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Close up Design and
Detail of Concrete
Buildings
Practical guidance for
sustainable construction
Gillingham House, Oct 2012
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14:00 – 14-10 Introduction
14:10 -14:45 Principles of construction for heavyweight buildings.
Different systems, and relative benefits - Elaine Toogood
14:45– 15:15 Thermal mass for cooling in non-domestic buildings
– Tom De Saulles
15:15 – 15:30: Refreshment Break
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15:30 – 17:00 Achieving visual insitu concrete - Andrew Cotter
17:00 – 17:30 Tea, Coffee and Sandwiches
17:30 – 18:40 Good practice detailing and specification for
sustainable construction – Elaine Toogood
18:40 – 18:50 Overview of Thermal Properties Calculator and Passive
Design Tool – Tom De Saulles
Further questions and close
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Principles of
construction for heavy
weight buildings
• Performance issues
• Construction methodology
• Types of construction
• Factors effecting choice
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How do we categorize
building methodologies-:
Light weight ?
Medium weight ?
or
Heavy weight construction?
Ideas Store, Hackney,
Adjaye Associates / Mott Macdonald
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Ideas Store, Hackney,
Adjaye Associates / Mott Macdonald
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The Hepworth Gallery,
Chipperfield Architects/ Ramboll
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City of Westminster College,
Schmidt Hammer Lassen Architects /Buro Happold
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City of Westminster College,
Schmidt Hammer Lassen Architects /Buro Happold
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Why use heavyweight
construction?
Inherent performance of concrete:
• Strength
• Durability
• Fire resistance
• Acoustic Performance
• Flood resilience
• Robustness
• Security
• Airtightness
• Thermal Mass
• Visual appearance
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Why use heavyweight
construction?
Other influencing factors:
• Cost
• Procurement
• Available skills
• Programme
• Quality
• Site conditions
• Health and Safety
• Flexibility / design changes
• Sustainability
• Design life
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Precast hollow cored floor
Post tensioned floors
Composite floors
Contoured/coffered floors
Ribbed floors
Sprayed concrete
Tilt up construction
Fabric formwork
Some construction techniques
using concrete
Concrete blocks (masonry)
Lightweight aerated panels
Insulated concrete formwork
Beam + block floors
Cast insitu
Precast Crosswall construction
Tunnel form
Twin wall
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Insitu construction ?
Or
Offsite construction ?
Or
Hybrid?
Construction techniques
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•Cast Insitu reinforced concrete (frames, floors)
•Tunnel form
•Sprayed concrete
•Steel permanent formwork
•Concrete blocks
•Beam + block floors
Construction techniques
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Pre-manufactured components
• Volumetric
• ‘Flat’ elements
Whole building systems
• Cross wall
Pre-cast elements
• Stairs
• external walls
• columns
• floor slabs
• cladding panels
Off Site construction
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• Twin wall
• Composite floors
• Combination of precast
and cast insitu elements
Hybrid structures
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Insitu or precast columns
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Traditional v. Modern Methods of Construction (MMC)
Construction techniques
The Homes+Communities
Agency used to require such
approaches for affordable
homes funding
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Include:
• Light weight aerated
panels
• Insulated concrete
formwork
• Cross wall
• Tunnel form
Modern methods of construction
• Twin wall
• Pre tensioned beams/slabs
• Tilt up construction
• Thin joint block work
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Sprayed concrete
Darwin centre
C.F Moeller/
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Ground floor:
•Insitu ground bearing slab
•Suspended slab
Screed
In-situ
reinforced
concrete
slab (150mm
dpm
Blinded fill
100mm
EPS
)
Trench fill
Ground floors
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•Suspended ground floor and
upper floors
•Precast prestressed concrete
beams and standard building
blocks
•Range of beam depths (150 -
225mm) and block widths
•Generally spans up to 8m
Beam and block
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• Key advantages:
• Voids can be introduced to reduce
self-weight
• Uses small repetitive components
• Easily handled and quick to place
on site.
• Immediately safe platforms
• Beam depths range from 150mm
to 225mm.
