WELCOME

A Brief Presentation
and Discussion over
the Casting Yard

Presented By:-
Manoj Singh
JE-I/Civil
What is a Casting Yard ?
A Casting Yard is a confined place where all
the Concrete structures like Segments,
Parapets, I-Girders/Beams, Boundary wall
panels, Cable Troughs etc. are
casted/manufactured, shifted to their stack
yard, Cured for the specific period/days and
then shifted to the working site/Viaduct
after they gain their required strength.
Facilities within a Casting Yard
Main gate
Side gate
Site office
Batching plant
Steel storage yard
Formwork storage yard
Steel Bending yard
Cement/sand/aggregate storage yard
Curing yard
Refuse dumping area
Casting yard
Lifting yard
Drain for proper drainage of water
Washing Bay/Yard
Canteen/Pantry
Emergency gathering area
Labor hutments
Announcement system
Laboratories for testing the materials
Proper Barricading in the Boundary
Emergency Medical Centre/First Aid Room
Store
Water Tank
Diesel storage
Requirements of a Casting Yard
Site for any Casting Yard should be easily accessible from all
site locations.
Land should be available from 25 Acres to 40 Acres for
establishing a casting yard
Approach Road leading to Casting Yard should be easily
identified
Good Environmental conditions
It should not more than 3 to 4 kms from working site
Proper Drinking Water facilities for Engineers, Supervisors &
Labours
Canteen facilities for the staff & Labours
Medical treatment Centre in case of emergency
Arrangements for the recreational activities for the staff
Volleyball Court, Badminton Court etc. for the staff
A Key Plan showing the Location of a Casting Yard
Site Office for the Engineer-in-Charge and other
Engineering staff at a Casting Yard
A Typical View of Site Office at a Casting Yard
 Things to do in Casting Yard

Pre-casting of
Batching & Mixing Segments, I-
Quality Control
Of Concrete Girders, Parapets,
panels, RE panels,
kerb stones.
 INGREDIENTS OF CONCRETE

CEMENT WATER AGGREGATES ADMIXTURES

Water
Treatment
Plant
 T
R
A M
N I
S X
I E
T R

For Transportation of Concrete

P
L
A
C Concrete Pump
I
N
G
O
F
C
O
N
C Pouring
R &
E Compaction
T
E
 Segments
Stacking
Arrangement
Of Pre- Cast Elements

Ker b
Stones Ribs
 Tests For concrete Materials in a
Casting Yard

The following are the tests that is to be

performed in the Laboratory in a Casting
Yard for the various Civil Engineering
Materials during the regular intervals of the
Project:-
Tests For concrete Materials
For Cement:
(1) Fineness test of cement by using ‘Sieve
analysis.’
(2) ConsistencyTest by usingVicat’s
apparatus.
(3) Setting Time Test.
(a)Initial Setting Time – 30 Minutes
(b)Final Setting Time - 10 Hours
(4) Soundness Test by using Le- Chatelier
apparatus.
 For Aggregates

(1) Sieve analysis

(2)Crushing value test
(3) Impact value test
(4)10% fines value test(Fineness Modulus)
(a)Fineness modulus of Fine Aggregates=2.0 to 3.5.
(b) Fineness modulus of Coarse Aggregates=5.5 to 8.0.
(5)Silt Content
(6)Specific gravity
(7)Flakiness
C
R
U
S
H
I
N
G

V
A
L
U
E

T
E
S
T

A P P A R AT U S f o r
Aggregates
I m p a c t Va l u e
Te s t A p p a rat u s fo r
A ggrega t e s
 Tests For Concrete
For non-self compacting concrete
Slump Test
It is used to determine the consistency of the concrete mix in
the field/Site. it indicates the behavior of the compacted
concrete cone under the influence of gravitational forces.
Normally it is done before placing the concrete.
Setting Time test
Initial setting time
Final setting time
Compacting Factor Test
It gives the behavior of fresh concrete under the action of
external forces.
 For Self Compacting Concrete
Flow Test
This laboratory test gives the consistency of concrete and also
the concrete mix to segregate. This test is not in use these
days.

