Have you driven past bridges and noted these blocks that fit like jigsaw puzzles under the bridge providing support? If you have –you have seen a pre-cast concrete block being used onsite. This is one of its most common applications as abutment walls, and/or retaining walls.
A precast concrete block is a concrete masonry unit (CMU) used in the fascia of a reinforced soil structure. Precast concrete blocks as the name suggests are pre-fabricated (in a factory) and cured in a controlled environment and are typically modular in nature. This means they fit into tight vertical and horizontal spaces, based on the specific site configuration. These blocks’ unique selling propositions (USPs) are speed, precision, control, and consistency, making them a preferred choice for geotechnical projects. It is a predesigned concrete block manufactured off-site and then brought on-site for installation. These blocks are manufactured using reusable molds and under a controlled environment, ensuring consistency and quality. After proper quality and durability checks , they are then transported on-site for easy installation. Our StrataBlock’s create durable structures owing to their design and inbuilt shear keys which allow for interlocking and improved lateral load bearing.
Precasting the concrete blocks is a wide concept. With advancements in technology, one can choose different types of precast concrete units. Our recommendations for the type depends on the site, loading conditions and other technical factors. Following are few precast concrete unit types-
The precast concrete walls are large panels manufactured using a concrete mix and shaped into wall-like structures. These can be used as interior or exterior walls. They are cast in rectangular panels and directly installed at the construction site.
Precast concrete beams and columns are the structure’s support system. They provide support to buildings and bridges. Depending upon size and style, they can be designed and manufactured. The most important fact to keep in mind while manufacturing precast concrete beams and columns is their load-bearing capacity.
These are the flat panels used for flooring and roofing purposes in the building. They are manufactured using the concrete mix and segregated into thin structures, making them easy and convenient to transport and install at the construction site.
These are pre-constructed stairs manufactured using the precast technique. These stairs are completely ready to install with the specific design and structure required by the client.
Retaining walls are extensively used to retain soil and maintain its load-bearing capacity. They are manufactured in sections with interlocking edges. These are then connected using the interlocked edges to form a continuous wall.
Although precast concrete blocks are a recent trend in the construction industry, they have proven highly beneficial in several ways. Some of these benefits are as follows:
The precast concrete blocks are manufactured with utmost quality assurance, and precision, under a controlled environment. This process reduces the chances of defects and bad quality, ensuring durability and making them a perfect option for a stable and reliable structure. Unlike wet concrete which may deform, or have other onsite challenges, this prefab structure is extremely versatile in usage.
The precast concrete blocks undergo a stringent construction process and are manufactured with the specific requirements stated by the clients in mind. Hence, the manufacturer ensures the supreme quality of the blocks and the durability that comes with it as an added advantage.
Traditionally, when the walls, floors and other sections of the structure are constructed onsite, they require extra labor and time. With precast concrete blocks, this extra labor cost is eliminated. They are pre-designed and manufactured off-site and are just installed onsite.
Since it is a pre-manufactured block, the installation doesn’t require skilled labor, dramatically reducing the labor cost. In addition, manufacturing these blocks is also inexpensive as the molds are already designed; the concrete mix just has to take the shape of those molds, reducing the manufacturing cost. Lastly, it is a durable construction material that doesn’t require maintenance often, reducing the overall maintenance cost. As a result, these blocks address cost on three levels.
One of the most important benefits of using these blocks is that it reduces the construction time. Since these blocks are already manufactured and transported to the construction site, they just have to be installed. Hence, this reduces the time needed for the construction and ensures that the tight deadlines of project completion are met. No need to worry about the weather, curing, and other issues with wet cement.
Another significant advantage of using precast concrete is the flexibility in choosing the design and type. It can be designed per the specific choices and is available in several types, depending upon the requirement.
These pre-manufactured blocks are easy to install. They are manufactured using connecting edges and are transported to the construction site; they just have to be installed by connecting the edges. Hence reducing labor and effectively managing time.
