ElecoPrecast Standard Products

Precast & Prestressed SolutionsElecoPrecast®

Precast & PrestressedStandard Products

® ®

www.elecoprecast.com 01476 562277 / 01594 8475002


Introduction

ElecoPrecast® combines and co-ordinates the design,

manufacturing and expertise of over 65 years in Bell & Webster

Concrete, and over 30 years in Milbury Systems, to deliver high

quality precast concrete products at competitive prices.

The Concrete Force

The Concrete Force defines our relentless drive to continually

improve on our own expectations while exceeding yours, ensuring

we add value to your project.

Concrete Commitment

ElecoPrecast® is committed to delivering more efficient, cost

effective and safety focused sustainable concrete solutions. Our

vision is to continue to exceed our customers’ expectations whilst

making an impact on new customers.

Certificate No: FM 167

Concrete Relationships

We believe in working with you as a partner from the start, which

means offering our expertise in designing and manufacturing

precast concrete to suit your individual project requirements.

Concrete Quality

Through our factories based in Lincolnshire and Gloucester-shire;

ElecoPrecast® has got your project covered across the entire UK.

Contents

L Walls 3-7

Rocket Walls 8-11

Prestressed Horizontal Panels 12-13

Prestressed Vertical Cantilever Panels 14-15

Tee Walls 16-17

Ground Beams 18

Barriers 19

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L Walls unitsElecoPrecast®

Introduction

The unit has a plain concrete finish as struck from the mould. Either

2No. or 4No. 30mm diameter holes are formed through the base

for anchorage, depending on the wall height. Additional holes are

provided through the stem for lifting and for the attachment of

corner strapping, if required.

Design Criteria

Designed in accordance with Eurocode: Basis of structural design

(BS EN 1990:2002) and Eurocode 2: Design of concrete structures

(BS EN 1992-1-1:2004) as well as BS 8110-1:1997. Concrete grade

C35/45 to BS 8500-1:2006. Nominal cover to reinforcement is

45mm (minimum cover = 40mm + �Cdev = 5mm). Units designed

to retain adequately drained material with a bulk density of

18kN/m3 on either or both sides – either level with the top of the

wall with a maximum surcharge of 10kN/m2 or at a maximum

incline of 32.5º to the wall. If required weepholes can be formed

during casting. It is usual to allow a 10mm joint as tolerance

between units to absorb creep. Customised units can be

manufactured within the range of standard sizes to suit specific

applications, consultation at design stage is recommended.

Customised units can be manufactured within the range of

standard sizes to suit specific applications.

Foundations

The foundation requirements should be determined by a qualified

engineer. Units placed on a concrete foundation should be bedded

on mortar and wedged to attain correct alignment. Where it is

necessary to anchor the unit to the foundation see “Stability”.

Stability

Anchors comprise of T.20 high yield deformed bar and two part

polyester resin mortar, used in accordance with the manufacturer's

instructions. Position the retaining wall units onto the concrete

foundation and align using a mortar bed and shims as required.

Using the 30mm diameter holes in the unit base as a guide drill into

the foundation to the required depth. Pour sufficient mixed resin

into the hole first then insert the T.20 bar so that it is just below

the surface of the unit and completely encapsulated in resin.

Important points to remember. Drill sufficient holes to allow the use

of a complete batch of mixed resin; The mortar is placed in the hole

first; follow the resin manufacturer’s instructions for placing the

anchor bars into the resin; when correctly fitted the bars should

finish below the surface of the wall unit completely encapsulated in

resin.


a f

s Standard Sizes

Height mm Width mm straight unit Width mm corner unit(s) Weight straight unit Weight corner unit(s)1000 1000 1000 394 kg 686 kg1500 1000 1000 631 kg 1046 kg1750 1000 1000 761 kg 1230 kg2000 1000 1000 890 kg 1400 kg2500 1000 1250 1316 kg 2600 kg3000 1000 1500 sections 1 & 2 1740 kg 2070 kg sections 1 & 2

