Prefabricated poles

prefabricated poles

Precast columns are reinforced concrete structural elements of square or rectangular cross-section, used as vertical supports in halls, warehouses and engineering structures. They are produced from concrete of class C30/37 or C40/50, in cross-sections from 25×25 to 60×60 cm, heights of 3-12 m, with reinforcement adapted to the loads. They are used in industrial construction, road infrastructure and as power and fence poles.

For each project precast columns price is calculated individually, taking into account the section, height and quantity of ordered elements. We guarantee competitive rates while maintaining the highest quality of precast reinforced concrete. We invite you to get a free quote tailored to your investment.

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Precast columns – reinforced concrete elements of the load-bearing structure

Prefabricated columns are the basic element of the skeletal structures of industrial and warehouse halls. They are manufactured from high-strength concrete by vibropressing in steel molds. Prefabrication technology ensures dimensional precision and repeatability of parameters of each column. A prefabricated column is characterized by a monolithic structure with integrated connection elements.

The structure of prefabricated columns is based on main and transverse reinforcement. Longitudinal reinforcement consists of ϕ16-32 mm bars of RB500W steel symmetrically distributed. Closed ϕ8-12 mm stirrups every 10-20 cm ensure the stability of the reinforcement. Subsequently, prefabricated columns have additional reinforcement in the connection zones.

Cross-sections of prefabricated columns are adapted to the loads and spans of the structure. Standard dimensions are 30×30, 40×40, 50×50 and 60×60 cm for square columns. Rectangular cross sections of 30×40, 40×50, 50×70 cm for higher loads are also available. In addition, the prefabricated column can have an I-beam or circular cross section.

The prefabricated column connection system allows for quick installation of the structure. Column heads equipped with consoles for supporting beams and girders. Column bases with anchor plates or foundation cups. In addition, prefabricated column s can have brackets for attaching curtain walls.

The heights of prefabricated columns cover the needs of various facilities. Standard lengths from 3 to 12 meters in 0.5-meter increments. It is possible to make multi-segment columns up to 20 meters high. However, the prefabricated pole is designed individually for each object.

The surface finish of precast columns depends on the exposure. Interior columns with smooth or textured architectural concrete. External columns with additional protective coatings. First of all, precast columns can be colored in the mass or painted.

Examples of prefabricated multi-storey columns

Prefabricated multi storey columns An example of the layout of the slopes of a multi storey hall

Prefabricated multi-storey columns with cantilevers. The arrangement of cantilevers (in one or two directions) is determined by the location of a given column in the overall structure.

The example layout of the multi-level hall structure (shown above) uses prefabricated columns mounted in footings with plug-in bars, girders and roof purlins.

Examples of prefabricated single-storey columns

Prefabricated poles

Figure 1: Prefabricated column, beams and girders are supported directly on the column.

Prefabricated poles

Figure 2: Prefabricated column, beams and girders supported in forks.

Prefabricated poles

Figure 3: Prefabricated column, beams and girders resting on a column undercut on two sides.

Prefabricated poles

Figure 4: Prefabricated column, beams and girders are supported on brackets.

Prefabricated poles

Figure 5: Prefabricated column, beams and girders are resting on intersecting brackets.

Prefabricated poles

Figure 6: Prefabricated column, beams and girders are supported on perimeter supports.

Key advantages of prefabricated columns

Prefabricated columns – instant assembly of structures

Prefabricated columns are assembled at a rate of 10-15 pieces per day eliminating time-consuming formwork. Finished elements set by crane directly into cup foundations. Immediate stability allows beams and girders to be assembled the same day. The time for erecting a 2000 m² hall structure is reduced from 2 months to 2 weeks. The modular system speeds up the commissioning of the building by 60-70%.

Precision manufacturing and repeatability

Manufacturing prefabricated poles under factory conditions guarantees tolerances of ±5 mm. The prefabricated pole maintains perfect straightness and verticality throughout its height. Identical parameters of all columns facilitate the installation of horizontal elements. In addition, precise seating of consoles and connectors eliminates matching. Quality unattainable with monolithic columns on site.

Extreme load capacity and strength

C40/50 precast concrete columns carry loads of up to 5000 kN. Reinforced concrete structure withstands horizontal forces from wind and cranes. Precast column designed with a safety factor of 1.5-2.0. Then resistance to dynamic loads and impacts. System proven in halls with 50-ton overhead cranes.

Prefabricated columns – fire resistance

Prefabricated columns provide R60-R240 fire resistance without additional protection. Thick reinforcement lagging of 30-50 mm protects the steel from temperature. The precast column retains its load-bearing capacity under fire conditions for the required time. In addition, concrete does not emit toxic gases during a fire. Construction safety at the highest level.

Durability for decades of use

High-quality concrete in precast columns guarantees 100+ years of durability. Tight C40/50 concrete structure resists carbonation and corrosion of reinforcement. A precast column requires no maintenance or repair for decades. However, F150 frost resistance and W8 waterproofing ensure resilience. An investment in construction for generations.

