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Dr.
Kim S Elliott University of Nottingham, UK
The Design and Construction of Precast Concrete Structures
Lecture course and frame design workshop KL : 24-25 July 2006 KK : 27-28 July 2006 www.nottingham.ac.uk
Programme:
1. Conceptual issues and architectural features 2. Precast concrete in mixed construction 3. Precast flooring and composite slabs 4. Precast frame analysis and components 5. Diaphragm action and frame stability 6. Connections 7. Progressive collapse 8. 10 storey frame design exercise
+ Special presentation from Belgium (May 2006)
The Design and Construction of Precast Concrete Structures
Conceptual Issues and Architectural Features
Precast concrete friend or foe
Precast concrete friend
Vauxhall Cross, London, 1995
Precast concrete foe
Precast wall frame, c 1960, Manchester, UK
7 September 2003
Paddington Station, London.
British Precast concerted efforts
Aalborgs prize winning staircase
Precast stairs for Tuborg, Denmark
and many special projects .
UK Concrete Society Winner
Cambridge Science Park, UK, 1988
and Loser !
National Building Frame, Portsmouth University, UK, 1966
..and all in safe working conditions ?
DO YOU KNOW THESE MEN ?
Conceptual Issues and Architectural Features

Contents
Background to the problem
Contents
Current climate for precast concrete
Contents
Buildability of skeletal frames
Contents
Integrated architectural structures
Contents
Current climate for precast concrete Discussion and future developments
Understanding the basic principles of precast concrete design and construction
Infill wall diagram DIAGONAL TENSION
Diagram of floor slab with no tie steel and screed Bournemouth
NO TIE STEEL
END REACTION
FRICTION
Spalling photo Bournemouth
Spalling
500 kN connector made and tested
Welding brackets for Lloyds of London
11 m x 3.6 = 40 sq.m per unit
3.6 m wide hollow core floors, MGM Hotel, Las Vegas
100 % repetition increases productivity by up to 50 %
Modular construction - repeated 360 times
Simmons Hall of Residence, MIT, USA
Egan Report 1998 Rethinking Construction :

sustained improvement targets: 10 % savings in capital costs 10 % reduction in construction time 20 % less defects 20 % improvement in predictability
Egan Report called for maximum use of standard components and processes .
Egan Report called for maximum use of standard components and processes
Precast concrete town near to Helsinki
Stack cast wall panels in Far East
Stack cast panels at Johor Baru, Malaysia
Economic indicators of precast concrete
C factor =
Cost of 1 day skilled labour Cost of 1 cu. m. insitu concrete
Current climate for precast concrete LABOUR 40-50 50 RC
UK where ratio of factory/site labour costs 1.5 2.0 : 1 Let C = 1.0
Nottingham University, UK, 2003
Current climate for precast concrete LABOUR RC 120 80-90
Scandinavia
C = 1.4
Arlanda Airport, Stockholm, 2000
Current climate for precast concrete LABOUR 50 70 RC
Southern Europe (Italy, Portugal) C = 0.7
italy
Current climate for precast concrete LABOUR US$40 RC US$75
Brazil C = 0.55
Current climate for precast concrete LABOUR AUS $65 RC AUS $130
Australia C = 0.5
Economic indicators for precast concrete LABOUR HK$100 RC HK$480
Hong Kong C = 0.2
Far East (e.g. Malaysia) C=?

School Building at Kuantan, Malaysia, 1994
italy
Current climate for precast concrete LABOUR R 50-70 RC R 180
Far East (e.g. Malaysia) C = 0.2 - 0.3
italy
School Building at Kuantan, Malaysia, 1994
50 t mobile over 3 months
Crane factor =
Daily hire of typical crane Daily labour rate
Crane factor
UK Scandinavia Europe Far East Brazil Australia
Crane factor
UK Scandinavia Europe Far East Brazil Australia 8 - 12 6 - 10 10 - 15 ? 15 - 20 17 - 20
Crane factor
UK Scandinavia Europe Far East Brazil Australia 8 - 12 6 - 10 10 - 15 25 - 30 15 - 20 17 - 20
Factory and site labour efficiency
Man x day / sq.m.
Case study is 10 storey frame of area 16,000 m 2 comprising :

RC Columns PSC Beams RC Walls RC Staircases 200 deep PSC hollow core slabs 60 mm insitu concrete topping
Man x day rate RC Columns PSC Beams RC Walls RC Staircases PSC slabs Insitu topping
UK rates 1996-2000
2.5 / cu.m
Man x day rate RC Columns PSC Beams RC Walls RC Staircases PSC slabs Insitu topping
UK rates 1996-2000
2.5 / cu.m 2.0 / cu.m 2.2 / cu.m 3.2 / cu.m
Man x day rate RC Columns PSC Beams RC Walls RC Staircases PSC slabs Insitu topping 2.5 / cu.m 2.0 / cu.m 2.2 / cu.m 3.2 / cu.m 0.13 / sq.m 0.05 / sq.m
Average = 0.35 0.40 man days /sq.m.
Contents
Buildability of precast skeletal structures
Dimensional stability to within 6 mm
Dimensional stability to within 6 mm
Precast Concrete Technology

