Most average-sized basements (1,000 sq. ft.) are installed in one day by our professional crews. Backfilling can begin immediately after the floor has been poured and the subfloor has been properly attached to the top of the wall. And, because the walls are cured in our facility before being delivered to the jobsite, you can begin construction right away.
You can lay your foundation in the morning and start working on your house in the afternoon, regardless of the weather.
CAN PRECAST WALLS BE ERECTED IN WINTER?
In terms of weather, our Manchester Concrete Contractors serve a large portion of Connecticut, where snow and cold can stymie construction. When the temperature falls below 50°F in colder parts of the country, traditional cast-in-place concrete is not an option.
The good news is that with our forecast, you won't be slowed down by the cold winter weather. The National Precast Concrete Association has many fascinating stories about cold weather construction projects in Connecticut.
Here are some of the most common issues we hear about precast concrete structures:
SECURE THE JOINTS
The sealing of precast concrete joints can cause issues. Joints can separate from one another over time, compromising and weakening the structure. When joint sealants are not applied correctly, this problem can occur. This is usually the result of incorrectly following the joint sealant instructions. If the joints are not properly prepared or cleaned before applying the joint sealant, the adhesion between the joints will be compromised, preventing the joints from properly sealing with one another. However, joint sealant issues are usually avoidable. If the joint sealant instructions are followed and all necessary preparations are made prior to applying the joint sealant, such as ensuring that the joints are clean and free of any dirt or debris, as well as checking that the joints are properly formed to fit together correctly by conducting a dry fit or checking the alignment prior to the joint sealant application, the application of precast joint sealants should be successful and problems with the joint sealant should be avoided.
THE PRODUCT SHIPPING
Shipping precast concrete can be difficult, and it should be a collaborative effort between the manufacturer and the job site contact. Because of the weight and potential size of the structures, precast concrete can be difficult to transport. To transport larger structures, specialized trucking and various preparations may be required. The greater the height, width, and weight of the structures, the more arrangements may be required to facilitate transportation. Permits are required for structures wider than 8 feet 6 inches. Structures wider than 14 feet require a permit and an escort. Structures wider than 16 feet will require a permit and two escorts. Precast concrete structures weighing more than a certain amount will also require a weight permit. Route inspections are required for shipments taller than 13 feet, and bucket lifts may be required to avoid powerlines. The route will be surveyed to ensure that the structures can travel safely. Transporting precast concrete may appear difficult logistically, but using expert hauling companies who understand the DOT rules and are equipped with the appropriate trucks and trailers can make the delivery seamless. If the structure is too heavy, too tall, or too wide to transport, precast designers can usually divide it into multiple sections to reduce the weight or size of each individual precast section. There are several methods for constructing structural connections between precast sections in the field. This allows for the transportation of these large structures while also reducing the lifting capacity required on site.
You can lay your foundation in the morning and start working on your house in the afternoon, regardless of the weather.
CAN PRECAST WALLS BE ERECTED IN WINTER?
In terms of weather, our Manchester Concrete Contractors serve a large portion of Connecticut, where snow and cold can stymie construction. When the temperature falls below 50°F in colder parts of the country, traditional cast-in-place concrete is not an option.
The good news is that with our forecast, you won't be slowed down by the cold winter weather. The National Precast Concrete Association has many fascinating stories about cold weather construction projects in Connecticut.
- Superior Walls can be installed in one day even in the coldest weather.
- What are the most common Precast Concrete issues?
- Precast concrete can be problematic. However, there are preventative measures and solutions available to address many of these issues.
Here are some of the most common issues we hear about precast concrete structures:
- Gluing the Joints
- Concerns about product shipping, offloading, and rigging
- Lack of Flexibility in Subgrade Preparation
- Spalls and Cracks Repair
SECURE THE JOINTS
The sealing of precast concrete joints can cause issues. Joints can separate from one another over time, compromising and weakening the structure. When joint sealants are not applied correctly, this problem can occur. This is usually the result of incorrectly following the joint sealant instructions. If the joints are not properly prepared or cleaned before applying the joint sealant, the adhesion between the joints will be compromised, preventing the joints from properly sealing with one another. However, joint sealant issues are usually avoidable. If the joint sealant instructions are followed and all necessary preparations are made prior to applying the joint sealant, such as ensuring that the joints are clean and free of any dirt or debris, as well as checking that the joints are properly formed to fit together correctly by conducting a dry fit or checking the alignment prior to the joint sealant application, the application of precast joint sealants should be successful and problems with the joint sealant should be avoided.