Beam and block
Janet Street Porter House
CZWG/
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• Continuous voids to reduce
self weight and provide an
efficient structural section
• Panel depths typically from
110mm to 400mm
• Panel widths typically
1200mm wide but others
are available
• Length of panel dependent
upon the project
(4m – 16m)
Pre-cast hollow core floors
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• Designed to have efficient
shear key joints between
slabs
• When grouted, the
individual slabs become a
system that behaves
similarly to a monolithic
slab
• Often pre-stressed to
improve span
• Min 200mm for shared
bearings before ties are
required
Pre-cast hollow core floors
Continuous wet mortar
to take up camber
Min 140mm bearing with
grouted reinforcement ties
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Key advantages:
• Range of spans and loadings
• Precasting reduces time on site
• Immediate safe working
platform
• The soffit can be exposed or
simply treated
• No propping or formwork on
site
• Thermal mass potential
Pre-cast hollow core floors
National trust HQ, Swindon
Fielden Clegg Bradley Studio /
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• Insitu flat slab
• ‘traditional’ steel reinforcement
(spans 4 - 12m)
• Post-Tensioned Slabs
(spans 6 -14m)
Cast insitu floors
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Key advantages
• Speed of construction
• Simple and fast formwork
• Flexible plan for partitions
and services
• Can aid daylight
• Simple services installation
• Pre-stressing can improve
spans and material efficiency
further
Flat slabs (aka solid slabs)
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Environmental benefits:
– Less concrete
– Reduced use of raw
materials
– Reduced lorry movements
Rapid construction:
– Larger pour area for same
volume of concrete
– Less traditional steel
reinforcement
Post-tensioned Concrete Floors
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Minimum floor thickness
– Minimises the self-weight and
foundations
– Up to 300mm less than steel frame
– Cladding area is minimised –
reducing cost.
– Reduces solar gain
Long spans
– Less columns and foundations
– Increased flexibility for space
planning
– Maximises net lettable area
Potential for an extra storey in
a ten-storey building.
Post-Tensioned Concrete Floors
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Flat slab with column heads:
• Supports higher loads and reduces
thickness of rest of slab
• Cost effective 5m – 10m spans
One-way flat slab with beams
• Beams in direction of longest span
• Upstand beams typical around
perimeter to maintain daylight
Flat slab options
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One-way flat slab band beams:
• Can be economical for columns
size for structures with light loads
• Thinner slabs
2 way flat slab with beams:
• Common for high loads and
limited services (eg warehouses)
• spans 4-12m
Flat slab options
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Ribbed slab with beams:
• Reduces self weight with
increased surface area
• 6 – 14m spans, and slightly deeper
Trough slab
• Similar to ribbed, but included
integral band beams
• spans 4-12m
Other insitu floors
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Waffle slab
• Uses less concrete with deeper
slabs
• Distinctive profiled soffit with
increased surface area
• 7 – 14m spans
• Higher formwork costs and longer
construction times
Other insitu floors
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Steel Deck Composite Floors
• Decking acts as permanent formwork
to the concrete, and provides
sufficient shear bond with the
concrete, so that the two materials
act compositely together.
• Principally for use with steel frames,
but can also be supported on brick,
masonry or concrete components.
• Reinforcement can be traditional
mesh or steel fibres
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Hybrid Construciton
• Precast concrete as permanent
formwork to insitu topping
• Eg: Twin wall; lattice girder
floors; omnia deck
• Composite floors using lattice
girder normally consists of a
temporarily propped pre-cast
plank which is not pre-stressed.
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Twin Wall construction
• This contains most of the
bottom reinforcement in
addition to the lattice
girder.
• Plank depths typically
range from 50mm – 100mm
• Finished overall depth
between 115 – 250mm
• Plank widths are usually
either 1200mm or 2400mm
• Depending on loadings and
overall slab depth, spans of
over 11.0m can be
achieved.
