Architectural Precast Concrete Presentation May 2009

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Dina Jones
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1 Presented by Nomenclature Architectural Precast Concrete Martin Newland B.E. M.I.E. Aust CP Eng SA Precast Pty. Ltd. 72 Days Road CROYDON PARK SA 5008 Ferrule Grout tube PHONE: FAX: Web Page: Packers Dowel Tilt - up Concrete (A brief overview) Clutch Cast in plates It is NOT to be confused with Precast Concrete Tilt - up concrete is manufacured onsite and then the panels are lifted into final position Lifter Shutter (Mould sides) 1

2 In all construction work safety is paramount. Precast concrete and tilt up panels are heavy and dangerous if mishandled. Panels onsite should be securely propped. An accident involving 6 tonne panels, only material damage, luckily there were no lives lost 2

Large open site Simple low rise design Large panels High quality finish is not paramount as high a build paint has

Factory made and taken to site Made on site and lifted into position Factory controlled quality Site controlled

available Variety of shapes Limited Shapes Restricted size & weight Extremely large panels can be made Relatively

Architectural Precast Concrete Apartments Building Westpac Jones House Offices Centre Hotel House Multistorey

The panels are made off site & ahead of time and where a high quality finish is required.

3 Large open site Simple low rise design Large panels High quality finish is not paramount as high a build paint has been used on exterior to cover imperfections Precast Concrete Panels Precast Concrete versus Tilt-up Concrete Factory made and taken to site Made on site and lifted into position Factory controlled quality Site controlled quality Large variety of colours Limited range of natural colours Larger variety of finishes Limited finishes available Variety of shapes Limited Shapes Restricted size & weight Extremely large panels can be made Relatively expensive Relatively inexpensive Best used for Commonwealth Embassy Horizon Convention KPMG David Origin Hyatt Architectural Precast Concrete Apartments Building Westpac Jones House Offices Centre Hotel House Multistorey buildings where space is restricted during construction. The panels are made off site & ahead of time and where a high quality finish is required. Ideal for warehouses, factory buildings where there is space to make the panels and where quality & finish are not paramount Westpac House King William Street Education Department Bldg Flinders Street KPMG House, Grenfell Street 3

4 David Jones, North Terrace Horizon Apartments North Terrace Embassy Apartments North Terrace Architectural Precast Concrete SA Water Building Grenfell Street BHP-Billiton House Grenfell Street SGIC Building, Victoria Square Price Waterhouse Centre, Hindmarsh Square Adelaide Bank Building, Hindmarsh Square 4

Stamford Grand Glenelg Stamford Grand Glenelg

Campus West UniSA, North Terrace How are

Shop Drawings Shop drawings are made using AutoCAD.

Design Engineer s drawings, the Architect s

Each panel has its own shop drawing & must contain

required to make the mould the location and type

panel is to be lifted & the capacity of the

to the surfaces the type and colour of concrete to

5 Stamford Grand Glenelg Stamford Grand Glenelg Origin Building, North Terrace The Hawke Building, Campus West UniSA, North Terrace How are Architectural Precast Concrete panels made? Shop Drawings Shop drawings are made using AutoCAD.They contain the information gathered from the Design Engineer s drawings, the Architect s Drawings and the specifications for the project. Each panel has its own shop drawing & must contain all the relevant information for the moulds and the panel to be manufactured. This information includes:- all dimensions required to make the mould the location and type of fittings to be cast into the panel how the panel is to be lifted & the capacity of the lifters the reinforcement to be used and the cover to the surfaces the type and colour of concrete to be used the surface finish to be achieved Elevations & Plans must be drawn showing the location of each panel on the building. 5