3750 1000 1300sections 1 & 2

1000sections 3 & 4

2596 kg 2460 kgsections 1 & 2

2532 kgsections 3 & 4

The loading 18 kN/m3 is approximately a bulk density of 1800 kg/m3

Unit Minimum Embedment Anchor SizeFoundation

(mm) Unit (mm) No. & Type Length(mm)

1000 125 115 2No. T.20 2751500 125 124 2No. T.20 2901750 125 130 2No. T.20 2902000 125 133 2No. T.20 2902500 200 151 2No. T.20 4003000 200 165 2No. T.20 4003000 200 165 2No. T.20 4303750 200 195 2No. T.20 4303750 200 195 2No. T.20 475

Anchors for Standard Conditions

H

4

L Walls units

fertiliser and silage root crops and grain aggregates and road

Standard Sizes

Anchors for Standard Conditions

Handling and Installation

Units are delivered laid down on their edge and are fitted with 2No. recessed lifting anchors. Quick release loops (1) and installation

shackles (2, 3 & 4) are available for purchase to use in conjunction with customer’s plant to offload, upright and erect. Conformitywith current lifting legislation and vehicle off-loading is the customer’s responsibility.

1 2 3 4

5www.elecoprecast.com 01476 562277 / 01594 847500

salt river banks fuel stores slurry and waste soil retention

L Walls straight units

ElecoPrecast®

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Dimensions - L Wall (4 holes) mmHeight a b c d e f h j l m1 m2 n p r

3000 3000 1500 1000 110 200 400 300 500 550 400 550 220 560 130

3750 3750 1875 1000 110 255 500 300 500 688 500 688 290 420 135

Dimensions - L Wall (2 holes) mmHeight a b c d e f h l m n p r

1000 1000 500 1000 103 120 240 200 315 185 250 500 104

1500 1500 750 1000 110 130 230 300 n/a 375 220 560 110

1750 1750 875 1000 110 135 235 300 438 438 220 560 120

2000 2000 1000 1000 110 140 240 300 500 500 220 560 120

2500 2500 1250 1000 110 180 305 300 625 625 220 560 125

6 www.elecoprecast.com 01476 562277 / 01594 847500

L Walls corner units

ElecoPrecast®

fertiliser and silage root crops and grain aggregates and road

3000mm highsections 1 & 2

1500mm high1000mm high

Dimensions 1 piece unit (2500mm, 2000mm, 1750mm, 1500mm, 1000mm)

Height a b c d e f h j l m m1 m2 n p r

1000 1000 1000 1000 103 120 240 200 n/a 315 n/a 185 500 250 500 104

1500 1500 1000 1000 110 130 230 300 n/a 375 n/a 375 250 235 530 n/a

1750 1750 1000 1000 110 135 235 300 n/a 438 n/a 438 125 240 520 120

2000 2000 1000 1000 110 140 240 300 n/a 475 525 n/a n/a 210 580 120

2500 2500 1250 1250 110 180 305 300 n/a 540 710 n/a n/a 330 590 125

Dimensions 3000mm unit, section 1 & 2 opposite handHeight a b c d e f h j l m m1 m2 n p r

3000 3000 1500 1500 110 200 400 300 500 490 1010 260 750 350 800 131


3750 3750 1300 1300 110 255 500 300 500 550 750 100 650 290 720 187


3750 3750 1875 1000 110 255 500 300 500 687 1188 500 688 290 420 135

1750mm high

www.elecoprecast.com 01476 562277 / 01594 847500 7

L Walls corner units

ElecoPrecast®

salt river banks fuel stores slurry and waste soil retention

2500mm high2000mm high

3750mm high sections 1 & 2

3750mm high sections 1, 2, 3 & 4

3000mm highsections 1 & 2

3750mm high sections 3 & 4


Rocket Walls®ElecoPrecast®

Introduction

The units are individually wet cast in bespoke steel moulds, giving

a plain concrete finish as struck from the mould. Either 4No. or 6No.