Spray on Plaster Finish
Pre-cast Plate
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• Panels craned into
position from the
delivery truck
• Panel weight
determined by
dimensions and number
of door/window openings
• 5 m long by 2.7 m high
panel will weigh approx
3.7 tonnes
Construction
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• At corners the outside skin
of the double wall panels
project beyond the inside to
provide a fully “shuttered”
junction
• All vertical joints are sealed
with foam filler or wood
Twin wall
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• Steel projecting from the
wall acts as a starter bar for
the next wall lift
• The timber kicker shutter
seals the 30 mm horizontal
gap at the base of the wall
• In filling the wall void the
concrete is driven out under
the wall plates to fill the
nominal 30 mm gap and
ensure full contact bearing
for the structural wall
Construction
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• Erection sockets are cast
into the face of the wall
panel for a rapid
connection of the push pull
props
• Note where the outside
face of the panel extends
on up to act as a shutter
for the edge of the floor
slab
Construction
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Self finished walls to
receive spray on thin
coat plaster
Structure Ready for Finishes
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• Precast permanent shuttering
• Hollow spheres (recycled high
density polyethylene) trapped
in reinforcement cages above
concrete biscuit
• Reduction in concrete usage by
approximately one third
• Opportunity for exposed soffits
• Precast reinforced panels upto
~ 2.4 x 9m
Permanent void formers
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• Prefabricated, lightweight formwork system for cast insitu concrete
• Different systems available:
– Block
– Plank
– Panel (Twin wall)
• Variety of fixing methods and systems
Insulated Concrete Formwork
(ICF)
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• Polystyrene insulation is used as
permanent formwork for the
concrete
• Provides monolithic structure
• Pour heights limited – usually
require additional falsework
• Very simple assembly
• Cold weather working
Insulating Concrete Formwork (ICF)
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Masonry (blockwork)
‘Traditional’ construction
• External walls
• cavity construction
• partial/full fill
• brick or block outer leaf
• Internal partitions
• Basement walls
• Separating walls
Walls
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• Modern method of
construction
•Special dimensionally
accurate aerated blocks
• Specific thin-joint mortar
• 2-3mm joints
• No pointing necessary
•Independent of brickwork
provides programming
benefits
Walls: thin joint masonry
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Prefabricated cavity wall system
• Rapid on-site build
• Consistent quality in controlled factory conditions
• No on-site wastage
• All weather construction
• Any combination of brick and blocks and any brickwork bond
• Higher resistance to rain penetration
• Immediate finished envelope and façade
Quickbuild™
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• Structural or as cladding
• Rainscreen or waterproofing finish
• Insulated sandwich panel options
• Range of finishes possible
Walls: Precast
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Athletes Village
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Crosswall construction
• Pre cast cellular building
system
• Particularly appropriate for
residential sectors including
hotels, student residences
• Comprises factory
engineered concrete
components including:
• Loadbearing walls
• Floors & Ceilings
• Lift Shafts and stair
• Elevation panels
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Crosswall Construction
• Prestressed flat
slabs spanning from
cross wall to cross
wall
External walls
with window
openings
Internal
dividing walls • Floor slabs are
stitched together
and act as a
diaghram providing
lateral stability
Ties in
every unit • Walls are stitched
together to form
load bearing joints
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Buildability
Construction and Design benefits:
• Less infill wall panels
• High quality finishes minimises
follow-on trades
• Flush walls and ceilings – no
downstands or columns
• Tight tolerances
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Construction
• Precast concrete panels are
delivered directly to site in
line with the construction
programme
• Units are lifted directly from
the delivery vehicles into
place
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Insitu-stitching carried out on site using reinforced
bar and a high strength non-shrink grout
Fixing Detail
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Fixing and Inspection Detail
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• Repeated elements will be
erected off foundations or a
transfer slab
• Scaffolding not always
necessary
• A movable safety netting
system is secured to the
concrete frame which moves
with the construction of each
floor
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For optimum solution try to
minimise number of
panels. This depends on:
• Crane capacity at precast
yard
• Crane capacity on site
• Site access
• Maximising number of
units on lorry
• Transportation limits
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University of East London, Fraser Brown MacKenna architects
Five seven-storey and four three-storey structures
3,526 precast panels
Constructed in 33 weeks
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•Time on site v time to design
•Co-ordination of trades
•Phasing of works
Programme and Resources
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Cost model studies
www.concretecentre.com/publications
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Flexibility/Design changes
•Time available to fix brief and design prior to start on site
•Future adaptability: on site and post occupancy
New Square, London
Bennetts Associates
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Cost
• Materials
• Labour
• Transport
• Programme
• Compare like for like
ie Include all additional finishes
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Independent study
•Architecture plb
•Arup
•Davis langdon
•Costain
• 6 structural
options considered
•Published 2008
Secondary School – 1400 Pupils
16,000m² of gross external Area
Mix of 2 & 3 storey spaces
Ground Floor Plan
Cost model study - school
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Less than 2% cost variation
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Cost model study - office
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Procurement
•Design responsibility and quality control
•Specialist items
•Specialism of different contractors
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Site Conditions
•Location
•Access for delivery
•Possible crane size and location
•Size of site (for storage)
•Local labour force
•Weather conditions / exposure
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Quality
•Design brief
•Fair faced finish
•Control and responsibility
•Workmanship
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Buildability
•Appropriate designs
•Sequence of works
•Skills/labour to match requirements
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•Space for working
•Falls from height
•Edge protection
•Safe access
•Heavy lifting
•Repetitive lifting
Health and Safety
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Sustainability issues
•Use of thermal mass
•Waste
•Use of recycled material in specification
•Use of local and responsibly sourced materials
•Design for future re-use or recycling
•Long term performance