Moulds Moulds are made using the information

Moulds can be made from concrete, timber, or

Moulds must be made accurately and rigid

Moulds must be made so the precast panel can

An advantage of precast concrete is that a

Mould bases can be flat and made of steel or

moulds Hooker Building King William Street

6 Moulds Moulds are made using the information contained in the shop drawings. Moulds can be made from concrete, timber, or steel or a combination of all three. Moulds must be made accurately and rigid enough to support the concrete before it sets. Moulds must be made so the precast panel can be easily removed once the concrete has set. An advantage of precast concrete is that a well designed mould can be reused many times. Mould bases can be flat and made of steel or concrete Excellent repetition of the panel moulds Hooker Building King William Street Mould bases can be curved & complex in shape Moulds can be used to make complex panel finishes 6

7 The mould sides (shutters) and block outs for window penetrations are fixed to the mould base, and the and the mould size is checked. Fittings and lifting devices are placed and secured. The mould is cleaned of debris & the location of fittings is checked against the shop drawings The Batch Plant The concrete is placed and vibrated in the mould The concrete is screeded and finished as the concrete casting proceeds 7

The next day the shutters are removed & the

The panel is lifted using a special spreader bar

or taken for further processing The panels are

Storing on edge minimises any warping and

number of common finish treatments available.

Removes the cement skin and gives a sandstone

The milling process removes the top 5mm on

8 The next day the shutters are removed & the panel is prepared for lifting. The panel is lifted using a special spreader bar and a gantry crane and taken to the storage area or taken for further processing The panels are stored on edge in pin racks. Storing on edge minimises any warping and twisting Concrete does not have to be a cold grey material. Apart from painting the surface there are a number of common finish treatments available. These are:- Acid washing. Removes the cement skin and gives a sandstone finish to the concrete. Sandblasting. Removes the cement skin but exposes the aggregate beneath. Polishing. The milling process removes the top 5mm on concrete from the panel face. The milled face is then polished with a series of polishing stones until all the scratches on the aggregates have been removed and a high gloss is achieved. Acid washing Sandblasting 8

9 Polishing Brick tile facing & Mould liners $500 Relative Precast Concrete Prices Price Per Square Metre On Truck On Site Polished, Brick facing & Mould Liners $400 $400 $300 $300 Acid Washed & Sandblasted $200 $200 Plain off form $100 Delivery to site Delivery to site 9

10 Lifting into position on site Lifting into position on site Environmental considerations. Use electric cranes in residential areas Favco STD 1500 crane with 61m boom 5 55 metres metres 140Tonne Liebherr mobile crane with 45m boom 5 34 metres metres 10

Fixing precast panels to the building The structure is constructed ahead of the

may be incorporated in the structure These panels are load bearing These precast

Grout tubes can be seen in the base of the outer two panels These precast Grout

top of the centre panel match the grout tubes in the bases of the other panels.

11 Fixing precast panels to the building The structure is constructed ahead of the Precast Panels being delivered to site These panels are not load bearing Panels may be incorporated in the structure These panels are load bearing These precast concrete panels are stored on there sides in a pin rack in the precast yard The Grout tubes can be seen in the base of the outer two panels These precast concrete panels are stored on there sides in a pin rack in the precast yard The Grout tubes can be seen in the base of the outer two panels The three dowels in the top of the centre panel match the grout tubes in the bases of the other panels. 11

12 These precast concrete panels are stored on there sides in a pin rack in the precast yard Fixing sequence on site The Grout tubes can be seen in the base of the outer two panels The three dowels in the top of the centre panel match the grout tubes in the bases of the other panels. Lifting points can be seen in the top edge of the centre panel This is how the building looks today Sealing the joints of the façade to make it watertight Pacific Apartments, Hindmarsh Square Help is available. Seek out this book in your library 12

13 Precast concrete can be simple or ornate Precast concrete can be simple or ornate Precast concrete can be simple or ornate Architectural Precast Concrete Web Page: 13

Precast Concrete at Paddington Rail Station, London. By George Jones Member of fib Commission 6

Precast Concrete at Paddington Rail Station, London By George Jones Member of fib Commission 6 Precast Concrete at Paddington Rail Station Project background. Reasons for using precast concrete and its