How is precast concrete installed?

Precast Concrete Systems

Precast Concrete Installation Process

1. Foundation & Substructure Prep
Anchor Verification: Check embedded bolts/plates in foundation for precise positioning.
Bearing Pads Installation: Place neoprene or steel shims to level and distribute loads.

2. Component Delivery & Staging
Sequenced Transport: Deliver elements in assembly order (e.g., columns before beams).
Laydown Area Setup: Clear ground near crane with timber dunnage to prevent damage.

3. Rigging & Lifting
Lift Point Selection: Attach slings to designated lifting inserts or loops cast into the unit.
Crane Operation: Use tower/mobile cranes with capacity for heaviest element + rigging.
Balance Control: Employ spreader beams for large panels to avoid cracking.

4. Positioning & Placement
Guided Alignment: Signalers direct crane operator; laser levels verify plumb/level.
Temporary Bracing: Install adjustable props or braces to hold elements until permanently connected.
Bearing Adjustment: Shim elements to match design elevations.

5. Structural Connections
Bolted Connections: Weld steel plates or tighten high-strength bolts for instant stability.
Grouted Sleeves: Inject cementitious grout into rebar sleeves for reinforced continuity.
Welded Joints: Securely weld embeds on adjacent elements (e.g., column-to-base).

6. Joint Sealing & Finishing
Weatherproofing: Seal joints with compressible foam backing + silicone/polysulfide sealant.
Architectural Touch-ups: Repair transport scratches; apply coatings or exposed-aggregate washes.

7. Post-Installation Checks
Tolerance Survey: Verify alignment (e.g., ±3mm for verticality).
Load Transfer Test: Confirm connections bear design loads (e.g., via load cells or strain gauges).