pre cast walls
WHAT IS
PRE CAST WALLS
A precast wall is made in a factory and then brought to a building site to be put up.
They come in different shapes and sizes and can be designed to look nice with
patterns or textures.
People make precast walls by pouring concrete into special molds, which are like
shapes that the concrete goes into. After the concrete dries and gets strong, the
molds are taken off, and the precast wall is finished.
Precast compound walls are modular walls that can be
used as boundary, security, or architectural walls. They
are made from concrete and steel materials, and are
very heavy and durable.
Cost
The cost of a precast compound wall starts at around
Rs. 50 or Rs. 80 per square foot.
The final price varies based on factors such as size,
color, shape, material, height, thickness, strength,
application, and brand.
Height and thickness
Precast compound walls come
in different heights ranging
from 2 feet to 20 feet.
Precast compound walls come
in different thicknesses
ranging from 50 mm to 100
mm.
Characteristics of Precast Concrete Walls
1. Thermal Resistance
The precast walls infer their warm execution attributes basically from the measure of protection set in the depression or
inside the reinforcement divider, which is ordinarily a metal stud divider.
2. Moisture Protection
The protection for the moisture in the precast walls is of high importance as the structural members such as columns
and beams are not structurally connected with the precast walls.
The sealer or the joint seal used in the connections and joints to prevent the moisture from entering the building. To
keep the uniformity of precast walls and the sealants, pigmented sealants are used.
3. Fire Safety
The precast walls are manufactured with concrete which has good fire-resistant material.
3. Acoustics
A precast wall with a veneer will give comparative execution with respect to sound transmission from the outside to the
inside of the building.
4. Durability
The durability parameter of the precast walls is the same as that of concrete. Anyhow, the durability depends on the
type of connections made with the structural member.
Any irregularities in the member can be rectified by sandblasting, uncovering total, corrosive washing, hedge pounding,
or different methods
manufacturing process
Types of pre cast walls
. Precast Concrete Wall:
Precast concrete walls are the most commonly used type of precast wall. They are
made by pouring concrete into molds and allowing it to cure before being transported
to the construction site. Once on site, the precast walls are installed and connected to
form the building structure. Precast concrete walls are strong, durable, and resistant to
fire, making them ideal for many types of buildings.
2. Precast Steel Wall :
Steel precast walls are made by welding steel plates together to form a panel that can
be used as a wall. These panels are often used in high-rise buildings because they are
lightweight and can be installed quickly. Steel precast walls can also be designed to
resist extreme weather conditions, making them suitable for buildings in areas prone
to hurricanes or earthquakes.
3. Precast Wooden Wall:
Precast walls can also be made from engineered wood products, such as cross-laminated timber
(CLT). CLT panels are made by gluing together layers of wood in alternating directions, creating a
strong and stable panel. Wood precast walls are lightweight and sustainable, making them an
attractive option for eco-friendly buildings
4. Precast Masonry Wall:
Precast masonry walls are made by casting concrete blocks or bricks and then assembling them
together to form a wall panel. Masonry precast walls can be used for both interior and exterior
walls and are often used in residential construction. They can also be designed to have a certain
aesthetic appeal, such as exposed brick or stone.
5. Precast Glass Wall:
Precast glass walls are made by casting glass panels in molds and then
assembling them into wall panels. Glass precast walls are often used in
commercial buildings and can provide an elegant and modern look to the
building facade. They can also be designed to allow natural light to enter the
building, creating a more inviting and energy-efficient space.
Components of pre cast walls
Precast concrete wall systems can be comprised of a
variety of shapes, and wall types. Typically, precast
concrete wall systems fall into three basic categories:
solid, sandwich and thin-shell. These can be panelized
and erected in either a horizontal or vertical position
and used on all types of structures, from residential to
commercial, and institutional to industrial. Wall panels
can be designed as non-loadbearing or loadbearing,
carrying floor and roof loads, as well as lateral loads.
Solid Walls
Solid wall panel refers to walls being made
of solid concrete as opposed to including
integral insulation. These wall systems
require insulation and an interior
wall/finishing system to complete the
building enclosures.
Since wall panels are cast in a flat
orientation, the form side is typically the
side that will be exposed to view in the final
construction. This face can be made with
virtually any type of finish. The back face is
commonly troweled smooth or may have a
light broom finish.
Sandwich Walls
Insulated sandwich wall panels can be architectural, structural, or a
combination of both. The difference between typical panels and insulated
sandwich wall panels is that the latter are cast with rigid insulation
"sandwiched" between two layers, or wythes, of concrete. The insulation
thickness can vary to create the desired thermal insulating property ("R"
value) for the wall.
Insulated sandwich wall panels can be designed to be
loadbearing and support floor and roof components. They
make an ideal structural element for this purpose, normally by
casting a thicker interior wythe to provide the necessary
support. They can also be non-loadbearing to complete a
façade.
As with typical wall panels, the panels are cast in a flat
orientation, so the form side is regularly the side that will be
exposed to view in the final construction. This face can be
made with essentially any type of finish. The back face is
generally troweled smooth or may have a light broom finish.
Thin-Shell and GFRC
Thin-shell wall panels consist of a thin,
outer-wythe of concrete, typically ranging
between 1.5 and 3 inches in thickness. This
is connected to a back-up system, usually
constructed of steel framing or studs, or
sometimes concrete. The back-up system is
what connects the wall panel to the
structural system of the building and often
provides the furring for interior finishes,
such as drywall to be attached. Many of
these systems can also incorporate a layer
of rigid insulation between the exterior
wythe of concrete and the back-up system.
Process of installation
PRECAST CONCRETE PROCESS
A large number of concrete structures (about
6% of the building frame market) are
precast. The individual components are
prefabricated off site then taken to site
where they are erected.
1. Production of reinforced cages and main connections:
The precast factory often
has specialist workshops
for the manufacture and
maintenance of moulds,
and for the production of
jig-built reinforcing cages
and connections.
2. Assembly of moulds:
The reinforced cage
is positioned in the
partly assembled
mould, then the
remaining mould
section is
completed.
3. Mix being poured:
Carefully specified
concrete is placed
into the mould.
Many precast works
now employ
computer controlled
batching plants.
4 Storage of high-quality units in works
area:.
The finished precast
components are stacked on
clean battens or plastic pads
positioned to suit the design
of the component. Care is
taken to keep the stacks
vertical and to ensure that
battens are placed directly
above one another within the
stack.
5. Erection at site:
The components
are erected straight
from the lorry. This
leads to faster
erection times with
reduced on-site
activity.
Uses Of Precast Wall
Precast walls are used in the construction of single-family homes, townhouses, and
apartment buildings.
Office buildings, shopping malls, and other commercial structures are built using
precast walls.
Factories, warehouses, and other industrial facilities are constructed using precast
walls.
Bridges and overpasses are built using precast walls.
Precast walls are used as noise barriers along highways and other noisy areas.
Retaining walls for slope stabilization and erosion control are made using precast
walls.
Flood walls are created using precast walls for areas prone to flooding.
Security barriers around high-security facilities such as prisons, military bases, and
government buildings are constructed using precast walls.
Precast walls are used in the construction of stadiums, arenas, and other sports
facilities.
Barns, silos, and other agricultural buildings are constructed using precast walls.