Cube strength : 50 100 MPa Variation : 3 - 5 MPa Water / cement ratio : 0.3 0.4 PFA : < 30% x cement content Self compacting concrete in all precast factories Recycled concrete coarse aggregate : < 20% 18 hour strength : 20 30 MPa Shrinkage strain : 150-300 x 10 -6
Stockyard after 24 hours
Precast beams for Lloyds of London
Column pitching on-site Day 1
6 storey columns at Grand island, Manchester
Fixing shear walls by Day 5
Shear walls at Grand island, Manchester
Fixing beams by Day 8
Beam-column bolted connection
Fixing prestressed slabs by Day 12
16 m span x 400 mm deep hollow core floor units
Skeletal structure after 4 weeks
Dudley Hill shopping centre, Birmingham, UK
Parking structure after 4 weeks
Cross span car park, UK
Parking structure after 5 months
The Big Apple, Helsinki
500,000 sq. m Europark, Italy
192 m
218 m
6 expansion zones, mainly 75-100 m x 75 m
218 m
Shopping centre after 6 months
Kepong Mall, Malaysia
..in spite of interruptions!!
Kepong Mall, Malaysia
Frame and wall construction in Sydney
Speed of precast construction m2 per week
Floor bay area 100 m 2 75 m 2 50 m 2

Floor bay = beam span x slab span
< 4 storey 1000 - 1500 900 - 1200 700 - 1000
Speed of precast construction ?? m 2 per week
2 2 2
Speed of precast construction 1200 m 2 per week
2 2 2
< 12 storey 600 - 900 400 - 700 300 - 500
Contents
Alternative finishes
Natural stone Polished granite Acid etched Grit blasted Polished Recon Portland stone Recon sandstone Brick slips/halves Pigments Paint
Spun columns. Opera House, Erfurt, Germany (2006)

c. BFT Journal 26 March 2006
RM6000 per sq. m !!
Contents
Discussion and future developments
Future Developments
Self compacting concrete, now upto C90
Future Developments
Self compacting concrete with 1% volume steel or polypropylene fibres
Future Developments
Self compacting concrete: surface crazing, corner bleeding and mould oil patches
Future Developments Mixed construction and SCC (New Wembley terraces)
Future Developments Accurate SCC surface finish: 2 mm depression / 3 m length
Future Developments
Prestressed tee beams
Double tee slabs
Future Developments
75 kg/m 2 Termacol floor units
Future Developments
Robotic formwork
Future Developments
Concrete delivery
Future Developments
Future Developments
Split skin system
Phase 1
Future Developments
Split skin system Phase 2
Future Developments
Split skin system
Phase 3
Future Developments mixed construction

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Dr.

Kim S Elliott University of Nottingham, UK

The Design and Construction of Precast Concrete Structures

+ Special presentation from Belgium (May 2006)

The Design and Construction of Precast Concrete Structures

Conceptual Issues and Architectural Features

Precast concrete friend or foe

Precast concrete friend

Vauxhall Cross, London, 1995

Precast concrete foe

Precast wall frame, c 1960, Manchester, UK

Paddington Station, London.

British Precast concerted efforts

Aalborgs prize winning staircase

Precast stairs for Tuborg, Denmark

and many special projects .

UK Concrete Society Winner

Cambridge Science Park, UK, 1988

..and all in safe working conditions ?

DO YOU KNOW THESE MEN ?

Conceptual Issues and Architectural Features

Background to the problem

Current climate for precast concrete

Current climate for precast concrete

Buildability of skeletal frames

Current climate for precast concrete

Buildability of skeletal frames

Integrated architectural structures

Current climate for precast concrete Discussion and future developments

Buildability of skeletal frames

Integrated architectural structures

Current climate for precast concrete

Understanding the basic principles of precast concrete design and construction

Current climate for precast concrete

Understanding the basic principles of precast concrete design and construction

Infill wall diagram DIAGONAL TENSION

Current climate for precast concrete

Current climate for precast concrete

Current climate for precast concrete

Understanding the basic principles of precast concrete design and construction

Diagram of floor slab with no tie steel and screed Bournemouth

Current climate for precast concrete

Understanding the basic principles of precast concrete design and construction

Current climate for precast concrete

Spalling photo Bournemouth

Current climate for precast concrete

Current climate for precast concrete

Current climate for precast concrete

500 kN connector made and tested

Welding brackets for Lloyds of London

Current climate for precast concrete

11 m x 3.6 = 40 sq.m per unit

3.6 m wide hollow core floors, MGM Hotel, Las Vegas

100 % repetition increases productivity by up to 50 %

Current climate for precast concrete

Modular construction - repeated 360 times

Simmons Hall of Residence, MIT, USA

Current climate for precast concrete

Egan Report 1998 Rethinking Construction :

Current climate for precast concrete

Current climate for precast concrete

Precast concrete town near to Helsinki

Current climate for precast concrete