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The Design and Construction of

Precast Concrete Structures

Precast Concrete in
Mixed Construction

International Airport Oslo 5 structural materials

Helsinki precast concrete, steel and timber

Houston Art Gallery precast


ferrocrete and integrated steel truss

Contents

What is
mixed &
composite
construction

Precast
with
timber and
masonry

Hybrid
precast &
insitu

Contents

What is
mixed &
composite?

Precast
concrete
with
steelwork

Precast
with
timber and
masonry

Hybrid
precast &
insitu

Contents

What is
mixed &
composite?

Precast
concrete
with
steelwork

Precast
with
timber and
masonry

Hybrid
precast &
insitu
concrete

Contents

What is
mixed &
composite?

Precast
concrete
with
steelwork

Precast
with
timber and
masonry

Hybrid
precast &
insitu

CONSTRUCTION TECHNIQUES

MONO single material


HYBRID precast and insitu concrete
MIXED concrete with other materials
COMPOSITE structural interaction

Mixed or composite?
Precast floor
units on steel
beams

Mixed or composite?

19 mm dia. x 125 mm @ 150 c/c


= 70 kN per stud

200 mm deep prestressed hollow core floor

Tie bars in slots = 1200 mm long


40-100 mm gap

Cast insitu concrete


grade 25
1200-1500 mm wide

150 300 mm
depth

Load

Full scale tests


without studs

Deflection

Cast insitu concrete


grade 25
1200-1500 mm wide

150 300 mm
depth

Load

Deflection

Cast insitu concrete


grade 25
1200-1500 mm wide

150 300 mm
depth

Load

Full scale tests


with studs

Deflection

Cast insitu concrete


grade 25
1200-1500 mm wide

150 300 mm
depth

Load

Deflection

Tie bars, say T12 or T16 @ 400 c/c

Precast

Insitu infill

Small cracks at interface

30 to 40% more moment capacity:


shallow beams, or greater spans?

BENEFITS of MIXED
CONSTRUCTION ?

- material performance suits structural and


architectural needs
- elements are optimised
- fewer elements & more prefabrication
- less scaffolding & site labour problems
- less wet concrete & reinforcement on site
- less risk of bad weather delays

POTENTIAL DIFFICULTIES ?

POTENTIAL DIFFICULTIES ?

POTENTIAL DIFFICULTIES ?
- too many suppliers
- split design responsibilities
- inadequate design information
- no codes of practice for the interfaces
- early design information
- tolerances
- mistimed deliveries
- construction sequence
- temporary stability and safety

Contents

What is
mixed &
composite?

Precast
concrete
with
steelwork

Precast
with
timber and
masonry

Hybrid
precast &
insitu

PRECAST ADDED TO STEELWORK

pretensioned floors onto beams and rafters


pretensioned beams to columns
faade panels to steel frames
hollow core wall panels to steel frames

PRECAST ADDED TO
STEELWORK

PRECAST ADDED TO STEELWORK

Offices for Ericsson, Sweden

resulting in a flat-slab ?

The Big Apple car park & shopping mall, Finland


16 m span x 400 deep + 20 mm steel soffit

Prefabricated Delta beam + composite slab

Steel columns and head fixing + precast


soffit units 16 m long x 3.6 m wide

Bracken House in London insitu columns,


prestressed beams and metal decking

753 million (RM 5000m) new soccer stadium .

Steel frame, precast terraces (SCC) and


composite steel beam + hollow core floors

Temporary steel roof to 6 storey precast car park

Hollow core wall panel + steel frame

Hollow core wall panel + steel frame

BENEFITS

rapid steelwork erection

long span precast floors

composite floor + beam

thermal efficiency in facade

PROBLEMS

BENEFITS

rapid steelwork erection

long span precast floors

composite floor + beam

thermal efficiency in facade

PROBLEMS

steel beam deformations


under temporary conditions

add steel ties whilst fixing


precast

torsional instability of steel


beams

tolerances

Contents

What is
mixed &
composite?

