ADVANCED MATERIALS AND CONSTRUCTION TECHNOLOGY

MOULDS
CONSTRUCTION DESIGN
 INTRODUCTION
Prefabrication is the process of making buildings, or components of buildings, in a different location than the

MOULDS- CONSTRUCTION DESIGN

job site itself. Construction companies will transport the completed unit to the final site, where they will also
complete the setup and handover buildings to their new owners. Precast construction technology consists of
various precast elements such as walls, beams, slabs, columns, staircase, landing, and some customized
elements that are designed for stability and durability of the building. Precast residential buildings involve
design, planning, lifting, handling, and transport of precast elements.

Moulds for precast elements shall be of steel and concrete. For design of the moulds for various elements,
special importance should be given to easy de-moulding and assembly of the various parts. At the same time
rigidity and strength and water tightness of the mould are also important taking into consideration forces due
to pouring of green concrete and vibration.

2
 MOULDS - CONSTRUCTION DESIGN
Conventional Mould

Titling Mould

Extrusion Machine

3
 MOULDS-CONSTRUCTION DESIGN
Wall Panel Parapet Beams Staircase

Hallow core slab Pod Element

4
 Titling tables for Wall Panel

Pre- Stressed Beam

MOULDS-CONSTRUCTION DESIGN
Pre stressed Hollow Core
Slab

5
 MOULDS- CONSTRUCTION DESIGN
6
FOR EXAMPLE - Glass fiber reinforced concrete

GRC presents architects and engineers with a material from which the most ambitious designs can be
created. It can be moulded to form modern futuristic designs or to replicate traditional historic features.
GRC can be painted, faced with fine aggregates, colored or simply left with a natural white or grey, smooth
or textured finish. GRC provides the designer with a complete technology that few other materials can

MOULDS-CONSTRUCTION DESIGN
match for versatility.

 GRC is environmentally friendly.

 GRC products reduce loadings on buildings leading to significant savings in superstructure and
foundations.

 GRC is excellent for reproduction and renovation.

 It can be moulded to form modern futuristic designs or to replicate traditional historic features.

7
Cladding

• Glassfibre reinforced concrete, GRC / GFRC is one of the most popular materials used for creative
prefabricated architectural cladding.

Features & Mouldings

MOULDS- CONSTRUCTION DESIGN

• TGRC products are formed by a variety of manufacturing techniques. One of the most versatile is to
cast the composite in moulds manufactured from rubber, timber or Glassfibre Reinforced Plastic
(GRP/FRP).

Making Domes

• Domes are used in a high variety of buildings, such as palaces, shopping center's, theatres,
universities or private villas of Turkish or Byzantine architectural inspiration. However, its major use is in
mosque construction, which accounts for 90% of dome utilization

8
9 MOULDS-CONSTRUCTION DESIGN
10 MOULDS-CONSTRUCTION DESIGN
H2O, Badalona Marina, Barcelona, Spain

GRC from GRCA Member PONCE Prefabricadosis used as facade and wavy curved imposts.

GRC from GRCA Member PONCE Prefabricados SL was extensively used on the 252 apartments near the
Badalona marina, a place in full transformation from industrial to residential. PMIST

MOULDS- CONSTRUCTION DESIGN

• The facade is made up of 7000 m2 of smooth white finished GRC panels, with self-cleaning water-repellent
sealant, and 1000 linear meters of wavy curved fascia, simulating the waves of the sea.

• Large elements and solid fixings of stainless steel, acts for the adversities of construction near the sea.

• The GRC was supplied in natural White color, with self-cleaning and water-repellent sealant.

11
 MOULDS–MAINTENANCE AND REPAIR
Materials and methods for repair and rehabilitation Precast Concrete Precast concrete has several benefits in the repair of
damaged concrete structures: ease of construction, rapid construction, high quality, durability, and economy. Precast
concrete is traditionally used for the following types of repairs:

MOULDS-CONSTRUCTION DESIGN
Dams Channels Levees
Navigation Locks

Flood Walls Costal Structures Marine Structure

12
 MOULDS-CONSTRUCTION DESIGN
Bridges Culverts Tunnels

Rtaining Wall Highway Pavment

Noise Barriers

13
 Common Hidden Dangers and Remedies of Relief Pipe Installation

Hidden danger: Material leaks from the fill-in pier base

Hazard
Compared to the precast concrete pier base, the fill-in pier base is lighter and moves more easily. A poor
design of the pier base structure or incomplete pier base components will cause material to leak from the

MOULDS-CONSTRUCTION DESIGN
pier base. Consequently, the pier base will not be heavy enough, which will affect the stability of the relief
pipe.
Good Practices for Installation & Maintenance Good practice as per requirement including Do’s & Don’ts
of working with Precast construction technology of the manufacturer shall be followed for erection and
maintenance of these sections. Maintenance Requirements It is assumed that no special maintenance is
required during intended working life. Should repairs prove necessary, it shall ably be carried out by the
trained persons using appropriate products and materials.

14
THANK YOU

P R E S E N TAT I O N T I T L E
M. KIRUTHIKA

123011201099

1st year – M.Arch

YAR 203 |Assignment No1

15