28mm diameter holes within a recessed profile are formed through

the base for anchorage, depending on the wall height and

proposed usage. Additional holes are provided through the stem

for lifting of the units with wire rope lifting devices, or a specialist

forklift attachment can be used to lift the units from the base.

Design Criteria

Designed in accordance with BS8110 and BS8002. Concrete grade

C35/45 to BS8500-1:2006. Nominal cover to reinforcement is

40mm. Units designed to retain granular material with a bulk

density not exceeding 16kN/m3 with an angle of repose of 35° on

either or both sides – either level fill with the top of the wall with a

maximum surcharge of 10kN/m2 or, alternatively surcharged at an

angle of 30°. It is usual to allow a 10mm joint between the units as

tolerance to absorb creep.

Foundations

The foundation / slab requirements should be determined by a

qualified engineer. Units placed on a concrete foundation / slab

should be bedded on mortar to ensure even bearing and preserve

alignment. Where it is necessary to anchor the units to the

foundation / slab, see ‘Stability’.

Stability

Dependant on unit type and proposed usage, anchors comprise of

either 16mm diameter excaliber screwbolt with washer (located fix),

or 16mm diameter threaded rod with nut and washer, located into

an M16x65 Spit Grip, encapsulated in a multigrout in accordance

with the manufacturer’s instructions (anchored fix). Position the

units one the concrete foundation / slab and align using a mortar

bed and shims as required. Using the 28mm diameter holes in the

unit base as a guide, drill into the foundation / slab to the required

depth. Pour sufficient multigrout (where required) into the hole first,

then insert the 16mm diameter excaliber screwbolt or threaded rod

and tighten to advised max torque.


Guidelines for offloading

Units should be offloaded and stacked upon timber bearers.

Offloading and installation should be carried out in this position using wire rope lifters (can be supplied) or a fork-lift attachment.

Conformity with current lifting legislation and vehicle off-loading is the customer’s responsibility.


Innovative retaining wall solutions for agricultural,industrial and recycling & waste facilities

Rocket Walls®

handling & installation

ElecoPrecast®

Guidelines for installation1 Position, line and level wall units on continuous

mortar bed both sides. Strike mortar off flush.

2 Drill 16mm diameter holes 125mm deep into base slab, using holes in unit as pilots.

3 Insert 16mm screw bolts with plate washer into each hole then tighten to 100N/m torque.

4 Using non-shrink mortar and a trowel, fill recess and strike off flush.

5 Leave to cure for a minimum of 48 hours before loading.

Timberbearers

Wire ropelifters (canbe supplied)

Forklift

Proprietary

liftingattachment

for forklift (can besupplied)


Innovative retaining wall solutions for agricultural,

Rocket Walls®

straight and corner units

ElecoPrecast®

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Dimensions - Rocket Wall (corner)Height Weight a b c d e f g h j k

2.4m 1091kg 2400 970 1200 100 131 131 710 1600 800 759

3.0m 1842kg 3000 1200 1200 110 150 165 870 2000 1000 680

4.0m Steel corner infill assembly

Dimensions - Rocket Wall (straight)Height Weight a b c d e f g h j

2.4m 1100kg 2400 970 1250 100 131 131 710 1600 800

3.0m 1860kg 3000 1200 1250 110 150 165 870 2000 1000

4.0m 2820kg 4000 1650 1250 94 169 185 1280 2600 1400

Unit Screw Bolt Requirements

Height (m) 2.4 unit 2.4 corner 3.0 unit 3.0 corner

Screw boltsrequired (no) 4 2 6 2

Diameter(mm) 16 16 16 16

Length (mm) 200 200 200 200

Length infoundation 100 100 100 100(mm)

Height (m) 4.0 unitThreaded rodfixed with a 6split grip (no)Diameter(mm) 16

Length (mm) 215

Length infoundation 65(mm)

Straight UnitsCorner Units

Dimensions


industrial and recycling & waste facilities

Rocket Walls®

ElecoPrecast®

� Fast and easy installation

� No protruding foot

� Easy to move for resitting

� Ideal for bunkers and division walls

� Self-shedding units – prevents the lodging of stored material

� Flexible layout opportunities –integrates with our standard retaining wall units

� Corner units available

� Load one side or both

� Forklift attachment available to aid and speed lifting

Load shareconnector

RubbingPlate

End coverplate

Introduction

ElecoPrecast® Prestressed Horizontal Panels are designed for

simple and fast onsite installation to enable costs to be kept to a

minimum.

