintenance free.

Project Efficiency/Speed of Construction

Precast concrete offers rapid, all-weather construction. It
can be constructed year-round, in all types of weather, making
fast-track construction a routine job meaning projects are done
faster and occupied sooner, for a quicker return on investment.
In addition, insulated wall panels maximize thermal efficiency
to save energy costs and conserve natural resources. Durable,
fire-resistant precast concrete also lowers maintenance costs
and insurance rates, for even greater savings, while plant

Precast building systems reduce vibration, assist in noise

control, and create a safer environment. Occupants can enjoy
the inherent quiet and comfort that precast concrete provides.
In fact, precast concrete buildings typically have higher
occupancy rates, greater tenant satisfaction, better lease rates,
and outstanding resale values. One of the most remarkable
competitive advantages of precast concrete is its performance
on life safety issues. Precast components and precast structural
systems have demonstrated added value in fire safety, wind,
flood, earthquake protection and noise control for overall

manufacturing of precast concrete under an established quality

occupant comfort.

assurance program ensures consistent reliability, and saves

Fire Safety

production costs through repetitive operations. As soon as

Precast is unsurpassed in providing fire protection and

Spancrete Hollowcore Plank is secured in place, it becomes

containment when incorporated into a comprehensive, balanced

a working surface for trades such as mechanical contractors,

design. Precast concrete does not burn or give off lethal fumes in

electricians, and plumbers. This advantage accelerates the entire

even the hottest of fires, and it maintains its structural integrity,

construction process, facilitating earlier occupancy. Because

giving occupants more time to evacuate safely and extinguish

construction crews work year-round, in all types of weather,

the fire. The fire rating of precast hollowcore plank saves on

Spancrete projects stay on or ahead of schedule.

insurance costs and enhances tenant satisfaction.

Green Building Construction

Weather Resistance

Precast concrete components reduce energy consumption in

Precast concrete provides protection against the winds of

several ways: precast construction allows minimal air infiltration,

hurricanes and thunderstorms, and has recently been cited as

thermal mass delays internal temperature changes and reduces

an effective barrier to damage from tornadoes as well. Precast

concrete also is impervious to termites and dry rot, creating a
structure that does not weaken over time.

Low Sound Transmission

Precast is a high-density material that provides excellent, if
not unsurpassed, sound reduction, allowing tenants to benefit
from a quieter and less disruptive environment. Precast floors,
roofs, and walls have high STC ratings and offer superior sound
Spancrete Highway Noise Barriers and Perimeter Walls

absorption and impact sound reduction.

For more information contact Suresh Tripathi - sctripathi1963@gmail.com

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CE&CR July 2015