THE PRODUCT SHIPPING
Shipping precast concrete can be difficult, and it should be a collaborative effort between the manufacturer and the job site contact. Because of the weight and potential size of the structures, precast concrete can be difficult to transport. To transport larger structures, specialized trucking and various preparations may be required. The greater the height, width, and weight of the structures, the more arrangements may be required to facilitate transportation. Permits are required for structures wider than 8 feet 6 inches. Structures wider than 14 feet require a permit and an escort. Structures wider than 16 feet will require a permit and two escorts. Precast concrete structures weighing more than a certain amount will also require a weight permit. Route inspections are required for shipments taller than 13 feet, and bucket lifts may be required to avoid powerlines. The route will be surveyed to ensure that the structures can travel safely. Transporting precast concrete may appear difficult logistically, but using expert hauling companies who understand the DOT rules and are equipped with the appropriate trucks and trailers can make the delivery seamless. If the structure is too heavy, too tall, or too wide to transport, precast designers can usually divide it into multiple sections to reduce the weight or size of each individual precast section. There are several methods for constructing structural connections between precast sections in the field. This allows for the transportation of these large structures while also reducing the lifting capacity required on site.
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CONCERNS ABOUT OFFLOADING AND RIGGING
Offloading and properly rigging precast concrete structures is another challenge. Cranes or large equipment are usually required to pick up and move the structures. Understanding the capacity of the crane, rigging, and lifting devices, as with any crane-related process, poses a risk. It is critical to use the proper rigging so that the structure is secure before lifting.
Improper excavation shoring can result in catastrophic failures and should be inspected and engineered if necessary. If there are overhead obstructions on a job site or there is a question about the shoring, it is a good idea to involve the crane company and walk the site before installation. Lifting diagrams and rigging plans should be created by certified engineers for extremely large structures to ensure the structure is lifted properly. If you able to understand just how to rig a precast structure properly, this is still not enough. What is going to be very important as well is being able to fully recognize the lifting capabilities of the equipment and rigging devices, and knowing which equipment is most appropriate for each individual lift will make the offloading and setting process safer and more efficient.
SUBGRADE PREPARATION
One of the most important aspects of a successful precast concrete installation is subgrade preparation. If this is done incorrectly, problems may arise. A weak subgrade can cause the structure to crack or sink if it settles incorrectly. For example, if electrical cables run through any of these structures as they shift underground, the cables can break, causing major problems. The best way to avoid this is to ensure that the subgrade is adequately prepared for the structure. To do so, the ground must first be properly excavated. Remove any unnecessary debris or materials. This will help to create a level and firm subgrade as well as prevent settlement or shifting that would cause the concrete to crack. In addition, the subgrade must be compacted and completely flat. It is critical to understand the permissible backfill material when backfilling the subgrade. Backfill should be compacted and distributed evenly. Properly preparing the subgrade will help to ensure that the structure stays in place and will greatly reduce the likelihood of any problems occurring.
LACK OF VERSATILITY
Because of its lack of flexibility once the structure has been built and delivered to the jobsite, precast concrete can be difficult to work with. Precast structures are sometimes designed using as-built drawings of what is expected to be encountered below ground. If a precast structure is built to connect to existing piping, the existing piping may not be in the expected location, rendering the precast structure useless.
To avoid this situation, prior to manufacturing the precast structure, partial excavations can be performed to confirm the location of utilities. Structures can also be designed with thin wall knockouts, which are sections of the precast wall that are specifically designed to be thinner and allow for the necessary break through. This allows for greater flexibility in the location of the pipe penetration in the precast wall.
SPALLS AND CRACKS REPAIR
Cracks and spalls in precast concrete structures are common. Poor form construction, rough removal from forms, improper storage, early removal of the structure, and poor structure handling methods can all cause structural spalls. Concrete repairs are classified into three types: structural repairs, cosmetic repairs, and architectural repairs. Repairs to lifting areas or structural connections are included in structural repairs. Cosmetic repairs are used to improve the appearance of the concrete on the outside, such as filling in any bug holes, honeycombing, or exposed rebar. Architectural repairs are increasingly focused on high visibility architectural concrete, which necessitates more exact color and texture matching.
Cosmetic repairs can be done with grout, a cement and sand mixture that can be applied with a sponge float or a steel trowel.
