Precast concrete is a type of concrete that is cast in a reusable mold and then cured in a controlled environment (precast plant). The cast structural member is then transported to the construction site and erected. Structural members such as concrete frames, concrete walls, and concrete floors can be constructed using precast concrete1. In the construction industry today, precast concrete elements are very popular among contractors and workers alike. Manufacturers aim to produce precast structures that express the beauty of architecture.
What is Precast Concrete?
Precast concrete can also be called readymade concrete or prefabricated concrete. It is a versatile construction material that is manufactured off-site in a controlled factory environment. This process involves pouring concrete into molds, often reinforced with rebar or wire, and curing it under optimal conditions. Once the concrete has hardened, it is transported to the construction site for assembly.
Advantages of Precast Concrete
There are many reasons to use precast concrete products for construction, landscaping, and roadwork projects. Precast concrete has several advantages over site-cast concrete, including time savings, quality control, cost-effectiveness, durability, and aesthetic versatility.
Saves Construction Time
Precast concrete construction saves time, and the risk of project delay is also less. The precast concrete casting can be carried on simultaneously with other works on site such as earthwork, survey, etc., and thus saves time. Because the parts being used come already created, no time is wasted forming, framing, pouring, or curing. The project can begin right away. The actual erection of the buildings on site is executed in a much shorter space of time compared to in-situ constructions.
Quality Assurance
The key factors which regulate the quality of construction such as curing, temperature, mix design, formwork, etc. can be monitored for pre cast concrete. So, improved quality construction can be performed. Precast Concrete products are monitored and quality checked before going to the jobsite. The curing process can be watched to ensure that no deformities occur. Because this form of concrete is cast in a controlled environment, these products can be more durable and long-lasting than other types of concrete. The factory workers who manufacture precast concrete can maintain ideal conditions and exact measurements throughout the process.
Cost-Effective
The simplified construction process reduces time, increases productivity, quality and safety and thus the cost is reduced. Industrialized construction with precast concrete elements offers many economic benefits and saves money, resources and time. A fluid assembling technique that doesn’t need as much labor ensures the process will save money. There is no need to constantly check on-site logistics and available workers, resulting in a lower labor cost which helps ensure sufficient profit.
Durability
Precast Concrete structure has a longer service time period and minimal maintenance. The high-density Precast Concrete is more durable against acid attack, corrosion, and impact, reduces surface voids, and resists the accumulation of dust. Concrete as a natural building material is 100% recyclable and is, in combination with steel, a safe, sustainable and earthquake-resistant material with little wear and tear.
Aesthetics
As the structures are made of prefabricated concrete in a controlled factory environment, several combinations of colors and textures can be used. A wide range of shapes and sizes are available to choose from with smooth finishing and thus the aesthetical value of products is increased. Manufacturers aim to produce precast structures that express the beauty of architecture.
Safe Construction Platform
A safe working platform is provided as no raw materials will be stocked on the job site for precast concrete construction. This also means there will be less risk of workplace accidents as the place is less crowded.
Usage of Prestressed Concrete
By using pre-stressed precast, structural materials of high strength and load-bearing capacity can be achieved, which can result in greater clear span, reduced size of the cross-section of structural members, etc.
Uniformity
Because the concrete components were put together in a factory using the same molds over and over, it is fairly easy to maintain uniformity among the precast concrete components.
Environmentally Safe and Sustainable
When considering precast concrete advantages, you cannot overlook its ability to eliminate clusters and other materials not needed at the construction site. Another thing is precast concrete only needs a one-time installation and lifting on the site. So there is no need for many workers in comparison to cast-in-place concrete. Precast concrete’s sustainability is also one of its many advantages.
More Energy-Efficient
Precast concrete wall panels are made with materials that can be found practically anywhere. This results in a more efficient process because there aren’t long transportation routes to bring everything together. Additionally, each precast plant only supplies to a certain radius around them so delivery and logistics delays are further reduced. In a controlled environment, there is more precision and technique that reduces the amount of waste in each project. Once on the site, a majority of the precast structure is complete so assembly can begin immediately. Precast limits the number of additional trades needed to install and erect the building, offering minimal construction site congestion, debris, and risk. A quick and coherent process allows for maximum efficiency. Precast concrete has excellent thermal, moisture, and sound insulation properties as well as high fire resistance.
Benefits of Precast Concrete vs Cast-in-Place Concrete
- Unfavorable weather conditions can impact the construction work when using cast-in-situ concrete. But this is not the case with precast concrete. Even on a rainy day, you can effortlessly lift your precast concrete into place just as you would on any other day.
- It is well known that concrete gains strength over time. Precast concrete is favored over cast-in-place concrete because it continues strengthening before it is needed at the construction site.
- The curing area for precast concrete is in a factory, which means that the process can be sped up without affecting the quality or strength.
- With site casting, you are at the mercy of fluctuating humidity and temperatures. The result is an inferior product even under the most ideal conditions.
- Precast is much more labor-efficient. Workers have access to tools and machinery that are unavailable on the job site. In comparison, site casting involves manual work that increases labor costs and overheads.
- Curing conditions for precast concrete are factory-controlled. Workers can speed them up while maintaining the product’s strength and quality.
- Precast concrete is ready for immediate placement on a construction site. Because of the space and labor required for on-site casting, you generally have to stop construction while you wait for your materials to be ready.
- An unexpected rainstorm can grind on-site casting work to a halt. If it is raining when your precast slabs arrive on site, you can still lift them into place.
- Because precast concrete is factory-made, you can incorporate elements like insulation, which is impossible with site-cast concrete. Adding insulation materials within the concrete slab can save labor and architectural design space when constructing a building.
Demand for Precast Concrete
The demand for precast concrete in the U.S. is on the rise, with a predicted growth of 6.4% from 2022 to 2028.
Choosing precast concrete products offers numerous benefits for your construction needs. From saving time and ensuring quality to being cost-effective and environmentally friendly, precast concrete stands out as a superior choice in modern construction. Its versatility and durability make it an ideal material for a wide range of applications, ensuring that your project is built to last.