The panels are designed to be stacked one on top of each other

to form a load bearing wall from either or both side, dependent

upon the arrangement of the structural steelwork.

Manufactured on 70m long prestressing beds the panels are

prestressed during manufacture, which provides an inherent

enhanced strength and resilience to many types of retained

materials.

Tongue and grooved joints assist with alignment of stacked panels,

with the added benefit of load transmission between the panels

sharing the retained loads.

During the casting process, engineered threaded sockets are cast

into the panels to facilitate fastening the fixing clips to the

structure. The units are cast as standard with a Class A steel mould

finish to one side and all edges, complete with a hand trowelled

or brushed upper surface. This allows for easy wash down due to

the smooth impervious surface.

Design Criteria

Panels are designed to BS8110, part 1, as prestressed units.

Individually wet cast in ‘long-line’ process and subjected to

accelerated curing on heated beds, cast indoors.

Foundations

Connected to the building frame by transmitting the load against

stanchions, these panels are held in place with bolts and cleats

and do not require foundations.

Stability and Durability

ElecoPrecast® prestressed panels are highly resistant to accidental

damage, as they have the ability to flex on impact where normal

block walls could crack and suffer structural failure.

Panels are easily removed and re-sited providing flexibility to

change a configuration of the structure as the Client’s future needs

evolve.

Using Horizontal panels (spanning between columns or fixed

within the walls) considerable wall heights can be achieved,

through stacking of the units. Various panel heights are available

including 1.00m, 1.20m and 1.50m; these may be mixed and

matched for the benefit of providing an overall wall height to meet

the Client’s requirements.

This system is particularly useful for raising internal or external

ground levels in or around a building frame, or for King

post applications to retain an earth bank.


Prestressed Horizontal PanelsElecoPrecast®

12


Panels to be offloaded fromdelivery vehicles and stacked onflat hard standing.Stacking timbers to be placedbetween panels directly above theone below, as shown. Do notstack panels more than 6 high.The panel weights are marked oneach panel.

Using suitable lifting machine, fixwire rope slings (or D shackles) topre formed holes in panels orproprietary lifting devices to cast-inlifters.

All units to be lifted under controlof banksman.

Ensure all 4 clips and bolts arefitted to panel and are tightenedbefore removing load from liftingmachine.

NOTE: Bolts must be regularlychecked for tightness.

Seal and tool jointsusing gunned mastic.

Refer to Milburymanual for instructions.

1 3 4



c

a

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Dimensions - Horizontal Panel(a) Panel Height 1.0m 1.2m 1.5m

(b) Panel Thickness 80mm 120mm 160mm 200mm

(c) Panel Length To suit the project, limited by load/span and handling considerations

Prestressed Horizontal PanelsElecoPrecast®

2

The ElecoPrecast® Prestressed Vertical Cantilever Panel system

provides the user with a more cost and time efficient system when

comparing against a traditional on site insitu wet-cast system.

ElecoPrecast® Prestressed Vertical Cantilever Panels allow greater

strength in a more slender panel than a comparable thicker

traditional insitu wall.

The panels are supplied with a tongue and grooved joint in the

vertical plane to assist with wall alignment, load share and ease of

sealing.

Manufactured on 70m long prestressing beds the panels are

prestressed during manufacture, which provides an inherent

enhanced strength and resilience to many types of retained

materials. Retained heights of up to 4m can be achieved for many

material types.

Where vertical cantilever panels are designed for wind only, such

as a security wall or fire wall, effective heights of up to 7.50m can

be achieved.

The units are cast as standard with a Class A steel mould finish to

one side and all edges complete with a hand trowelled finish to

the other face.