A structural engineer should analyze structural repairs and develop a detailed procedure to ensure proper repair completion. To repair structural cracks or spalls, an epoxy mortar or polymer-modified cement-based grout is frequently used. In general, the damaged concrete should be removed first, and then the surface should be prepared for the new repair material. Steel reinforcement should be cleaned and exposed, and a primer should be used to ensure proper material adhesion. Following that, the new mortar should be applied and allowed to set and cure.
Using precast concrete in your construction process has its drawbacks, but if handled correctly, the benefits to your schedule and installation costs can far outweigh these drawbacks. Consult with your local precaster, and we will assist you with installation or if you have any other concerns or questions about your next project at Manchester concrete contractors Connecticut.
GET IN TOUCH
If you are considering precast concrete for your next project and have any questions or concerns, please contact us. Call us at 860-733-6292
Offloading and properly rigging precast concrete structures is another challenge. Cranes or large equipment are usually required to pick up and move the structures. Understanding the capacity of the crane, rigging, and lifting devices, as with any crane-related process, poses a risk. It is critical to use the proper rigging so that the structure is secure before lifting.
Improper excavation shoring can result in catastrophic failures and should be inspected and engineered if necessary. If there are overhead obstructions on a job site or there is a question about the shoring, it is a good idea to involve the crane company and walk the site before installation. Lifting diagrams and rigging plans should be created by certified engineers for extremely large structures to ensure the structure is lifted properly. If you able to understand just how to rig a precast structure properly, this is still not enough. What is going to be very important as well is being able to fully recognize the lifting capabilities of the equipment and rigging devices, and knowing which equipment is most appropriate for each individual lift will make the offloading and setting process safer and more efficient.
SUBGRADE PREPARATION
One of the most important aspects of a successful precast concrete installation is subgrade preparation. If this is done incorrectly, problems may arise. A weak subgrade can cause the structure to crack or sink if it settles incorrectly. For example, if electrical cables run through any of these structures as they shift underground, the cables can break, causing major problems. The best way to avoid this is to ensure that the subgrade is adequately prepared for the structure. To do so, the ground must first be properly excavated. Remove any unnecessary debris or materials. This will help to create a level and firm subgrade as well as prevent settlement or shifting that would cause the concrete to crack. In addition, the subgrade must be compacted and completely flat. It is critical to understand the permissible backfill material when backfilling the subgrade. Backfill should be compacted and distributed evenly. Properly preparing the subgrade will help to ensure that the structure stays in place and will greatly reduce the likelihood of any problems occurring.
LACK OF VERSATILITY
Because of its lack of flexibility once the structure has been built and delivered to the jobsite, precast concrete can be difficult to work with. Precast structures are sometimes designed using as-built drawings of what is expected to be encountered below ground. If a precast structure is built to connect to existing piping, the existing piping may not be in the expected location, rendering the precast structure useless.
To avoid this situation, prior to manufacturing the precast structure, partial excavations can be performed to confirm the location of utilities. Structures can also be designed with thin wall knockouts, which are sections of the precast wall that are specifically designed to be thinner and allow for the necessary break through. This allows for greater flexibility in the location of the pipe penetration in the precast wall.
SPALLS AND CRACKS REPAIR
Cracks and spalls in precast concrete structures are common. Poor form construction, rough removal from forms, improper storage, early removal of the structure, and poor structure handling methods can all cause structural spalls. Concrete repairs are classified into three types: structural repairs, cosmetic repairs, and architectural repairs. Repairs to lifting areas or structural connections are included in structural repairs. Cosmetic repairs are used to improve the appearance of the concrete on the outside, such as filling in any bug holes, honeycombing, or exposed rebar. Architectural repairs are increasingly focused on high visibility architectural concrete, which necessitates more exact color and texture matching.
Cosmetic repairs can be done with grout, a cement and sand mixture that can be applied with a sponge float or a steel trowel.
A structural engineer should analyze structural repairs and develop a detailed procedure to ensure proper repair completion. To repair structural cracks or spalls, an epoxy mortar or polymer-modified cement-based grout is frequently used. In general, the damaged concrete should be removed first, and then the surface should be prepared for the new repair material. Steel reinforcement should be cleaned and exposed, and a primer should be used to ensure proper material adhesion. Following that, the new mortar should be applied and allowed to set and cure.
Using precast concrete in your construction process has its drawbacks, but if handled correctly, the benefits to your schedule and installation costs can far outweigh these drawbacks. Consult with your local precaster, and we will assist you with installation or if you have any other concerns or questions about your next project at Manchester concrete contractors Connecticut.
GET IN TOUCH
If you are considering precast concrete for your next project and have any questions or concerns, please contact us. Call us at 860-733-6292