MANUFACTURING METHODS OF PRECAST ELEMANTS

Logesh V 121ce144
Khanthavel B K 131ce509
Gowthaman K S 131ce504
 CASTING TECHNIQUES

i. Wet Casting
ii. Flat Casting
iii. Gang Casting
iv. Stack Casting

v. Battery Casting
 WET CASTING
• Wet-cast means that the concrete has a water-cement ratio of about 0.4 or higher.

• The moulds are set up within a working centre which is preferably covered and

enclosed.

• The working centre must offer facilities for man movement, handling of sub-

assemblies, placement of concrete and removal of the completed work to the

allocated storage area.

• The manufacturing process carried out by manually, handling facilities must be

available for large volume of work.

 In wet cast techniques, the structural concrete
will have,
• Cube strength – 21 to 50 N/mm²
• Slump value – 0 to 175mm
• Compacting factor – 0.8 to 0.97
 DRY CASTING
• Dry-cast concrete is very dry it has w/c of 0.30 to 0.36 and has zero slump

• Dry-casting requires an expensive dry-casting machine and is typically

used for mass production of products like concrete pipe or manholes and
also in concrete block production.
 FLAT CASTING
• By the production of flat casting techniques, thin skin production
can be used to achieve.
• Good concrete placement and compaction can be achieved due to
the opportunity for spreading the concrete mix uniformly
throughout the mould.
• Concrete cover should be maintained properly.
• Complicated units can be casted.

• Variety of methods for surface finishing.

 GANG CASTING
• Ganging is the process of combining numbers of moulds into a
unit assembly, generally width-wise.
• It reduces the amount of structural support needed to the mould
face.
• It allows a better utilization of the available casting space.
• Ganging can be arranged horizontally and usually allows
concrete to be placed faster.
• Compaction is done by using immersion-type vibrators.
 STACK CASTING

• Stack casting can be used to produce frames and similar components.

• Before placing the stack of casting,

• the treatment of nosing's and chamfers requires attention

As per IS:15916-2011, Stack casting is used for,

• Floor and roof slab panels
• Length : Any desired length
• Breadth : 1 to 4 m
• Mass : 5 t
 BATTERY CASTING
• The use of battery moulds is popular in large panel construction.
• Manufacture of
» Flat structural panels,
» Floor slabs
» L – shaped components such as lift enclosures,
» Balcony elements.

• The moulds consists of a series of leaves or plates spaced apart.

• Battery moulds are ideal for vertical casting of all kinds of solid
concrete walls.
• This casting offers high output and flexibility.
• The elements produced in a battery mould a very precise, smooth
and have a ready to paint finish on both sides.
Vertical battery mould
• The system is very flexible.
• It allows producing elements of various thickness, widths and
lengths.
• The smooth finishing of both sides are of high quality.
• Care and attention is required in the assembly operations as it
should be securely tied.
• It allows a high density of casting to be carried out in a
given space.
• The moulds are extremely durable, easy to handle and operate,
safe from damage and dirt, and provide even curing.