Concrete Structures Ltd

A complete design manufacture and erect solution

 Overview
Overview
Contents

Overview 3 Precast Concrete Structures is the industry specialist in the design, manufacture and erection
Hotels 5 of offsite modular building techniques using precast concrete manufactured by our production
Student accommodation 9 facility in Stoke-on-Trent and other manufacturing partners.
Apartments 13
Architectural concrete 17 Precast Concrete Structures has built a reputation based on extensive experience of
Twin-wall 21 economical design, the latest manufacturing processes and the use of composite steel and
Cross-wall construction 23 concrete materials most appropriate to the project. The adoption of modern methods of
Progressive collapse 25 building construction is limited when restricted to a single material and is often constrained
by conventional design thinking.

Precast Concrete Structures designs are innovative in both manufacture and concept.
By directly employing in house erection teams the practicality of the erection process is
factored into the project design.

With the experience of the Precast Concrete Structures team a partnership can be developed
with the Project Design Team and assist in developing new solutions, by providing critical design
information at early development stages. This can assist in the choice of precast concrete as
the correct solution to the building design development.

Ramada Encore Hotel, Warrington Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 3
 Hotels
Hotels
Cross-wall construction

Precast Concrete Structures uses a system of precast elements which link together to form
a cross-wall format. Panels can be formed in solid or twin wall styles to suit the design
requirements of the structure. Whichever solution is selected the sections are produced in
high quality finish which is suitable for direct decoration, with minimal preparatory work,
obviating the need for plaster finishes, leading to cost and programme savings.

The philosophy of Precast Concrete Structures is to produce a design which will provide the
most cost effective solution, utilising the most appropriate materials for the project. This can
include such items as hot rolled steel sections and cold rolled steel infill panels as appropriate.

Benefits of using Precast Concrete Structures include:

n High quality concrete designed for direct decoration or exposure

n Architectural and structural quality components
n Large volume supply capacity
n Dedicated experienced project management
n In house erection by trained and qualified erection personnel
n Solid room size slabs
– prefinished for direct ceiling decoration
– suitable for direct carpet application
n Reduced structural zones free from downstands
n Erection of stair and lift cores as erection progresses allowing
safe access for subsequent trades
n Pre-fitted windows option

Precast Concrete Structures specialise in the fast efficient delivery of the building structure,
where minimal wet trades and high quality finish are essential to follow on trades.
Precast Concrete Structures strive to be market leaders in quality of finished product and
offer an innovative and non-contractual approach to building structures.

Ramada Encore Hotel, Warrington Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 5
 Hotels
Brunel University, Uxbridge Police Federation HQ, Leatherhead
 Student accommodation
Student accommodation
Cross-wall construction

The use of cross-wall construction in student accommodation gives significant benefits for
short-term build projects where a deadline for opening is critical.

Precast concrete construction offers extremely durable accommodation, capable of sustaining

even the toughest conditions of student living.

By the use of direct finishing techniques to the walls and ceiling, together with solid room-sized
slabs, and the preinstallation of bathroom pods, cross-wall construction offers speed of
construction together with economy.

Key requirements for economical construction in student accommodation include:

n Repetition of room layout

n Consistency of vertical alignment to division walls
n Repetition of elevational treatment

By adhering to these basic principles, Precast Concrete Structures will provide advice and
innovative solutions on the most economical means of manufacturing the components and
sequencing the erection to the maximum benefit of the client.

These benefits include:

n Fast-build programme within term-time constraints

n Direct decoration to walls and ceilings, with only minor pre-decoration treatment
n Pre-installation of windows
n Early “dry-box” working for subsequent trades
n A variety of elevational treatments using non-loadbearing cladding systems
(loads are transferred via the cross-walls and do not rely upon external walls for support)
n Reduced structural zone without downstands

Brunel University, Uxbridge Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 9
 Student accommodation
Brunel University, Uxbridge
 Apartments
Apartments
Modular build system

Apartment construction has become increasingly popular as a modular build alternative to

traditional steel and insitu concrete frame methods. The system adopted uses cross-wall
construction in a similar method to the hotel construction system, but differs in that the
variability of room layouts and external elevations require differing techniques and innovative
thinking to produce fast-build economical solutions. The options for apartments are both
extensive and flexible providing key criteria in design are met. Precast Concrete Structures
has broad experience in developing solutions for alternative construction, particularly suited
to the Design and Build market.

