sitecast

Sitecast, also spelled site-cast or site casting, refers to the practice of casting material, most commonly concrete, directly on the construction site in its final position rather than producing components off site. The term distinguishes cast-in-place elements from precast elements that are manufactured elsewhere and transported to the site.

In practice, sitecasting involves placing reinforcement, formwork, and pourable material on site, followed by compaction, curing, and finishing. Concrete mixes for sitecast work are selected for workability, strength, and durability, and curing conditions are carefully managed to control shrinkage and cracking. Weather, temperature, and moisture play significant roles in the quality and timing of the pours.

Typical applications include structural slabs, walls, columns, foundations, bridge decks, and architectural or decorative concrete elements that are poured and cured in place. Sitecasting is favored for complex geometries, customization, or when transport of precast components is impractical or cost-prohibitive. It can also reduce handling and lifting requirements for large panels, though it often requires extensive formwork and longer on-site construction time.

Advantages of sitecasting include design flexibility, reduced transportation costs, and the ability to inspect and adapt work on site. Disadvantages include susceptibility to weather and curing conditions, potential variability in quality, and longer schedules compared with precast systems. In practice, engineers weigh sitecast against precast options based on project size, geometry, schedule, and logistics.

See also precast concrete, in situ concrete, and on-site casting.