Versatility of applications

Prefabricated columns used in every type of construction – from shelters to high halls. A wide range of sections and heights cover all needs. Prefabricated column can act as a support, frame or bracket. In addition, it is possible to manufacture special poles to order. A comprehensive system for any building.

Precast columns – the aesthetics of architectural concrete

Precast column can be a decorative element of the interior or facade. The smooth surface of architectural concrete does not require finishing. Precast columns with texture or die imprint create a visual effect. Then the possibility of leaving the raw concrete in the industrial style. Structural function combined with aesthetic value.

Economics of the solution

Prefabricated columns offer a total cost 30-40% lower than monolithic columns. Prefabricated column eliminates the cost of formwork and scaffolding on site. Reduction in labor by 60% due to quick installation. In addition, shorter construction time reduces overall investment costs. Return on choice of prefabrication already at the first hall.

The use of prefabricated columns in construction

Prefabricated columns are used primarily in production and storage halls. They are used as the main load-bearing elements of structures with spans of 12-30 m. The prefabricated column carries loads from roof girders and overhead cranes. In addition, they are used in multi-aisle halls as internal columns. The system dominates in industrial construction, accounting for 70% of implementations.

Logistics centers and high-storage warehouses use prefabricated columns with increased load capacity. The 50×50 cm prefabricated pole can withstand loads from high storage racks. Used in warehouses up to 15 m high with automatic systems. Then used as supports for mezzanines and loading platforms. A key component of modern distribution centers.

Commercial facilities use prefabricated column in mall and hypermarket structures. Prefabricated columns allow large spans of sales rooms without supports. Used in multi-story parking lots as load-bearing elements for floors. Also used in gas station canopies. An economical solution for large-scale facilities.

Road infrastructure uses prefabricated columns in bridge structures and overpasses. Prefabricated column is used to support spans and intermediate pillars. Used in noise barriers along highways and expressways. However, also as gantry posts over roadways. The system complies with the requirements of the General Directorate for National Roads and Motorways.

The power industry uses prefabricated pole as supports for power lines. Prefabricated spun E10.5 and E12 poles for medium voltage lines. Also used as traction poles in rail transportation. Primarily valued for their durability and lack of maintenance. An alternative to steel poles in aggressive environments.

Technical parameters of prefabricated columns

Standard cross-sections of prefabricated columns:
– 25×25 cm – light poles up to 4 m high
– 30×30 cm – loads up to 800 kN, height up to 6 m
– 40×40 cm – loads up to 1500 kN, height up to 8 m
– 50×50 cm – loads up to 2500 kN, height up to 10 m
– 60×60 cm – loads up to 4000 kN, height up to 12 m
– Rectangular sections: 30×40, 40×50, 50×70 cm
Dimensional tolerances: ±10 mm for section, ±20 mm for length

Concrete parameters for precast column:
– Class of concrete: C30/37 (standard), C40/50 (reinforced)
– Compressive strength: fck ≥ 30-40 MPa
– Modulus of elasticity: Ecm = 32-35 GPa
– Water resistance: W8
– Frost resistance: F150
– Exposure class: XC4, XF3, XA1

Reinforcement of precast columns:
– Reinforcing steel: RB500W, BSt500S
– Main reinforcement: 4-12 bars ϕ16-32 mm
– Reinforcement grade: 1.0-3.0% of the concrete section
– Stirrups: ϕ8-12 mm every 10-20 cm
– Console reinforcement: additional ϕ16-20 mm bars
– Reinforcement cover: 30-50 mm

Bearing capacity of precast column:
– Axial force: NRd = 800-5000 kN (depending on the section)
– Bending moment: MRd = 50-500 kNm
– Transverse force: VRd = 100-800 kN
– Limiting slenderness: λ ≤ 120
– Buckling factor: β = 1.0-2.5

Weight of precast poles:
– Pole 30x30x400 cm: about 900 kg
– Pole 40x40x600 cm: about 2400 kg
– Pole 50x50x800 cm: about 5000 kg
– Pole 60x60x1000 cm: about 9000 kg
– Density of reinforced concrete: 2500 kg/m³

Installation of prefabricated columns – step-by-step instructions for implementation

Preparation of foundations for prefabricated columns requires the precise construction of cups or footings. Socket foundations with dimensions larger by 20 cm than the cross-section of the column. The depth of the cup equal to 1.0-1.2 of the cross-section of the column to ensure rigidity. Then the bottom of the cup leveled with a layer of lean concrete C12/15.The axes of the foundations delineated by surveyors with an accuracy of ±5 mm.

Vertical transport of the prefabricated column carried out by a crane with appropriate capacity. Column hooked up by mounting loops in the upper part or special handles. Adjustable slings used to ensure vertical lifting. In addition, prefabricated poles secured with directional ropes. Minimum load capacity of the crane 1.5 times the weight of the pole.

Setting precast columns in cup foundations requires precision. Column lowered slowly with vertical control in two directions. The base of the column rested on the shims in the socket. Precast column then leveled with wooden or steel wedges. Plumb controlled with a theodolite with an accuracy of 1:500 height.

