What are the benefits of using precast concrete blocks?
Meaning of precast concrete blocks
A precast concrete block is a type of Concrete Masonry Unit (CMU) commonly used in the fascia of reinforced soil structures. As the name suggests, precast concrete blocks are manufactured in a factory and cured in a controlled environment. They are typically modular in design. This allows them to fit precisely into tight vertical and horizontal spaces, depending on the site configuration. Their key advantages include speed, precision, quality control, and consistency, making them a preferred choice for geotechnical projects. They are produced using reusable molds in a controlled environment, ensuring consistent quality. After passing quality and durability checks, they are transported to the site for easy installation. Our StrataBlocks create durable structures thanks to their design and inbuilt shear keys, which enable interlocking and improve lateral load-bearing capacity.
Types of precast concrete
a. Precast concrete walls:
Precast concrete walls are large concrete panels manufactured in molds and shaped into wall sections. They can be used for both interior and exterior applications. These panels are cast in rectangular shapes and installed directly at the construction site.
b. Precast concrete beams and columns:
Precast concrete beams and columns form the core support framework of buildings and bridges. Their design and dimensions can be customized based on project requirements. Special attention is given to their load-bearing capacity during manufacturing to ensure structural safety.
c. Precast concrete slabs and planks:
These are flat panels used for flooring and roofing in buildings. They are cast as thin, lightweight structures, making them easy to transport and convenient to install at the construction site.
d. Precast concrete stairs:
Precast concrete stairs are manufactured off-site using the precast technique and delivered ready for installation. They are designed according to the client’s specific requirements, ensuring precise fit and finish.
e. Precast concrete retaining walls:
Precast concrete retaining walls are designed to hold back soil and prevent erosion. They are manufactured in interlocking sections, which are connected on-site to form a continuous, stable wall.
Benefits of using precast concrete blocks for construction
Superior quality:
Precast concrete blocks are manufactured with strict quality control and precision in a controlled environment. This process minimizes defects and inconsistencies, ensuring durability and reliability. Unlike wet concrete, which is prone to deformation and on-site challenges, these prefab structures offer versatile and stable performance.
Durability:
Precast concrete blocks undergo a stringent production process and are manufactured to meet specific client requirements. This ensures superior quality and long-lasting durability.
No skilled labor:
Traditional on-site construction of walls, floors, and other structural elements often requires skilled labor and additional time. Precast concrete blocks eliminate this need, as they are pre-designed, manufactured off-site, and installed directly on-site.
Cost-effective:
Being pre-manufactured, precast concrete blocks reduce the need for skilled labor during installation, lowering labor costs. The use of reusable molds also makes the manufacturing process cost-efficient. Additionally, their durability reduces long-term maintenance expenses, making them a cost-effective solution at every stage of the project.
Rapid construction:
One of the key advantages of precast concrete blocks is their ability to reduce construction time. Since the blocks arrive ready for installation, projects can proceed quickly, helping meet tight deadlines. Additionally, this method eliminates weather-related delays and the need for on-site curing, unlike traditional wet concrete.
Design flexibility:
Precast concrete offers excellent design flexibility. Panels and blocks can be customized to meet specific architectural or structural requirements and are available in various shapes, sizes, and finishes.
Easy to install:
Precast concrete blocks are designed for easy installation. With interlocking or connecting edges, they can be quickly assembled on-site, reducing labor needs and saving time.
Fire Resistant:
Precast concrete blocks are made from inherently fire-resistant materials. They do not ignite or release flammable residues, enhancing the safety of the structure.
Aesthetic look:
Modern precast concrete blocks offer a wide range of design options including patterns, textures, colors, and finishes. With thoughtful selection, these blocks can enhance the aesthetic appeal of a structure while keeping costs and effort low.
Precast solutions offered by Strata
StrataBlock™:
The StrataBlock reinforced soil wall is a composite system that combines concrete block units with a reinforced soil mass, stabilized using StrataGrid. Strata introduces StrataGrid, an innovative uniaxial geogrid designed to offer efficient and reliable soil reinforcement. With its high tensile strength, this product provides a stable network of apertures, creating a geometric grid. The tensile strength of StrataGrid improves lateral load bearing capacity, with interlocking features, through the use of shear keys which are built into the design. We typically recommend using StrataBlock in combination with geogrids to reinforce non-plastic soils. The blocks can tolerate deformations without visible distress at the wall face. Our blocks are also engineered to withstand hydrostatic pressure and local pore water pressure.
Strata’s contribution to providing precast concrete solutions
Case 1
Client: National Highway Authorities of India (NHAI)
Location: Surat – Dahisar, India
Product used: Stratablock™ and StrataGrid™
Application: Construction of RS Wall to widen the National Highway
About the project:
On the National Highway – 8 (NH-8), a section between Dahisar, a suburb region in Mumbai and Surat, was overburdened with heavy traffic, especially heavy goods vehicles. Considering this grave situation, NHAI decided to construct 16 new structures to widen the road to 6 lanes.
Considering the soil conditions, it was concluded that the best solution for this project would be to construct these 16 new structures using an RS wall system. Based on the prevailing soil conditions, StrataGrid and StrataBlock were used. Due to their proven performance, high load-bearing capacity, durability, and easy installation, NHAI approved using Strata products.
Strata’s design team revamped the structure’s designs to address the adverse problems associated with the project, such as tough soil properties, weather conditions, traffic, proposed load-bearing capacity, and groundwater problems. We successfully completed the project before the assigned deadline and provided the best quality precast material, which allowed it to overcome difficult challenges easily.
Case 2
Client: National Highways Authority of India (NHAI)
Location: Tumkur-Chitradurga, NH 4, Karnataka, India
Product used: Stratablock™ and StrataGrid™
Application: Construction of reinforced soil wall
About the project:
The National Highway Authority of India (NHAI) felt the need to widen the National Highway-4 (NH-4) as it connects the thickly populated areas of Tumkur and Chitradurga, situated in Karnataka. Due to this route’s heavy traffic, the authority wanted to extend the highway into 6-lane roads.
Considering the terrain and subsoil conditions, the conventional solution of RCC retaining walls was expensive and time-consuming and designing and constructing the approaches to the raised foundation was essential.
It was suggested that the foundation levels of these walls should be raised enough to meet the technical requirements and to make them more cost-effective. Reinforced soil material was also utilized in these walls. Both the walls and berms were constructed with stringent quality control. Using StrataGrid and StrataBlock resulted in a considerable cost reduction compared to traditional RS wall construction.
Strata Geosystems has played a key role in delivering precast concrete block solutions for several major infrastructure projects across India. Our product, StrataGrid, has remarkably provided extensive stability and tensile strength to some of the significant national highways, easing the traffic in those busy corridors. This innovative geogrid has provided a highly efficient soil reinforcement solution. With the interweaving of high-tenacity polyester yarn, StrataGrid offers a stable network of apertures that are cost-effective and provide an exceptional lifespan of 100+ years to the structure.
To know more about the services and products offered by Strata, contact our experts today!