During the casting process, cast in Wavy Tail Lifters can be cast in

the top edge of the panel to assist with on site installation.

The stem is designed as a Class 2 prestressed element with limited

tensile cracking. The prestressing of the panels reduces the

incidence of tensile cracking in the panels.

ElecoPrecast® provide a full design service which includes for the

design of both the stem and the structural foundation to support


Prestressed VerticalCantilever Panels

ElecoPrecast®

the stem. ElecoPrecast® are able to supply the foundation rebar

or purely a rebar schedule for the client to procure direct from a

local supplier.

Panels are designed to BS8110, part 1, as prestressed units.

Individually wet cast in ‘long-line’ process and subjected to

accelerated curing.

ElecoPrecast® Vertical Cantilever Panels are used in numerous

applications, for example soil retention, coarse

material / aggregate retention, silage clamps, under-ground slurry

stores, basements of structures, waste recycling bunkers, prison

security walls, substation fire walls, and flood alleviation schemes.

As the concrete panels are cast

from high grade concrete the

units can support loads from

above such as a floor or roof

planks, which make them an

ideal solution as a basement

wall up to 3.60m effective

height in many situations.

Vertical Cantilever Panels can

be designed to support loads

from one or either side, or

both sides as a double

loaded unit.


Panels to be offloaded fromdelivery vehicles and stackedon flat hard standing.

Stacking timbers to be placedbetween panels directly abovethe one below. Do not stackpanels more than 6 high.

The panel weights are markedon each panel.

Foundation trench is excavatedand a strip footing formed inthe base. Cradles are set outon the footing, and the panelslowered into them, shimmedand levelled as necessary.Temporary propping must beused - the frequencydepending on height andexposure.

Second Panel to be propped asdetailed in stage 3.

Load maintained by liftingmachine until panel isadequately propped.

Set up rebar and framework.

If a prop happens to be in theway do not move any props.

Seal joints as required. Pourand compact concrete.

Props to remain in position untilfoundation concrete is in excessof 25N.

1 3 42


Prestressed VerticalCantilever Panels

ElecoPrecast®


a

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Dimensions - Vertical Panel(a) Panel Lengths: To suit the project, limited by load/span and handling considerations

(b) Panel Thicknesses: 120mm, 160mm and 200m

(c) Panel Widths: 1.5m standard, 1m and 1.2 special order


Tee WallsElecoPrecast®

Introduction

The unit has a plain concrete finish as struck from the mould. 4 No.

30mm dia holes are formed through the base for anchorage.

Additional holes are provided through the stem for lifting the

various heights of unit.

Design Criteria

Designed in accordance with B.S.8110 Part 1 1997. Concrete grade

45/20 O.P.C. Manufactured using Portland Cement to B.S.12 and

aggregates to B.S.882. Bulk density of retained material 18kN/m³

(approx 1800 kg/m³). Surcharge 10kN/m2 350 angle of friction. The

units are designed to retain material on either or both sides. The

design assumes that the material is adequately drained. If required

weepholes can be formed during casting. It is usual to allow a

10mm joint as tolerance between units to absorb creep.

Foundations

The foundation requirements should be determined by a qualified

engineer. Units placed on a concrete foundation should be bedded

on mortar and wedged to attain correct alignment. Where it is

necessary to anchor the unit to the foundation see “Stability”.

Stability / Anchors for Standard Conditions

Anchors comprise of 4No. T20 high yield deformed bars with

nominal penetration of 150mm both into the foundation and the

unit, used with a two part resin mortar* in accordance with the

manufacturer’s instructions. Position the tee walls onto the concrete

foundation and align using a cement mortar bed and shims as

required. With the 30mm diameter holes in the unit base as a

guide, drill into the foundation to the required depth using a 28mm

diameter rotary percussive drill to give rough sided holes (do not

use a diamond drill which leaves a smooth sided hole). Pour

sufficient mixed resin into the hole first then insert the T.20 bar to

the full depth so that the resin covers and encapsulates the bar.