Cube Test for Hard Concrete

Compression Test
The size of the cube should be 150 X 150 X 150 mm.
Slump test
 Preparation Of
Boxes For
Testing Of
Crushing Value

Shuttering Oil
V For Self Compacting Concrete

F
U
N
N
E
L

T
E
S
T
Mixer For
Laboratory
Preparation Of
Concrete
Universal Testing Machine(UTM)
Universal Testing Machine(UTM)
Diesel storage area at Casting Yard
A Crane
having
Long
Boom
Length
being
used for
lifting
the
Constructi
on
Materials
A Crane having Long Boom Length being used
for lifting the Construction Materials
Construction of Cement Go down for stacking the
Cement Bags at Casting Yard
Preparation of Base for Placing the aggregates,
sand at Batching Plant
A Typical Batching Plant for feeding the
Concrete at Casting Yard
A Typical Batching Plant for feeding the
Concrete at Casting Yard
Batching
Plant

Aggregates

Silo
SILOS FOR CEMENT AND FLY ASH FINE & COARSE AGGREGATES
 Batching of Concrete

Raw materials
Cement
Fly Ash
Water
Admixture
Fine aggregate
Coarse aggregates of 10mm &20mm size
 Batching
The process of measuring the quantities of
cement, fine aggregates, coarse aggregates and
water for Concreting operation, ensuring
uniformity of proportions and aggregate grading is
called batching.
Proper batching of concrete ingredients will
ensure:-
Strength
Workability
Durability
Economy
The cement used is O.P.C. of 53 grade. Cement & fly ash both are
stored in hoppers which are attached with the motor to transfer
them to higher head.

The admixtures used are:-

Accelerating admixtures(Calcium Chloride)
Retarding Admixtures(Sugar)
 Water reducing Admixtures(Ca or Na Salts)
 Air-Entraining Admixtures(Animal & Vegetables fats, oils) and
Super plasticizers Admixtures(Available in liquid form)

The Sand and the coarse aggregates are kept in the form of heaps
at the batching plant.
Maximum amount of fly ash which can replace the cement
is 30%.
The minimum amount of cement which has to be added in
any batching activity is 400 kg & maximum amount is 520
kg.
The amount of cement used per unit area is 225 kg/cm2 &
that of the fly ash is 600 kg/cm2.
The Water Cement ratio shuffles between 0.1 & 0.4,
depending upon the workability of the concrete.
Concrete of grade up to M65 is used. For segments and
other pre casted elements normally M45 concrete is used.
For fine & coarse For Cement & Fly Ash
aggregates
 For
Admixtures

For
cement

For Fly
Ash
Mixing Tank
An Aerial View of a Batching Plant at Casting
Yard
Submission of Quality
Progress Report on
Monthly Basis during
the Project
The Test to be conducted by in house
laboratory at the casting yard:-
S.N Materials Test to be Frequency Remarks
o. Conducted
1. COARSE Gradation/Sieve Daily As per IS :
AGGREGATE analysis 2386
20mm
2. COARSE 10 % fine value Monthly As per IS :
AGGREGATE 2386
20mm
3. COARSE Flakiness index Monthly Not more
AGGREGATE than 35%(As
20mm per MORTH)
4. COARSE Impact & Monthly As per IS :
AGGREGATE crushing Value 2386
20mm
S.No. Materials Test to be Frequency
Conducted
5. COARSE Specific Gravity & Weekly
AGGREGATE 20mm water absorption
6. COARSE Gradation/Sieve Daily
AGGREGATE 10mm analysis

7. COARSE 10 % fine value Monthly

AGGREGATE 10mm

8. COARSE Flakiness index Monthly

AGGREGATE 10mm

9. COARSE Impact & Monthly

AGGREGATE 10mm crushing Value

10. COARSE Specific Gravity & Weekly

AGGREGATE 10mm water absorption
S.No. Materials Test to be Frequency
Conducted
11. COARSE 20 :10 mm Daily
AGGREGATE 10mm Gradation
12. F INE AGGREGATE Gradation/Sieve Daily
analysis

13. F INE AGGREGATE Silt Content Every Lot

14. F INE AGGREGATE Specific Gravity & Weekly

water absorption

15. CEMENT Fineness test Every Lot

16. CEMENT Consistency Every Lot

S.No. Materials Test to be Frequency
Conducted
17. CEMENT Initial & Final Every Lot
Setting Time

18. CEMENT Compressive Every Lot

strength

19. Water Ph Value Weekly

20. Admixture Ph Value Weekly

The Things to be Ensured in the
casting yard:-
The roads within the casting yard shall
be properly cleaned, dust & mud free.
There should be a arrangement of Water
Sprinkler Vehicle in the casting yard for
continuous & time to time water sprinkling
arrangement.
The Directional signage's shall be fixed
at the various locations, Hazardous
areas, turning points etc. some of the
signage's are:-

 Hard Hat Area.