Benefits include:

n Direct decorative finish to walls with only minor pre-decoration treatment, negating the
requirements for wet plaster
n Optional methods of floor construction, allowing flexibility for individual client requirements,
including: traditional hollow-core, wide slab composite flooring, pre-finished solid slabs
n Direct soffit finishing in replacement of suspended ceilings, significantly reducing construction
build costs
n Reduced structural zone without downstands
n Construction of common stairs and lift cores as the erection progresses, permitting early
access for subsequent trades
n Pre-fitted windows
n External pre-finished cladding panels, grey concrete inner leaf only or curtain-walling/
metal stud permitting total flexibility in elevational treatment

Apartment construction is usually designed with traditional building solutions which are
subsequently modified during the design process to obtain a competitive edge in Design and
Build solutions. The benefits of early consultation with Precast Concrete Structures will result
in significant savings in both cost and time, resulting from economical manufacture solutions
and reduced erection periods.

The Hub, Manchester Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 13
 Apartments
Budenburg Haus, Altrincham Middlewood Locks, Salford
 Architectural concrete
Architectural concrete

Feature concrete finishes

Precast Concrete Structures has extensive experience with design, manufacture and erection
of architectural and structural building components.

Sections are bespoke and can be manufactured within the programme for our standard
materials with a wide range of finishes and colours including:

n Brick
n Wet cast reconstituted stone cladding and dressings
n Composite architectural/structural insulated columns
n Exposed structural elements

Buildings are considered on an individual basis and assessed for integration of structural
components to reduce programme and to ultimately drive down costs.

This project (right) is a flagship example of the benefits of incorporating architectural cladding
into the structure. Originally concepted as an insitu frame, with independent cladding, the
revised Precast Concrete Structures proposal produced cost saving and significant overall
programme reduction.

Precast Concrete brickwork cladding panels Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 17
 Architectural concrete
Budenburg Haus, Altrincham Carver’s Warehouse, Manchester
 Twin-wall
1
1 Stepped leaves Twin-wall
2 Lintel rebate
4 3 Twin-wall panel
4 Steel cassette panels
5/6 Pod locations and packing shims Walls for direct emulsion finish
3
7 Grout stop
8 Lifting points A production technique used by Precast Concrete Structures as an alternative to cross-wall
9 Lattice girders vertical cast production which is used to provide all the benefits of cross-wall with the
2
10 Services riser knock-out additional advantages:
7 11 Dry packing
12 Temporary props n Flat cast production to both faces from high quality mould faces produces outstanding
quality of finish suitable for direct decoration of faces with minimal pre-decoration treatment
being necessary
n Insitu fill of the cavity provides enhanced continuity giving the benefits of insitu with the finish
quality of precast
12 n Optional insulation application to insulate outside faces without the requirement for post
fixing on site
n Concrete continuity at joint interfaces between wall and floor providing greater security in meeting
6 the requirements of sound reduction in the Building Regulations at component interfaces
n A system of sway frame design allowing removal of shear walls in the longitudinal direction
11 and allowing non structural elevation cladding, glass infill or clear openings between walls
5
Optional hollow core or composite slabs with cast in fittings for passive fall protection.

Optional limited services incorporated within wall panel to permit direct finishing of the wall face
without rebates.

Precast Concrete Structures manufactures concrete in both UK and Germany, thereby offering
a very large production capacity.

10

9
Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 21
 Cross-wall construction
Cross-wall construction

Frameless building method

Cross-wall is a generic method of building construction using a series of division or party walls
which transfer the floor loads through the building to foundation or transfer slab level.

Precast Structures’ system of cross-wall incorporates vertically cast walls providing two faces
of formwork-cast concrete suitable for direct decoration, with only minor predecoration treatment.

External walls to achieve “dry-box” working are effectively only cladding panels supporting
their own weight and do not necessarily contribute structurally to the stability of the building.
The system allows either concrete perimeter wall infill, or lightweight cladding alternatives for
a variety of elevational treatments.

