Because precast concrete components provide a flexible and effective substitute for conventional building techniques, they have completely transformed the construction sector. These components are made by pouring concrete into a reusable mold, or "form," which is then moved to the construction site, lifted into position, and allowed to cure in a controlled environment. By using this process, high-quality control is possible, guaranteeing that every piece is manufactured in accordance with precise requirements.
The variety of goods and structures that precast concrete can produce is one of its main advantages. Precast concrete offers unparalleled flexibility for a wide range of applications, from straightforward parts like wall panels, beams, and columns to intricate architectural features and entire building systems. Reinforced concrete also adds strength and durability to these components, which makes them appropriate for a variety of uses, such as tunnels, bridges, and multi-story buildings.
Precast concrete components come in a few primary varieties, each with a distinct function in building. Precast structural elements like slabs, columns, and beams supply the necessary framework for infrastructure and buildings. Precast architectural elements preserve structural integrity while adding aesthetic value, such as decorative facades and cladding panels. Precast stairways, flooring systems, and utility parts like pipes and culverts are among the other specialty items. This range of applications highlights how versatile and valuable precast concrete is in contemporary building.
Precast Concrete Elements | Description |
Concrete Slabs | Flat pieces of concrete used for floors, roofs, and walls |
Beams | Horizontal structures supporting loads, like in buildings and bridges |
Columns | Vertical supports for carrying loads from beams and slabs |
Wall Panels | Pre-made concrete sections used for walls in buildings |
Stairs | Precast steps for convenient and consistent stair construction |
- Characteristics of reinforced concrete structures
- Reinforcement
- Types of reinforced concrete structures
- Monolithic
- Precast reinforced concrete products
- Reinforced concrete slabs
- Trusses
- Beams and crossbars
- Piles
- Posts
- Columns
- Volumetric blocks
- Sanitary cabins (STK)
- Prefabricated monolithic concrete products
- Video on the topic
- Reinforced concrete forms RC . All sizes can be ordered .
- How panel houses are made. Reinforced concrete products plant.
- Master class. Reinforced concrete molder
Characteristics of reinforced concrete structures
Engineering facilities, industrial structures, and residential and commercial buildings are all constructed with reinforced concrete. Precast reinforced concrete is most frequently used, but monolithic and precast-monolithic structures are also possible. Elements are created using high-quality, durable concrete and steel reinforcement to achieve a low weight product while maintaining properties and indicators.
The majority of the structures function best in a temperature range of -70 to +50 degrees Celsius; the precise properties of the product vary depending on the application.
– hangars, workshops, warehouses, and production sites.
Monolithic and precast reinforced concrete elements exhibit several key benefits, including: increased strength over time; a minimum of 50 years of service life; resistance to fire and frost; optimal cost; independent construction or assembly (albeit requiring specialized equipment); resistance to seismic activity; and the capacity to form any architectural form out of concrete.
Large mass, the requirement for extra thermal insulation measures, the possibility of cracks, and the significance of accurate calculations (without which the slab, column, foundation, or floor will not function and may even cause destruction under the weight of its own objects) are the drawbacks of reinforced concrete.
The quality of the binder and fillers used in the preparation of the concrete directly affects all the properties displayed by monolithic or precast reinforced concrete. Concrete’s porosity and density have a significant impact on its final quality. The strength of the concrete monolith increases with density and pore count.
Concrete structures are frequently used in the construction of industrial enterprises and industries where high temperatures are observed because of their resistance to fire. It is imperative that concrete exhibits exceptional indicators of resistance to frost and can effectively tolerate drastic variations in temperature.
Concrete is reinforced with reinforced steel and other materials because, despite all of its benefits, it cannot withstand tensile strength. The best qualities and performance are ensured by the combination of metal and concrete.
Reinforcement
A series of actions known as reinforcement is used in residential and commercial construction to strengthen and increase the dependability of concrete structures. In addition to being used to pour foundations and monolithic buildings, reinforced concrete is also used to create a variety of products and elements, ceilings, and columns.
- Wire meshes and steel rods.
- Polymer meshes.
- Fiberglass meshes.
A relief surface is used as reinforcement for a more dependable connection with concrete, greatly increasing adhesion. Typically, a four-sided, mixed coating, ring, or sickle is used to create the surface. Make sure the reinforcement bars are the right section and volume to achieve the desired indicators. Kilograms per cubic meter of solution are used to calculate consumption, and each purpose has a unique indicator.
