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Manufacuring Process

Our Manufacturing Processes

At Mohira Precast, we utilize three distinct, high-quality production methods—Hand-Made, Horizontal Casted, and Vertical Casted—to manufacture a diverse range of durable and precisely engineered precast concrete structures. Each method is chosen to optimize the product's finish, complexity, and structural requirements.

1. About Hand-Made Panel

This process is generally reserved for highly customized, complex, low-volume, or large-scale panels that require intricate finishes or unique geometries. It combines skilled craftsmanship with controlled factory conditions.

Manufacturing Process:

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  1. Mold Creation: Custom molds, often made from wood, steel, or fiberglass, are constructed precisely to the panel's specifications, including any architectural finishes (e.g., stone texture form-liners).
  2. Reinforcement Placement: The steel reinforcement cage (rebar/mesh) and lifting/connection hardware are meticulously placed and secured within the mold.
  3. Manual Pouring & Compaction: Concrete is carefully mixed in small batches and hand-poured into the mold. Handheld or external vibrators are used to compact the concrete, removing air pockets and ensuring the mix fills every detail of the mold and encapsulates the reinforcement.
  4. Finishing & Curing: The exposed surface is hand-finished (troweled, textured, etc.). The panel is then covered and cured in a controlled environment (temperature and humidity monitored) to achieve maximum strength and quality.
  5. De-molding & Storage: Once the concrete reaches sufficient strength, the panel is carefully removed from the mold and stored in the yard to continue curing until it achieves its full design strength.

Pros & Cons by Casting Type

Manufacturing Type Pros (Advantages) Cons (Disadvantages)
1. Hand-Made Panel
  • High Customization: Unmatched ability to create unique shapes, large panels, and complex architectural details.
  • Higher Cost: Due to intensive skilled labor and custom/single-use formwork.
  • Superior Finish Variety: Optimal for specialty aggregates, custom textures, and intricate details requiring a hands-on approach.
  • Slower Production Rate: Lower daily output compared to mechanized systems.
  • Excellent for Prototypes/Low Volume: Economical for one-off or small-batch projects.
  • Finish Consistency: Heavily reliant on the skill of the craftsman, which can introduce minor variations.
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2. About Horizontal Casted

This is the most common and efficient method, especially for large flat elements like slabs, walls, and architectural cladding. The panels are cast face-up, allowing for a superior architectural finish on the exposed face.

Manufacturing Process:

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Mohira Precast

  1. Form Setup: Large, flat casting beds (often steel or concrete) are prepared and cleaned. Edge forms are set to define the panel dimensions. If an architectural finish is required, the form-liner is placed face-up on the casting bed.
  2. Reinforcement Placement: The steel reinforcement is positioned within the form, elevated to ensure proper concrete coverage (cover depth).
  3. Machine Pouring & Vibration: Concrete is poured rapidly onto the form using an overhead dispenser or truck. High-frequency vibrating tables or internal vibrators are used to consolidate the concrete for high density and strength.
  4. Top Surface Finishing: The top (non-form) surface is finished using mechanical trowels or by hand to achieve a smooth, monolithic surface.
  5. Curing & Stripping: The panels are cured, often with accelerated methods like steam or heat, to quickly reach the required de-molding strength. They are then stripped from the mold and prepared for transportation.

Pros & Cons by Casting Type

Manufacturing Type Pros (Advantages) Cons (Disadvantages)
2. Horizontal Casted
  • Best Architectural Finish: The top face can be easily finished (broomed, sandblasted, exposed aggregate) while the bottom against the form is smooth.
  • Increased Labor for Lifting: Panels must be tilted or lifted from a flat position, which requires robust equipment and careful planning.
  • High Efficiency: Excellent for large, flat, and repetitive elements like floor/roof slabs and large wall sections.
  • Space Intensive: Requires significant factory floor area for the large, flat casting beds.
  • Precise Dimensions: Controlled setup on a flat, stable surface ensures high dimensional accuracy.
  • One-Sided Finish: Typically, only the surface in the mold gets the perfect form-face finish.
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3. About Vertical Casted

This highly industrialized process is ideal for large volumes of standardized, thinner, non-architectural elements like solid wall panels. Panels are cast between two vertical surfaces, maximizing factory floor space.

Manufacturing Process:

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Mohira Precast

  1. Mold Assembly (Battery Mold): A series of vertical casting cells, known as a "battery mold," are prepared. These steel molds can cast multiple panels simultaneously.
  2. Reinforcement & Inserts: Reinforcement cages, along with all necessary embeds, connection hardware, and service openings (conduits, pipes), are placed and secured vertically within the mold cells.
  3. Concrete Injection: High-slump concrete is precisely injected from the top or sides of the mold. The narrow mold cavity typically requires self-compacting concrete or intense external vibration.
  4. Curing & Heat Treatment: The casting cells are often heated (e.g., using steam or hot water) to accelerate the curing process, allowing for production cycles of just 24 hours.
  5. Stripping & Cleaning: Once cured, the vertical cells are opened and the panels are lifted out. The molds are immediately cleaned and prepared for the next casting cycle.

Pros & Cons by Casting Type

Manufacturing Type Pros (Advantages) Cons (Disadvantages)
3. Vertical Casted
  • Very High Production Speed: Quick turnaround (often one panel per day per cell) due to accelerated curing and rapid cycling.
  • Limited Thickness/Shape: Best suited for uniform thickness and simpler rectangular panels; complex geometries are difficult.
  • Space Efficient: Molds are stacked vertically, maximizing output per square meter of factory floor space.
  • Standardized Finish: Both faces are smooth from the steel mold; limited options for complex architectural textures or custom aggregates.
  • Excellent Dimensional Uniformity: Produces a highly consistent product due to rigid, reusable steel molds.
  • Air Pockets/Voids Risk: The narrow vertical pour requires specialized concrete and vibration to prevent internal voids.
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Mohira Precast

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Readymade Boundary Wall in Narsinghpur

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Compound Boundary Wall in Jabalpur

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Mohira Precast

Mohira Precast specializes in premium precast boundary walls and ready-made compound walls. Our customizable solutions prioritize security and aesthetics, ensuring unparalleled protection and visual appeal for your property.

Quick Link

Contact Info

NH-22 Village Karapgaon Bamanwada Road
Tehsil-Gadarwala
Distt. - Narsinghpur (MP)

MohiraPrecast@gmail.com

8878365160 , 9755133332

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