All structures, signs, barriers, or equipment upstanding should be supported by something. All of that is available by using precast concrete bases: a load-rated concrete base designed to be cast in the factory and installed without delays at the site. From light poles to signage, fencing to equipment enclosures, knowing how precast bases work will help you get the product you need for a project in Dubai or anywhere in the UAE.
Precast Concrete Bases are what?
Precast concrete base is a preformed concrete member used to attach and secure a structure of any kind above it, such as a lamp post, road sign, camera mast, fence post, cabin or mechanical equipment. A precast base is made offsite in a controlled environment and can be delivered ready to place and join together, unlike a cast in place footing where excavation, formwork and curing onsite must be completed before it can be loaded.
This also reduces the time needed for the base to cure once it arrives on site, as it can be fully designed offsite without the need to wait for cure.
Precast Bases are used anywhere on the road.
The use of precast concrete bases can be seen in a wide variety of infrastructure and construction applications:
1. Street lighting and lamp posts — Ensuring a load-rated footing for street lighting columns along streets and public areas.
Road signage and traffic signals — securely anchor road signage and signal masts from wind loading and vehicle vibration.
3. Security cameras and telecom masts — Backing up surveillance poles and communication equipment, which must have a stable and firm foundation.
Fencing and boundary systems — Anchoring fence posts along site boundaries without having to pour concrete at the individual post locations.
5. Portable cabins & site offices — Providing a level stable footing for temporary or semi permanent site structures.
6. Mechanical and electrical equipment — Supporting machinery such as transformers, generators, HVAC and other equipment that need a firm, vibration-free foundation.
When selecting precast bases, there are several features that are important to consider:
Not all bases are created equal. These are the things to consider when assessing a supplier:
Load capacity – the base needs to be designed and reinforced for the load it is intended to support, including the weight of the structure and any dynamic loads (e.g. wind).
Dimensional accuracy — A fit with the structure it supports, without instability, misalignment, or site modifications will be achieved.
Reinforcement detailing – Proper placement of steel is vital in order to assure that the base will not bend, crack or settle in over time under sustained load.
Cast-in fixings — Bolts, sleeves or anchor points that are cast in directly into the base help to make the installation easy and ensure the connections to the structure above are secure and accurate.
Lifting provisions: Cast-in lifting points are provided for safe and efficient lifting and handling with basic site equipment for transport and placement.
Durability under UAE conditions — Concrete mix should be resistant to deterioration due to the heat, humidity and where applicable, the ground salinity in the UAE.
The UAE has no standards for compliance.No UAE standards for compliance.
The precast concrete products supplied to Dubai are regulated by the Administrative Decision No. 316 of 2012 issued by Dubai Municipality which outlines the approval procedures for precast concrete elements in the construction industry. Manufacturers that make precast products for the Dubai market are anticipated to have a valid DCLD-CQPS Certificate of Conformity, which guarantees that the manufacturing process and the end product conforms to the specified quality standards.
Responsible manufacturers also formulate and sample their concrete according to recognised British Standards for strength, durability and quality control, and stick to these principles in forming, mixing and curing the concrete.
Before you commit to any project using precast bases, it is important to verify that you will be able to get documentation from your supplier that certifies the base meets local regulations and the materials used to make the precast base.
The benefits of precast bases over cast in place bases.
Faster installation — Bases are delivered cured and ready to install; curing delays on site are eliminated, reducing the time to install.
Quality consistency is maintained — Factory controlled batching and curing is more consistent and predictable than site circumstances.
Minimized site disturbance — No formwork, no wet concrete pours, less downtime on active sites due to excavation.
Repetitive accuracy between units — Street lighting rollouts, precast manufacturing (and dozens of other projects) demand repeated accuracy between units.
The production of precast concrete bases.
The first step in manufacturing is to create formwork that precisely matches the dimensions required for the product, be it a small fence-post base or a larger footing for a site cabin or equipment enclosure. Reinforcement is located in accordance to the structural design, and is proportioned to the loads that the base will support.
Cast-in fixings are bolts, sleeves or anchor brackets installed exactly where required before the pouring of the base has been completed, thus allowing the above structure to be connected without an on-site fixings process or improvisation. The concrete is then poured, mechanically vibrated to ensure full compaction, eliminating air voids which could reduce the quality of the unit and cause water ingress and potential long term deterioration.
Bases are cured under controlled factory conditions after the casting process until they achieve their ‘design strength’. Quality checks are performed throughout the process to verify that the formwork dimensions and fixing placement, reinforcement positioning and final surface and dimensional accuracy has been verified and accepted before the units are dispatched.
The following is a list of size and specification considerations to take into account when sizing this product.
The base size and the load rating will depend on the structure that it will support and the conditions which it will be subjected to. When ordering precast bases, it is important to check the following:
Structure weight and dimensions — The bottom ought to be dimensioned according to the weight and footprint of whatever is supported.
Wind and dynamic loading – In cases of lighting columns and signage masts, when exposed to wind, a tall structure requires a base capable of withstanding wind overturning.
Preparing type and layout — bolt patterns and sleeve positions must match the base plate of the structure being installed so that rework on the job is avoided.
Ground conditions — The bearing capacity of the soil and the drainage can influence the size of the base or if additional preparation is required under the unit.
Volume specifications — If you are getting a rollout project, like a light show or fencing for an entire worksite, it is important to work with a manufacturer that can manufacture a consistent range of products at volume.
Installation Best Practices
Elevated on level base — The base should be placed on a properly prepared, level surface, so that it will not settle or tilt over time.
Correct lifting — Use lifting points and proper equipment to prevent chipping the edges and stress on the unit during installation.
Precise alignment of fixings – Check bolt or sleeve alignment with the structure before it is securely positioned in place, otherwise adjustments will be required after the base is in place.
Backfill and compaction — If bases are partially buried, it is important to compact the backfill around the unit properly to offer lateral support.
Frequently Asked Questions
Are there any custom dimensions available for precast bases? Yes. If the structure and fixing layout are unique, manufacturers that have the in-house mould-making capacity can create bases that meet the requirements.
What is the difference between a precast base and a normal cast in place footing? The precast base is produced off-site in the cured condition and is delivered ready for installation, whilst the cast-in-place footing needs to be formed, poured and cured on-site prior to loading.
Can precast bases be used for heavy equipment? Yes, if the base is designed and reinforced to carry the weight and forces of the equipment. Also, it is important to verify the load requirements in advance to detail the base accordingly.
Are precast bases supplied with fixings as well? Many precast bases are made with cast in bolts, sleeves or anchor points to ensure that the structure can be attached to the base with ease on site.
KKK Precast: Production of Concrete Bases for the UAE Market.
KKK Precast Concrete Industry, an establishment located in Jebel Ali, Dubai, produces precast concrete bases for various applications including lighting, signage, fencing, cabins and equipment installation throughout the UAE. Our bases are manufactured under a controlled factory, and tailored to the load and fixing details of each application.
When it comes time to embark on a project that requires reliable, regulation-compliant precast bases, contact us to discuss your structure specifications, fixing layout and delivery schedule.