*as for Retaining Walls

Important Points to Remember�

� Drill sufficient holes ahead to allow the use of a complete

container of mixed resin.�

� The mortar is placed in the hole first.�

� Follow the resin manufacturer’s instructions for placing the

anchor bars in the resin.�

� Anchors are to prevent sliding and are the suggested

method for location on concrete surfaces.�

� Alternative methods may be used that give the equivalent

resistance.


10No. 30mmdia holes in stem and base

1300

2800

750

1100 1100

750

200

2600

200

200 200 200

200

Code 1 Unit C

750

750

750

750

3000

2000

2500

1500

1100

750250500

200

200 200

Code 2 Unit

Tee WallsStandard Sizes and Unit Dimensions

ElecoPrecast®

grain stores marinas sewage treatment plantshousing estates national parks

250

500 1000

250

s n

1000

s n

Unit heightmm

WeightCode 1

WeightCode 2

2000 2304kg 1632kg

2500 2544kg 1872kg

3000 2784kg 2112kg

250

s n

250

500 1000


Design Beams are designed to BS 8110 The structural use of concrete

Loading To suit project specific requirements

Section Up to 400mm wide x up to 800mm high

Lengths Up to 8000mm

Bearings Minimum end bearing 300mm

Anchor Dowels T.32 – Hole diameter 75mm

Lifting Proprietary recessed lifting eyes

Concrete mix Minimum compressive strength 40N/mm2@ 28 days

Cement Ordinary Portland

Aggregate Trent Valley 20mm max size

ReinforcementCharacteristic strengths, Main bars 460N/mm2, Links 250N/mm2

Minimum cover 40mm

Ground BeamsElecoPrecast®

ground beams raised flooring construction sitesroad building poor ground conditions

Introduction

ElecoPrecast® are a company of assessed capability under the

BSI Quality Assurance Scheme, to BS EN ISO 9001: 1994. We

manufacture precast concrete ground beams to a variety of

designs and dimensions as specified by the client. We also

manufacture a range of standard beam sizes to suit the design

criteria.

Design Criteria


� Beams are delivered and off-loaded using the quick

release lifting loops attached to the recessed eyes.

� Simply lifted into their final position using the same

method.


Connection by projecting loops & steel pins

Unit length = 3000mmUnit weight = 1894Kg

BarriersElecoPrecast®


ElecoPrecast® Barriers are provided with 2No. 30mm dia holes

through the face and 2No. recessed anchors in the top for lifting.

Slots are formed in the underside for forklift truck handling.

Units are connected together via, 2No. Galvanised wire loops with

a minimum 1000mm embedment into the barrier and left

projecting at each end and linked with a 25mm dia high yield steel

pin.

Introduction

For years Bell & Webster have designed and manufactured an

enviable range of products for prestigious clients in the civil

engineering, commercial, industrial, agricultural and utilities

sectors.

Bell & Webster have adapted the Type 4 permanent barrier

originally for use in traffic management schemes, to allow greater

flexibility for a variety of situations.

The ElecoPrecast® Barrier has been designed for easy handling

and can accommodate uneven surfaces and changes in

direction. There are many uses for the ElecoPrecast® Barrier in

protection and containment situations.

With further modification to allow a fencing panel to be combined

securely to the ElecoPrecast® Barrier, the barriers offer greater

benefits and a wider range of applications. These include:

� Airport Security

� Building Security

� Car Parks

� Unauthorised Access Area

� Additional Building Protection

� MoD

� Ports


www.elecoprecast.com

Eleco Precast Products are available from:

Bell & Webster Concrete Limited Milbury Systems LimitedAlma Park Road, Grantham, Lydney Industrial Estate, Harbour Road, Lydney, Lincolnshire NG31 9SE Gloucester GL15 4EJTel: 01476 562277 Tel: 01594 847500Our range of products is constantly under review. Data relating to new products will be issued when available. We reserve the right to amend our specifications. January 2013

® ®

ElecoPrecast Standard Products

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