The cross-wall system generally utilises stair cores and lift cores for overall stability, using
the floors as stiff diaphragms for the transmittal of horizontal forces into shear walls located
at staircase and lift shaft positions. The floors are made up of either hollow core, solid slab,
or composite construction.

Brooklands Avenue, Cambridge Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 23
 Progressive collapse
Progressive collapse
55 70 55
55 70 55

T16 VERTICAL
T161500
TIE BAR, VERTICAL
LONGTIE BAR, 1500 FFL
25
25
25
25 FFL
Design for robustness BS8110
60mm screed (by others)
LONG FFL FFL 60mm screed (by others)
A252 MESH

675

36

36
A252 MESH 35mm DRY
Concrete building structures whether insitu or precast, are required to perform in the

675

36

36
PACK 35mm DRY

15

10
15
PACK
F.F.L. event of accidental damage or explosion by meeting the design criteria set out in BS8110

10
F.F.L.

75
for progressive collapse.

75

55

55
180mm thk. 180mm thk.
175

180mm
slab thk. solid180mm
slab thk.
175

solid Within the building structure, ties are incorporated to resist calculated forces determined by

150

150
solid slab solid slab

150

150
85 85 a variety of factors, including:
60 60 85 85
60 60
500mm long end slots
650

500mmcrs long end slots T8 tie bars n Number of stories

650

at 600mm in all (MkT8

05 tie bars
& 06)
at 600mm
Hollowcore crs in
slabs. all
Slots (Mk 05 &n 06) Site strands
Centres of walls/size of spans
Hollowcore slabs. Slots Site strands
to line through each n Total loads carried
to line
side of wall through each C30 insitu concrete 200
side of wall C30 insitu concrete 200
60 60 60
Section through internal twin wall 60 60 60 Section through internal twin wall These are achieved by the use of the following ties incorporated into the precast cross-wall design:
180
with 60mm composite plank 180 with 150mm solid plank
n Vertical ties
n Horizontal ties
Peripheral ties
SECTION THROUGH INTERNAL TWIN WALL SECTION THROUGH INTERNAL TWIN WALL SECTION THROUGH INTERNAL TWIN WALL
n

25 SECTION THROUGH INTERNAL TWIN WALL

60mm screed (by others)
SECTION THROUGH INTERNAL TWIN WALL SECTION THROUGH
Internal ties INTERNAL TWIN WALL
FFL
WITH 100mm HOLLOWCORE PLANK
n

WITH 60mm COMPOSITE PLANK

WITH 60mm COMPOSITE PLANK WITH 150mm SOLID PLANK WITH 100mm HOLLOWCORE PLANK
WITH 150mm SOLID PLANK
36
15

10
Joints between panels are tied together using pre-shuttered insitu-fill to create a robust joint
F.F.L.
with minimal finishing required. The joints use wire ties designed to meet the specific tie-force
75

55
criteria and also allows flexibility in assembly tolerances during erection.
180mm thk.
solid slab
150

150
85
Peripheral and internal ties use high strength steel strand within the nominal insitu joints at cross-
wall locations and around the perimeter of the building to create a continuous tie arrangement.
500mm long end slots T8 tie bars
at 600mm crs in all (Mk 05 & 06) Building design is analysed for structural stability by Precast Concrete Structures consultants
Hollowcore slabs. Slots Site strands
who have extensive knowledge in the design stability of cross-wall building structures.
to line through each
side of wall C30 insitu concrete 200 Section through internal twin wall
with 100mm Hollowcore plank
60 60

80

Precast Concrete Structures Ltd A complete design manufacture and erect solution Page 25

H INTERNAL TWIN WALL SECTION THROUGH INTERNAL TWIN WALL

 Addenbrookes Hospital key worker accommodation under construction using a combination of precast brickwork balconies, twin wall,
structural steel, insitu gable cantilevers and precast hollowcore flooring erected by PCS specialist erection labour.

Typical crosswall construction A new experience for SDC builders and the basis of a future relationship.
 Concrete Structures Ltd

Precast Concrete Structures Ltd

Building 101, The Waterfront
Stonehouse Business Park
Stonehouse
Gloucestershire
GL10 3UT

Tel 01453 820960

Fax 01453 820961

www.precaststructures.com September 2009