Temporary stabilization of the precast column against flooding of the cup. Mounting braces in two perpendicular directions secure the position. Prefabricated tall columns additionally stiffened with lashings. In addition, possible temporary connection between columns. The stabilization system remains until the concrete sets in the socket.

Pouring of foundation cups performed with C30/37 plastic concrete. The space between the column and the walls of the socket 10 cm filled in layers. Prefabricated column protected against displacement during concreting. However, concrete compacted with a hollow vibrator to eliminate voids. Surface leveled with a slope from the column.

Installation of horizontal elements on precast columns after 7 days after concreting. Beams and girders supported on column consoles by elastomeric washers. Welded or bolted connections according to the design of the structure. Above all, check the geometry of the entire structure before final connection. Survey acceptance confirms compliance with the design.

Prefabricated columns Various installation methods

Figure 1. Installation of prefabricated columns on the footing with built-in contacts.
In the column, in the support zone are concreted steel corrugated pipes, so-called robusta pipes, with a cross-section usually from 60 mm to 80 mm, which are clipped onto the foundation prongs, i.e. the rods coming out of the footing. The mounting holes are later filled with properly selected high-strength mounting mortar. The columns are stabilized and plumbed with steel struts.

Prefabricated columns Various installation methods

Figure 2. Installation of prefabricated columns in cup footing.
Cup footings are prefabricated structural elements of varying dimensions adapted to the dimensions of the slopes based on the design documentation. They are connected to the poured foundation slab with steel rods and stirrups. In the cup, the base of the column is set and then, after adjusting the alignment of the column, the free space is filled with a suitable high-strength mounting mortar.

Prefabricated columns Various installation methods

Illustration 3. Mounting on the footing using professional, dedicated, system screw connectors.
Screw connectors are also used in connecting columns to each other in the case of multi-story buildings (the connection of columns is always done at the height of the ceiling).

Prefabricated poles price – current price list 2024/2025

Precast column s price depends on the section, height and degree of reinforcement of the elements. Precast columns price takes into account the class of concrete and the type and amount of reinforcing steel. Precast column price increases proportionally to the volume – a 50×50 element costs 2.5x more than 30×30. Precast columns price per piece is the basis for calculating industrial halls. In addition, prefabricated columns price includes the cost of consoles, fasteners and surface finish.

Prefabricated columns price – calculation by section

Prefabricated column price for cross section 30×30 cm is the basic price base. Prefabricated columns price for cross section 40×40 cm higher by 70-80% with higher load capacity. Prefabricated columns price for 50×50 cm increases 2.5 times the basic. Prefabricated column price of the largest cross sections 60×60 cm can be 4 times higher. Then prefabricated columns price takes into account reinforced reinforcement for heavy loads.

Prefabricated poles price list 2024 – current rates

Prefabricated column price list in 2024 reflects price stabilization after a period of increases. Columns prefabricated price 2024 increased by 5-7% compared to the end of 2023 mainly by steel costs. Prefabricated columns price is effective from January 2024 for all standard sections. Prefabricated column price quoted per unit or running meter in height. However, prefabricated poles price may include discounts for orders of more than 20 pieces.

Element height – prefabricated columns price per meter

Prefabricated pole price increases linearly with height for elements up to 6 m. Prefabricated columns price per meter height constant in this range. Prefabricated columns price of elements 8-10 m higher by 20% per meter due to transportation. Prefabricated column price above 10 m calculated individually – extraordinary transportation. In addition, prefabricated columns segment price may be higher by 30%.

Transport and installation – prefabricated poles comprehensive price

Prefabricated pole transport price significant at 1-9 tons per piece. Prefabricated columns delivery price by semi-trailer 200-400 PLN per piece. Prefabricated poles installation price by crane in addition 300-500 PLN per pole. Prefabricated pole price may include free transportation for large contracts. In addition, prefabricated poles turnkey price with assembly higher by 40-50%.

Prefabricated poles price 2025 – forecast of changes

Prefabricated pole price in 2025 projected with an increase of 4-6% year-on-year. Columns prefabricated price list 2025 will take into account rising energy and transportation costs. Prefabricated columns price can be stabilized by automation of production. Columns prefabricated price in 2025 will depend on the boom in industrial construction. Above all, prefabricated columns price will remain competitive with steel structures.

Special elements – prefabricated columns option price

Prefabricated columns standard price is for straight elements without consoles. Prefabricated column price with beam consoles plus 15-20% per piece. Prefabricated column price with bifurcated heads plus 25-30%. Prefabricated pole price of two-branch elements increases by 40-50%. However, prefabricated columns price of each option increases the functionality of the structure.

Prefabricated columns final price calculated after analysis of the structural design. Prefabricated column price includes static calculations and selection of reinforcement. Prefabricated columns price includes technical documentation and certificates. Prefabricated column price guarantees the optimal solution of the load-bearing structure. Ultimately, prefabricated columns price is an investment in the rapid implementation and durability of the object for decades.

Prefabricated poles

Here are just some of our implementations of prefabricated columns. This list includes only large investments on which our prefabricated products have appeared.

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