For instance, load-bearing floors are reinforced with 200 kilograms of steel rods for the foundation, which uses 150–200 kilograms of reinforcement per cubic meter of concrete on average.
Only a few years ago, relief steel rods and meshes were used to reinforce concrete. Fiberglass, fiber additives, and other materials are used today for reinforcement. However, the combination of steel rods and concrete is still relevant despite the range of solutions.
- The ability to make structures of even the most unusual shapes and configurations reliable.
- Resistance to temperature effects.
- Significant increase in service life.
- Significant increase in strength and permissible mechanical loads.
- Protection against crack propagation in the structure.
The disadvantages include heavier products that perform better, trouble adding reinforcement to an already-existing structure, metal corrosion risk, and concrete destruction due to improper use of certain products or low-quality reinforcement.
Precast concrete elements are manufactured concrete products from factories that are shipped to their final location after being cast and cured off-site. These components include a range of constructions like slabs, walls, columns, and beams that are frequently strengthened with steel reinforcement. Precast concrete components come in several primary varieties, including architectural panels, hollow-core slabs, beams, and columns. Precast concrete is a popular option for contemporary construction projects because it provides a number of benefits, such as enhanced quality control, quicker construction times, and lower labor costs.
Types of reinforced concrete structures
Size, arrangement, and shape of a reinforced concrete structure can vary, but production method and functional characteristics are the primary sources of variation.
Products made of metal and concrete can be non-stressed or prestressed. The most well-liked designs and products include farms, floor slabs, beams, foundations, panels, and columns. There are over 20 distinct positions in the nomenclature of reinforced concrete.
- B – beams (BC – crane, BS – rafter, bo -binding);
- K – columns;
- Lm – staircases, lp – staircases;
- OP – supporting pillows;
- PR – jumpers;
- C – piles;
- P – crossbars;
- W – sleepers;
- FBS – foundation blocks;
- FS – rafter farms, FP – toothing farms;
- TF – non -pressure pipes, BT – pressure pipes.
In terms of application, reinforced concrete structures can be used to build complex objects, special structures, public buildings, residential buildings, and industrial buildings, among other things. However, there are four official categories: public-based, industrial, housing construction, and engineering structures.
Pile construction, floor slabs, foundation blocks, wall panels, trays, beams, and jumpers are used to construct residential buildings. Except for piles, which are made of concrete from M200 and above, this class is composed of concrete from brands M150 and above. Frame technology and prefabricated components, such as floor beams, columns, crossbars, purlins, etc., are utilized in multi-story construction. Concrete M200 and higher is used for these products.
Monolithic
The strongest and most stable kind of structures are monolithic reinforced concrete structures. It is employed in the construction of diverse kinds of buildings and structures. It is composed of a mass of concrete into which reinforcing is poured; it is assumed that there are no connections, ensuring monolithicity.
Thanks to the use of monolithic reinforced concrete, it is possible to significantly speed up construction, ensure the spatial integrity of the structure, maximum durability. Monolith is characterized by simplicity of shaping, low costs for creation and operation.
A few drawbacks to consider are the potential for shrinkage of the concrete, which can lead to the formation of cracks, as well as high density and heat/sound permeability. Since the monolith is poured right at the construction site, other factors to consider include the time of year and the impossibility of working in subfreezing temperatures.
Precast reinforced concrete products
Precast reinforced concrete structures are factory-made, ready-to-assemble products that are transported to the construction site and assembled into the desired configuration. Factories are able to draw in customers thanks to their high productivity and capacity to lower product costs. For many years, large-scale, rapid construction was made possible by precast reinforced concrete products.
Products made of reinforced concrete are versatile, adaptable, and suitable for installation year-round in a range of applications and building types. Because of their weight, the only drawback to using such elements is that special equipment must be present on the site.
It is also important to emphasize the significance of accurate calculations and the creation of a suitable project; every product has unique features and indicators, is made to withstand specific loads, and is intended to last a long time while taking into account all design parameters.
Reinforced concrete slabs
A popular variety of reinforced concrete products used in the construction of partitions, ceilings, and walls in both commercial and residential spaces. Typically, the slab is created as a rectangle with window and door openings and window sill protrusions. There shouldn’t be any openings if the slab is a ceiling slab. The dimensions, parameters, technical features, and loads can all vary greatly.