The material used for manufacturing these precast blocks is fire-resistant. This fantastic material does not catch fire or release any residues that can catch fire.
Traditional buildings constructed using boring gray concrete are now outdated. With many options for constructing precast concrete blocks, you can now choose the design, pattern, color, and load-bearing capacity. Using a little creativity, you can achieve the aesthetic look with minimum cost and effort.
StrataBlock reinforced soil wall is a composite system consisting of concrete block units in combination with a mass of soil, which is reinforced and stabilised by StrataGrid™. Strata introduces a revolutionary precast solution, StrataGrid, an innovative uniaxial geogrid offering an efficient soil reinforcement solution. 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. Its versatile application makes it more cost-effective and a preferred choice for project managers. We typically recommend using this product with geogrids to provide reinforcement for non-plastic soils. The blocks can tolerate deformations without visible distress at the wall face. We have also designed our blocks such that they can withstand hydrostatic pressure or local pore water pressure.
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
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 innovative 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. The client highly appreciated the services provided by Strata Geosystems.
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
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. The client was highly satisfied with this step’s outcome and the project’s on-time completion.
In a nutshell, precast concrete blocks have significantly changed the facet of the construction material. They have significantly replaced traditional concrete solutions. Using precast blocks has eased the construction process in multiple ways. It has significantly reduced manufacturing and labor costs, construction time, and effort to construct various sections of the structure.
Strata Geosystems has played an important role in providing precast concrete block solutions to various important projects in India. Their 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.
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Director, President – Glen Raven Technical Fabrics
Strata/Glen Raven tenure: 10 years/28 years
Total industry experience: 35 years
MBA – Wake Forest University
Directs the strategic direction of Glen Raven’s automotive, protective apparel, military, geogrid, outdoor and logistic businesses.
Director, General Manager, Strata Inc.
Strata/Strata Inc. tenure: 3 years/14 years
Total industry experience: 25 years
MBA – Georgia State University
Led the integration of Strata Inc. business operations into the headquarters of GRTF and transition from USA based to India based manufacturing.
Director
Strata tenure: 17 years
Total industry experience: 47 years
CA – ICA
Played a key role in the establishment of Strata’s India operations. Provides vision for product innovation and leveraging new technology trends.
Global Technical Sales Director
Strata tenure: 7 years
Total industry experience: 32 years
Civil & Geotechnical Engineer (First class)
Provides highly technical and innovative civil engineering solutions in India and around the world. Responsible for the design and execution of large-scale geotechnical projects around the world including Australia, Asia, Europe, Africa, Middle East, and South America.
CTO – Chief Technology Officer
Strata tenure: 9 years
Total industry experience: 48 years
BTech (Hons), MTech (Civil) Both IIT Bombay, DMS (Bombay University), FIE, FIGS, Chartered Engineer
Streamlines the designs of Geosynthetics and has brought innovation in geogrid and geocell design application.
COO – Projects and Sales
Strata tenure: 13 years
Total industry experience: 24 years
MBA – University of Gujarat
Leads the monetization of products and solutions while ensuring highest execution quality and project profitability.
COO – Technical Textiles
Strata tenure: 13 years
Total industry experience: 33 years
BE (Mechanical) – Nagpur University
Drives excellence in process design, product features and cost effectiveness in production.
CFO – Chief Financial Officer
Strata tenure: 8 years
Total industry experience: 35 years
CA – ICA, ICWA – ICWAI
Leads the finance, accounting, taxation, commercial, legal and IT functions and assisting on all strategic and operational matters.
CDO – Chief Development Officer
Strata tenure: 10 years
Total industry experience: 13 years
MBA – ISB, Hyderabad
Leads diversification of the product portfolio, monetizing the new products and ensuring successful sustained financial growth of the company top line.
CEO – Chief Executive Officer
Strata tenure: 14 years
Total industry experience: 42 years
B Tech (Chemical) – IIT Delhi
Leads day-to-day business operations of the company with focus on capacity expansion, product and process improvement.
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