What are precast monolithic floors and their advantages and disadvantages, installation, replacement, cost

Precast monolithic floors are a common option in contemporary building because they combine efficiency, adaptability, and durability. Concrete is cast into a reusable mold, or "form," and allowed to cure in a controlled environment to create these floors. The precast sections are delivered to the building site, where they are assembled into a single, seamless floor system after being allowed to harden. In contrast to this process, conventional cast-in-place concrete involves pouring and curing the concrete right on the construction site.

The quick installation of precast monolithic floors is one of their key benefits. In comparison to traditional methods, the on-site assembly process is much faster because the concrete components are prepared off-site. This shortens project timelines and lowers labor costs. Furthermore, the controlled manufacturing environment guarantees uniform, high-quality components, which improves structural durability and integrity.

Precast monolithic flooring do have certain drawbacks, though. Large, heavy concrete sections can be expensive and logistically challenging to transport. Skilled labor may be more expensive overall because installation requires exact measurements and careful alignment. Furthermore, mold and form setup can be costly initially, particularly for smaller projects.

Precast monolithic floor installation is a multi-step process. To start, precise measurements and design blueprints are necessary. After that, the precast sections are manufactured in a factory and undergo quality assurance and curing procedures. When the sections are prepared, they are brought to the construction site and cranes are used to lift them into position. To ensure a seamless and robust bond, the sections are carefully aligned and connected, frequently using concrete grout and reinforcing steel.

Precast monolithic floor replacements can be difficult and expensive, frequently necessitating the removal of entire sections. Frequent upkeep and examinations are essential to spot and resolve any problems early, extending the floor’s life and lowering the need for replacement.

Precast monolithic floor prices vary according to the project’s size, design complexity, and labor and material costs in the area. Even though the upfront costs might be higher than with traditional techniques, they might end up being more affordable in the long run due to advantages like durability, less maintenance, and quicker construction times.

What is SMP: general information about the system

Prefabricated floors are triangle-shaped blocks positioned in between beams. The latter are constructed as a unique triangular type reinforcement frame.

Once the concrete mixture is poured, the shape unifies into a single entity. The monolith will be stronger the more porous the structure is.

In order to reduce the overall weight of the floor, blocks made of expanded clay, gas polystyrene, or foam concrete are utilized as building materials. When compared to reinforced concrete, the building’s foundation bears a lower load (weight is decreased by nearly 35%).

The floor beam (made of steel or concrete) is the part of the entire structure that bears weight. Depending on the span that needs to be covered, they can be up to 9 meters long.

A 100 x 100 mm metal mesh is placed on blocks and beams for reinforced products. The mixture is poured into the gaps on top of it (by 50 mm) on the beams in between the rows of blocks.

Advantages and disadvantages

Precast monolithic floor DIY installation has the following benefits:

1. Have a flat surface as a ceiling or floor and do not contain joints after the work is completed.
2. No construction equipment required. To install the structure if it is necessary to cover a basement, attic or interfloor space, the efforts of several people are sufficient.
3. In most cases, additional insulation is not necessary, since the material has good thermal conductivity parameters.
4. The total costs of building a house made using elements from a prefabricated monolith and using SMP will decrease.
5. You can lay a floor covering on the resulting surface after pouring. There is no need for additional leveling and multiple layers of screed.
6. It is convenient to lay communications using the voids in the blocks. The operation is performed before pouring the mixture.
7. Before installation on the construction site, the necessary elements are adjusted to the required size. Possibility to produce complex shapes, for example when working with walls.
8. Roof dismantling is not required during the reconstruction of a building when monolithic prefabricated products are used.

The following categories apply to this type of ceiling’s drawbacks:

• The need to set the supports every 150 cm every 150 cm, in the case when the beam is long, the supports are used only for installation and set of strength with the material, and then removed;
• the segments are unacceptable to dock, so a long (more than 5 m) reinforcement is used.