Even with the elements’ extreme strength, adherence to the transportation regulations is required. The product is installed vertically with a 10 degree slope during transportation; slabs cannot be transported in contact (only with special pads).
– utilized to build highways, airfields, training grounds, and intricate road intersections. Prestressed or non-prestressed reinforcement can be added to the robust slabs, which can withstand temperatures as low as -40 degrees. During the production process, 175×300 centimeter pieces of concrete with a density of 2200–2500 kg/m3 are typically corrugated on top.
Trusses
Floors in commercial, industrial, and cultural buildings require trusses. These products are constructed as grating-adorned rectangular flat structures. carried in a vertical orientation.
High levels of stiffness, strength, fire resistance, and frost resistance are characteristics of reinforced concrete trusses. Concrete, either structural or lightweight, is used to make them. When using this kind of reinforced concrete, careful construction is required. When working with trusses, it’s crucial to install them correctly based on precise calculations of the bearing capacity.
The products’ quality, adherence to the design specifications, and the support installation location are all examined during installation.
Beams and crossbars
Other supporting structures are attached to the beam, which serves as a horizontal support element. The primary function of the beam is to evenly distribute the rafters’ weight across the beams. The material used to create the beam determines its shape; for example, reinforced concrete is typically used to create long, square-section supports.
One of a structure’s structural components, a beam’s primary job is to facilitate bending. Wood or reinforced concrete can be used to construct this supporting structure. Since concrete ones are thought to be more dependable and long-lasting, residential and multi-story construction actively uses them.
These components go into making roofs and foundations. Beams can be rectangular or single/double-pitched. Beams and beams are installed vertically during transportation. Pads are used as support; they are positioned beneath the products from below. Separators thicker than ten centimeters are sandwiched between multiple elements during transportation.
Since it is the primary component of construction, the beam is utilized more frequently. Beams are only utilized as a covering or ceiling when building a structure.
While a beam is a part of the frame and is fixedly attached to the posts, a beam is an independent element of the structure. The beam is very difficult to calculate during the design phase.
Piles
In order to provide a foundation on unstable soils, piles are utilized in the construction of both residential and commercial structures. Piles show excellent chemical and corrosion resistance as well as resistance to frost and water. Installing piles is a simple task that contributes to the structural integrity of sturdy, long-lasting foundations.
Prefabricated and monolithic piles can be poured on-site or delivered ready to use at the construction site. They are separated into three categories: driven, bored, and cast-in-place. The section can be square or round, and the reinforcement can be longitudinal or longitudinal-transverse.
The products’ strength, resilience to various environments, bearing capacity, and other qualities vary depending on the application.
Posts
Lighting fixtures and power lines are supported by reinforced concrete posts. The ability to consistently hold wires at the necessary distance from the ground or water’s surface is their primary function. A unique concrete solution combined with an internal reinforcement frame ensures the strength and dependability of the supports.
Every post has a different design and function; some are end, intermediate, corner, and anchor supports. Single- and double-circuit products are also available. produced under tight adherence to GOST guidelines. According to SNiP 2.01.07-85, the materials and design of the racks enable their use in harsh environments, at -50 degrees Celsius ambient temperature, in seismic zones up to nine points, and with ice and wind loads that correspond to regions V and VII.
Columns
Columns made of reinforced concrete are unique components intended to fortify the structure’s frame. The product is used to fasten trays, crossbars, beams, purlins, and arches, and it serves a supporting role in a variety of building structures. The heavy concrete used to make precast reinforced concrete columns must at least be of grades M200/M300. Special elements are used to create the reinforcement frame.
Columns made of reinforced concrete are typically used to reinforce multi-story, residential, commercial, and single-story buildings. They serve to disperse the weight from surfaces and other components. Reinforced concrete mixtures in the shape of standard vertical elements with a narrow cross-section are used to create two-branch reinforced concrete columns.
High resistance to external influences, stability against seismic impact, assurance of compliance with declared load-bearing characteristics, tightness against moisture and water, and stability against high/low temperatures are the primary attributes of reinforced concrete columns.