Precast
concrete
with
steelwork

Precast
with
timber and
masonry

Hybrid
precast &
insitu
concrete

PRECAST WITH CAST INSITU CONCRETE

pretensioned floors onto/within beams


precast shell beams with insitu continuity
pretensioned beams onto columns
precast frames onto insitu foundations
precast facades on insitu frames

Precast for speed + insitu for difficult access.


Eastern Pretech, Kepong, Malaysia.

London Gatwick airport precast floor units


span 16 m onto insitu beams and columns

20 m long post-tensioned beam with hollow


core slabs, used compositely?

No composite
action used
between insitu
beam and
precast floors.

Composite cast insitu beams


and prestressed floor units

Tie steel in 1500


mm long slots

Composite slab with shallow post-tensioned


beams possible in a 150 m long car park.

Underground car park, Italy.


Floor x beam span = 80 sq.m
Total depth = 250 mm

Precast composite slab


= 250 mm deep hollow core + 75 mm
insitu topping to span about 10 m.

cast insitu
columns,
steel
diagonals,
precast +
insitu floor
diaphragm

VNO Tower, The Hague, Netherlands

Stability =

Cast insitu = precast progress

BENEFITS

horizontal elements prefabricated

minimise formwork

continuity at beam-column
connections giving greater
span/depth ratio
immediate working platform

PROBLEMS

BENEFITS

horizontal elements prefabricated

PROBLEMS

minimise formwork

continuity at beam-column
connections giving greater
span/depth ratio

immediate working platform

tolerances

mistimed deliveries
formwork removal
relative shrinkage and
creep movements

Contents

What is
mixed &
composite?

Precast
concrete
with
steelwork

Precast
with
timber and
masonry

Hybrid
precast &
insitu

PRECAST CONCRETE MIXED


WITH TIMBER

pitched roof rafters


exposed face beams, e.g. Glulam
timber frames with precast floor planks
timber housing with precast concrete
walls and floors

PRECAST CONCRETE MIXED WITH TIMBER

Supermarket in Belgium.
Who designs the precast-to-timber connection?

Total precast concrete car park in Sweden ?

. with glue-laminated timber roof

Timber frame with .

Timber frame with two-way spanning


precast floor units

BENEFITS

long span, lightweight, rafters


provide clear open office space

Glulam beams are both


architectural and structural

can be integrated with precast


and steelwork

speed of erection

PROBLEMS

BENEFITS

long span, lightweight, rafters


provide clear open office space
Glulam beams are both
architectural and structural
can be integrated with precast
and steelwork
speed of erection

PROBLEMS

no design information

unfamiliar details

connection design

end rotations greater than


precast

more expensive than steel


rafters

The Dutch House; precast masonry walls, psc


or rc hollow core, prefab masonry panels

Same idea in many European countries

Prefabricated brickwork fascia spandrel beams


Insitu brickwork infill shear walls

PRECAST CONCRETE MIXED WITH MASONRY


Michael Hopkins Inland Revenue, Nottingham

600 prefabricated brick pillars 3 variants


305 precast floors 15 variants

Precast floors 14 m x 3.6 m with exposed soffit

The rotunda and air con control tower

BENEFITS

accurate prefab masonry

horizontal elements prefabricated

lightweight floors in hollow core


or beam and block

infill shear walls possible

immediate working platform

PROBLEMS

BENEFITS

accurate prefab masonry

horizontal elements prefabricated

lightweight floors in hollow core


or beam and block

Infill shear walls possible

immediate working platform

PROBLEMS

bearings

delays due to strength of


masonry during precast fixing

tolerances

floor shrinkage/creep effects

CONCLUSIONS
mixed construction used in 75% new buildings

mixed does not always mean composite

to replace one material element with another for


the benefit of the whole building process

precast concrete has central role both as


primary and secondary elements
some architectural demands only satisfied
using mixed construction

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