 Wear Safety Helmet, Shoes while
working.
 Adopt Safety…Save Accidents.
 Danger Zone.
Restricted Area.
Road Turning Ahead.
Go Slow .
Testing Laboratory Ahead.
Diesel Store.
 Cement Go down.
Materials stacking Yard.
Canteen.
Workshop.
Site Office.
First Aid Centre.
Speed Limit 20 km/h
A Typical Elevation of Gantry while Lifting the
Segments at Casting Yard
A Typical Elevation of Gantry for Lifting the Segments &
other Materials at Casting Yard
Lifting of Segments with the help of Gantry after Post
Concreting /Deshuttering at Casting Yard
A Regular & Detailed Inspection of the
Precast Segments at Casting Yard
Checking of a Reinforcement Cage at Casting
Yard by DMRC Engineers
A Safe and Aligned shuttering arrangement for the
Concreting of Segments at Casting Yard
A Safe and Aligned shuttering arrangement for the
Concreting of Segments at Casting Yard
A Chair arrangement for binding the Reinforcement
cage of Segments at Casting Yard
 SHUTTERING
“Shuttering used for concreting should be sufficiently
stiffened to avoid excessive deflection and joints shall be
tightly buttled to avoid leakage of slurry.”

The steel shuttering should be properly repaired before

use and properly cleaned with shuttering oil to avoid:-
Stains
Honey combing
Blow holes
Discoloration of concrete
Seepage of slurry through joints etc.
 Removal of Formwork:-
(1)For walls, Columns & Vertical faces = 24 to 48
hours.
(2)Slab spanning upto 4.5m = 7 days.
(3) Slab spanning over 4.5m = 14 days.
(4)Beams spanning upto 6.0m = 14 days.
(5)Beams spanning over 6.0m & upto 9.0m = 14
days.
 Shuttering Surface Preparation for binding the
Reinforcement cage of Segments at Casting Yard
Reinforcement Cage Binding for Precast span Segments
at Casting Yard
Reinforcement Cage Ready for Placing
Reinforcement Cage Placing for Concreting
Reinforcement Cage Placing for Concreting

Reinforcement Cage Ready for Placing

A General Concreting Operation of a Substructure/Pile Cap
Rail Path for the Gantry Movement
 Casting of Plinth Beam for the
Gantry Movement at Casting Yard
 Curing
Curing is the Very important operation of any RCC
structure that is to be maintained for a particular
period/days so that structure can gain its required
strength.
OR

“Curing may be defined as the operation of keeping a

freshly placed concrete moist during a specified
period/days after its finishing, to ensure complete
hydration of cement particles or other cementing
material for obtaining a properly hardened concrete.”
IS:456 stipulates a minimum of 7- days
moist-curing. Normally it is done from 14 to
21 days by covering the concrete surface
with the Hessian cloth or making pond &
continuous sprinkling of water over it.

In case of ordinary Portland cement(OPC), a

minimum of 10 days curing under hot
weather conditions.
Systematic Water Curing of the Precast U-
Girder/Segments at DMRC Casting Yard
 •Segments
Type of segment: Spine Box Type
Parts of a segment:
• Soffit
• Web
• Ribs
• Deck slab
•Grade of concrete normally used is M45.
•The segments are generally of 9.1m.
•Width of each segment = 3.0m
•The segments identification numbers S1,
S2, S3 etc.
•Weight of each segment varies from 35 to
45 tones.
Stacking of the Precast Segments at Casting Yard
Stacking of the Precast Segments at Casting Yard
Stacking of the Precast Segments at Casting Yard
Stacking of the Precast Concrete RE Panels at
Casting Yard
Stacking of the Concrete Blocks at
Casting Yard
Initial Placing & Fixing of the Barricades at
Casting Yard
 Proper Alignment, Painting of the
Barricading installed at Casting Yard
Proper Alignment, Painting of the Barricading
installed at Casting Yard
 Thank You
for
Cooperation