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PRECAST COMPOUND WALL
BY : HARSH G. BOTHRA
Roll No.: 3141060
Under the Guidance of Prof: M. M. MAKWANA
Department of Civil Engineering, MITCOE
PUNE
Introduction
 The precast concrete compound-wall panel has been used in
Europe for decades.
 The original compound-wall design consisted of two types of
reinforced concrete and of plain concrete.
 Compound (Boundary) walls include privacy walls, boundary-
marking walls on property, and town walls.
Characteristics
 Precast concrete was developed by combining the best aspects of two familiar
technologies: the durability, fast erection, and architectural versatility of precast
concrete and the light weight and high strength of panelised cold-formed steel
stud framing.
 The strength-to-weight ratio is high.
 The precast units can support their own weight and be lifted off the casting
tables only 24 hours after casting, making cycle-time short and efficient.
 Large panel sizes are practical to cast and light enough to handle with lighter
equipment, resulting in fewer panels to erect and fewer panel joints to seal.
Benefits & Sustainability
 Installation of precast compound wall creates time and material savings
that can potentially substantially reduce construction costs and time.
 This is also an environmental benefit, as reducing construction time
reduces energy consumption of construction equipment and the impact
of workers on the site.
 Since it is made of concrete and steel, it does not support pest
infestation. Recycled material can be incorporated into precast wall.
Recycled steel can be used as raw material for the reinforcement. The
concrete can contain recycled aggregate and be made from locally
extracted materials. Some manufacturers have 25% or more recycled
content
Manufacturing Process
 1.) Moulding Method
 2.) Prestressed Method
Moulding
In this type of manufacturing
process the concrete mix is
poured into the mould ( plastic,
pvc, rubber or steel) and then
the mould in which concrete is
poured is kept aside to harden .
According to the necessity the
colours , design , size can be
varied .Mostly 24 hrs are
required to concrete to harden
and attain the desired strength .
Two types of compound wall
can be manufactured
1.) Reinforced Concrete Wall
2.) Plain concrete wall
Reinforced pvc mould Steel mould for
compound wall vertical pole
Prestressed Method
 Pre-stressing is a method in which compression force is applied to the
reinforced concrete section.
 The effect of pre stressing is to reduce the tensile stress in the section to
the point till the tensile stress is below the cracking stress. Thus the
concrete does not crack.
 It is then possible to treat concrete as a elastic material.
 There are two basic methods of applying pre-stress to a concrete member
 Pre-tensioning – most often used in factory situations
 Post-tensioning – site use
Pre-tensioning
In Pre-tension, the tendons are tensioned against some
abutments before the concrete is place. After the concrete
hardened, the tension force is released. The tendon tries to
shrink back to the initial length but the concrete resists it
through the bond between them, thus, compression force is
induced in concrete. Pretension is usually done with precast
members
Post tensioning
 In Post tension, the tendons are tensioned after the
concrete has hardened. Commonly, metal or plastic
ducts are placed inside the concrete before casting. After
the concrete hardened and had enough strength, the
tendon was placed inside the duct, stressed, and
anchored against concrete. Grout may be injected into
the duct later. This can be done either as precast or
cast-in-place.
Design of Reinforced wall panel
 Posts shall have typical dimension of 84” height and 50 mm
thick
 Posts shall be reinforced with 5 Rods of 4mm Prestres wire
(typical)
 Panels shall have typical dimensions of 120” long by 12"
height by 50mm thick
 Panels shall be reinforced with 2mm ms weldmesh having 3
horizontal bars and at least 10 to 12 vertical bars.
Cost Comparison
 Precast wall costs around rs 120 per sq feet.
 Brick wall costs around rs 165 per sq feet.
Advantages
 The concrete of superior quality is produced as it is possible to have better
technical control on the production of concrete in factory.
 It is not necessary to provide joints in the precast construction.
 The labour required in the manufacturing process of the precast units can easily be
trained.
 The moulds employed for preparing the precast units are of steel ,pvc or plastic
with exact dimension in all directions. These moulds are more durable and they can
be used several times.
 The precast articles may be given the desired shape and finish with accuracy.
Advantages
 The precast structures can be dismantled, when required and they can then be
suitably used elsewhere.
 The transport and storage of various components of concrete for cast in situ work
are eliminated when precast members are adopted.
 The work can be completed in a short time, when precast units are adopted.
 Quality can be controlled and monitored much more easily
 Weather is eliminated as a factor-you can cast in any weather and get the same
results, which allows you to perfect mixes and methods
 Recycled aggregates and steel can be used to manufacture precast concrete
products.
Disadvantages
 If not properly handled, the precast units may be damaged during transport.
 It becomes difficult to produce satisfactory connections between the precast
members.
 It is necessary to arrange for special equipment for lifting and moving of the
precast units.
 The economy achieved in precast construction is partially balanced by the amount
to be spent in transport and handling of precast members. It becomes therefore
necessary to locate the precast factory at such a place that transport and handling
charges are brought down to the minimum possible extent.