Independent installation

The following actions must be taken in order to install ceilings of the monolithic prefabricated type:

1. You can use sliding racks as a support that will support the boards of 20*25 cm, blocking the flight. Savorns can be done after laying blocks.
2. The surface of the walls in the horizontal plane is cleaned and from each other at a distance of 62-65 cm, longitudinal beams of reinforced concrete are placed. To increase density and strength, 1.5 cm thickness is placed a solution of cement M100.
3. To make a monolithic slab, wooden formwork is installed along the future perimeter of the structure.
4. After this, they begin laying the blocks in transverse rows, trying to create minimal gaps between the elements.
5. In prefabricated floors, metal or plastic reinforcement is placed between areas with a monolith and formwork. If necessary, leave at least 150 mm of overlap to make rod joints.
6. Dirt and dust formed on the surface are removed.
7. Concrete M250 with strength characteristics higher than B15 of fine-grained consistency is poured into the structure and leveled.

The coating will harden over the course of three days. Plastic film needs to be applied to the surface, and it needs to be continuously moistened. After the material has solidified and the formwork has been removed, wooden supports can be removed.

What to consider when installing SMP

It is best to use a pump to ensure that the concrete is poured in a uniform layer. In this instance, it may be possible to segment the work and install the formwork gradually. This will make manual labor less taxing. Furthermore, you should be aware of the following characteristics:

1. A road mesh laid on top of the blocks in an overlap is secured to the trigons with knitting wire.
2. To prevent concrete from leaking into the cracks, the blocks should be laid closer to each other.
3. There is no need to measure the installation angle for each of the beams. It is enough to install one block on both sides between the pairs. This will eliminate unnecessary measurements.
4. For the 3-5 days that will be needed for the structure to set, supports for installing the beams can be rented.

Large, prefabricated concrete slabs known as precast monolithic floors are used in building construction to provide sturdy, long-lasting flooring systems. These floors have a number of benefits, such as quicker installation times, consistent quality, and lower labor costs at the job site. They may, however, also have disadvantages, such as greater upfront expenses and the requirement for heavy lifting tools during installation. Because of their size and weight, replacing these floors can be difficult. Making decisions about these factors’ use in construction projects requires an understanding of how they balance.

Replacing worn-out floors

Old buildings frequently have rotted wooden floors to which special impregnations were not applied, posing a risk to the occupants.

Buildings will last longer and operate safer when sturdy, dependable monolithic prefabricated structures are used in place of wood. The guarantee on polystyrene concrete and its products (blocks) is higher.

It is frequently not possible to use reinforced concrete flooring in homes constructed with antiquated technology. Additionally, operating construction equipment is challenging.

It should be remembered that private buildings’ foundations are not designed to support additional weight.

An inventive flooring option that combines the efficiency of prefabrication with the strength of concrete is precast monolithic flooring. Because these floors are manufactured in controlled factory settings off-site, construction times are accelerated and quality is guaranteed. They are swiftly installed after being transported to the construction site, which lowers labor costs and minimizes on-site work. This process not only expedites the construction phase but also improves the overall effectiveness of the project.

Precast monolithic floors have many benefits, two of which are their strength and longevity. Because they are made of high-quality concrete, these floors are perfect for both residential and commercial buildings because they can bear heavy loads and environmental wear and tear. Additionally, compared to conventional on-site concrete pouring, the accuracy of factory production results in better quality control and fewer defects.

But there are a few disadvantages to take into account. Precast monolithic floors may have a higher initial cost because of the costs associated with manufacturing and shipping. Additionally, the cost of the project may increase due to the need for specialized equipment to install the precast units due to their heavy weight. Moreover, since precast units are manufactured in uniform shapes and sizes, there may be less design flexibility than with traditional techniques.

Precast monolithic floor installation is comparatively simple, but it does need careful planning and coordination. Large precast units need to be installed on the site, and competent personnel are required to guarantee correct alignment and strong connections. Despite being less common because of their durability, these floors can require complicated and expensive replacement, which calls for expert handling and assessment.

It’s crucial to account for both the upfront costs and ongoing savings when calculating the total cost. The longer construction period and less labor required on-site can make up for the higher initial costs. Precast monolithic floors’ longevity and minimal upkeep needs can also result in substantial cost savings over the course of the building.

To sum up, precast monolithic floors provide a strong and effective flooring option with significant advantages in terms of construction speed and durability. For many building projects, they are a worthwhile investment due to their overall advantages, even though there are certain cost and flexibility considerations.

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