Volumetric blocks
Residential and public buildings are constructed using reinforced concrete volumetric blocks. These are essentially prefabricated building components with unique window and door openings and a hollow, rectangular shape with thin walls. possibly consisting of panels and other insulating materials.
Volumetric blocks are prefabricated spatial structures with precise rigidity, strength, and stability specifications that are manufactured in a factory. Volumetric block construction makes it possible to create ready-made blocks the size of a room in a factory, which ensures high quality, reduce labor intensity, and minimize the number of assembly elements and operations on the construction site.
The need to develop a new design scheme, the limitations of architectural and planning solutions, challenges with transportation, production, and installation of volumetric blocks are just a few of the drawbacks of volumetric block construction that are worth mentioning. Buildings with the same room structure, such as hotels, residences, and boarding houses, are typically constructed using volumetric blocks.
The center of gravity of reinforced concrete volumetric blocks can be shifted in both longitudinal and transverse directions, making them sensitive to dynamic loads. Specialized stubborn ledges are used in the transportation process to keep this out.
Sanitary cabins (STK)
Within the sanitary unit’s spatial structure are monolithic reinforced concrete products known as sanitary cabins. These cabins are frequently utilized during the construction of public and residential structures. A suitable slab element and a volumetric unit are included in the design. Usually, there is a separate bathroom (restroom and bathroom) with specialized ventilation installed.
Superior heavy concrete, used to create STC, has a compressive strength of B15 and above. Chemical additives are frequently added to the solution to increase moisture, fire, and frost resistance in order to improve performance properties. High-grade wire and welded reinforcing mesh are used as reinforcement to make the structure more robust and durable.
Concrete, reinforcement, and embedded products are coated with specialized anti-corrosion compounds. The design incorporates mounting loops for ease of installation; the SVC’s dimensions and configurations may vary.
Prefabricated monolithic concrete products
Products made of prefabricated monolithic reinforced concrete combine several components. The process of assembly involves the placement of precast reinforced concrete and a monolith. The way that prefabricated parts interact with monolithic elements is crucial in this situation. Variations in the sizes and shapes of prefabricated elements are acceptable for optimal connection quality.
In a nutshell, SMZhB are structures made from prefabricated individual parts that are assembled (in this case, monolithically) at the construction site into a single whole. Both kinds of structures function together after monolithic casting because of a stiff connection.
Precast components for SM reinforced concrete structures can include a variety of beams, columns, and slabs made of lightweight concrete or hollow ceramic blocks. The primary reinforcement and formwork are components of the precast variety. Prestressed reinforcement is used in precast elements, while welded meshes and frames are installed in monolithic concrete. High-strength, fast-setting concrete is used to cast nodes in a monolithic manner.
Precast reinforced concrete typically serves as formwork in precast-monolithic reinforced concrete products, as previously stated. However, monolithic pouring provides spatial rigidity while consuming a significantly smaller amount of building materials. All the benefits of the other two options are combined in SMZhK, allowing you to construct things more rapidly and effectively while also saving money.
It is deemed economically advantageous to use this option because, although these structures have many benefits, they also almost have no drawbacks. Because you don’t need scaffolding, formwork, scaffolding, etc. to work with them, the building process is less expensive.
Modern construction relies heavily on precast concrete components because of their effectiveness, robustness, and adaptability. These components—which comprise products made of both plain and reinforced concrete—are produced in a controlled setting prior to being delivered to the construction site. Because of the high quality and consistency this process guarantees, precast concrete is a popular option for many different types of projects.
Precast concrete elements come in two primary varieties: non-structural elements like panels and facades and structural elements like beams, columns, and slabs. Steel reinforcement is used in reinforced concrete products, which give them extra strength and are crucial for load-bearing applications. These components add to the overall stability and safety of the structure because they are made to fulfill particular project requirements.
There are many benefits to using precast concrete, including shorter construction times and lower labor costs. The weather has less of an effect on the construction schedule because the elements are produced off-site. Because there is less formwork and concrete mixing done on-site when precast components are used, the construction site can also be safer and cleaner.
Overall, precast concrete is a very useful material in the construction industry because of its dependability and versatility. Precast concrete components offer a reliable solution that satisfies the requirements of contemporary building practices for projects involving infrastructure, commerce, or residential buildings. Precast concrete is expected to be used more often as methods and technology advance, which will strengthen its influence on the built environment.