Product Applications
 Compound wall
 Godown/industrial shed
 Office building
 Labour quarters
 Security Room
 Road Elevated dividers with Aesthetics look

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Precast compound wall

  • 1. PRECAST COMPOUND WALL BY : HARSH G. BOTHRA Roll No.: 3141060 Under the Guidance of Prof: M. M. MAKWANA Department of Civil Engineering, MITCOE PUNE
  • 2. Introduction  The precast concrete compound-wall panel has been used in Europe for decades.  The original compound-wall design consisted of two types of reinforced concrete and of plain concrete.  Compound (Boundary) walls include privacy walls, boundary- marking walls on property, and town walls.
  • 3. Characteristics  Precast concrete was developed by combining the best aspects of two familiar technologies: the durability, fast erection, and architectural versatility of precast concrete and the light weight and high strength of panelised cold-formed steel stud framing.  The strength-to-weight ratio is high.  The precast units can support their own weight and be lifted off the casting tables only 24 hours after casting, making cycle-time short and efficient.  Large panel sizes are practical to cast and light enough to handle with lighter equipment, resulting in fewer panels to erect and fewer panel joints to seal.
  • 4. Benefits & Sustainability  Installation of precast compound wall creates time and material savings that can potentially substantially reduce construction costs and time.  This is also an environmental benefit, as reducing construction time reduces energy consumption of construction equipment and the impact of workers on the site.  Since it is made of concrete and steel, it does not support pest infestation. Recycled material can be incorporated into precast wall. Recycled steel can be used as raw material for the reinforcement. The concrete can contain recycled aggregate and be made from locally extracted materials. Some manufacturers have 25% or more recycled content
  • 5. Manufacturing Process  1.) Moulding Method  2.) Prestressed Method
  • 6. Moulding In this type of manufacturing process the concrete mix is poured into the mould ( plastic, pvc, rubber or steel) and then the mould in which concrete is poured is kept aside to harden . According to the necessity the colours , design , size can be varied .Mostly 24 hrs are required to concrete to harden and attain the desired strength . Two types of compound wall can be manufactured 1.) Reinforced Concrete Wall 2.) Plain concrete wall
  • 7. Reinforced pvc mould Steel mould for compound wall vertical pole
  • 8. Prestressed Method  Pre-stressing is a method in which compression force is applied to the reinforced concrete section.  The effect of pre stressing is to reduce the tensile stress in the section to the point till the tensile stress is below the cracking stress. Thus the concrete does not crack.  It is then possible to treat concrete as a elastic material.  There are two basic methods of applying pre-stress to a concrete member  Pre-tensioning – most often used in factory situations  Post-tensioning – site use
  • 9. Pre-tensioning In Pre-tension, the tendons are tensioned against some abutments before the concrete is place. After the concrete hardened, the tension force is released. The tendon tries to shrink back to the initial length but the concrete resists it through the bond between them, thus, compression force is induced in concrete. Pretension is usually done with precast members
  • 10. Post tensioning  In Post tension, the tendons are tensioned after the concrete has hardened. Commonly, metal or plastic ducts are placed inside the concrete before casting. After the concrete hardened and had enough strength, the tendon was placed inside the duct, stressed, and anchored against concrete. Grout may be injected into the duct later. This can be done either as precast or cast-in-place.
  • 11. Design of Reinforced wall panel  Posts shall have typical dimension of 84” height and 50 mm thick  Posts shall be reinforced with 5 Rods of 4mm Prestres wire (typical)  Panels shall have typical dimensions of 120” long by 12" height by 50mm thick  Panels shall be reinforced with 2mm ms weldmesh having 3 horizontal bars and at least 10 to 12 vertical bars.
  • 12. Cost Comparison  Precast wall costs around rs 120 per sq feet.  Brick wall costs around rs 165 per sq feet.
  • 13. Advantages  The concrete of superior quality is produced as it is possible to have better technical control on the production of concrete in factory.  It is not necessary to provide joints in the precast construction.  The labour required in the manufacturing process of the precast units can easily be trained.  The moulds employed for preparing the precast units are of steel ,pvc or plastic with exact dimension in all directions. These moulds are more durable and they can be used several times.  The precast articles may be given the desired shape and finish with accuracy.
  • 14. Advantages  The precast structures can be dismantled, when required and they can then be suitably used elsewhere.  The transport and storage of various components of concrete for cast in situ work are eliminated when precast members are adopted.  The work can be completed in a short time, when precast units are adopted.  Quality can be controlled and monitored much more easily  Weather is eliminated as a factor-you can cast in any weather and get the same results, which allows you to perfect mixes and methods  Recycled aggregates and steel can be used to manufacture precast concrete products.
  • 15. Disadvantages  If not properly handled, the precast units may be damaged during transport.  It becomes difficult to produce satisfactory connections between the precast members.  It is necessary to arrange for special equipment for lifting and moving of the precast units.  The economy achieved in precast construction is partially balanced by the amount to be spent in transport and handling of precast members. It becomes therefore necessary to locate the precast factory at such a place that transport and handling charges are brought down to the minimum possible extent.
  • 16. Product Applications  Compound wall  Godown/industrial shed  Office building  Labour quarters  Security Room  Road Elevated dividers with Aesthetics look
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