Professional Documents
Culture Documents
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INTRODUCTION 270
1 PART 1 – GETTING STARTED 271
1.1 COMFORTABLE HOMES 271
1.1.1 Traditional New Zealand Houses 271
1.1.2 The Living Environment 271
1.1.3 Thermal Mass 271
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2.6.8 Structural Drawings 291
2.6.9 Further Information 291 I E
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3 PART 3 - CONSTRUCTIO
CONSTRUCTION
N 292 I
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3.1 CONSTRUCTION CONTRACTS 292 S &
3.1.1 Head Contractor 292
3.1.2 Construction Documents 292
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Introduction
Concrete has been used extensively as a building material in civil and commercial construction for many
years and is a proven building material providing great strength and durability.
The leaky homes crisis of the late 1990’s has seen many changes to building regulations and a considerable
increase in the compliance
compliance costs for traditional timber
timber framed houses. This has lead to an increase
increase in
interest in the use of alternative materials for residential construction. Concrete panel housing, in particular,
is rapidly gaining in popularity.
However, while there is a wealth of information, knowledge and experience on the use of concrete in
commercial construction this is yet to filter in to the residential market.
This manual has been written to provide a guide to developers, architects, engineers and contractors who
may be considering taking advantage of the benefits available from the construction of a concrete panel
house.
The manual is divided into 3 parts.
PART 3 – CONSTRUCTION
While each site will have its own unique conditions this section highlights some common construction and
project management issues that should be considered.
These sections have been written based on Reid’s™ experience of over 20 years leading the precast and
tilt-up construction industry as a developer and supplier of concrete reinforcing, fastening and lifting
solutions.
This manual will give the reader an overall appreciation of the process of designing and building a concrete
panel house.
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PART 1 – GETTING STARTED A O
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O U
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1.1 COMFORTABLE HOMES U T
Thermal mass is term used for the property of a E
material to absorb and store heat.
1.1.1 Traditional New Zealand Houses
New Zealand houses are traditionally structural timber Concrete is a high thermal mass material with the
F A
framing with veneer cladding of timber, brick or ability to absorb a considerable amount of heat energy A N
S C
composite material for weather tightness and aesthetic when the outside temperature cycles outside the T H
E O
appeal. comfort zone. This energy is then released slowly to N R
E S
While insulation is installed within the timber keep the internal temperature within the comfort zone. R
frame there is still a common complaint Thermal mass has the overall effect of flattening out S &
that New Zealand homes have a range of the temperature variations of the internal environment.
temperature extremes. Maintaining an even
comfortable temperature is difficult and often
F R
E
not well managed. I
T I
Table 1.1.3 T D
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I
N A
1.1.2 The Living Environment Material
Thermal Mass (volumetric G R
heat capacity, kJ/m3 /˚k) S &
Comfortable homes are ones where the occupant Water 4186
does not tend to notice the changes in the external Concrete 2060
Sandstone 1800
environment because the internal air temperature is
S L C
Compressed Earth Blocks 1740
comfortable and stable.
Rammed Earth 1673 Y O
S I
F N
FC Sheet (Compressed) 1530
T T C
1.1.3 Thermal Mass
Brick 1360 N R
E I
M G E
Earth Wall (Adobe) 1300
S T
Concrete Block E
Figure 1.1.2 Timber
5
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MIDNIGHT MIDDAY MIDNIGHT
S L
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TIME OF DAY
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In the event of a natural disaster like flooding, concrete 1.2.8 Architectural Finishes
walls can easily be cleaned and restored with minimal
work. Concrete will not rust, rot, corode or warp like Concrete can be finished in many ways, from exposed
other materials. aggregate to honed or polished coloured concrete.
Because concrete does not rot, split, warp or corrode it
provides a superior base for paint or textured coatings
to be applied and will not cause paint coatings to
deteriorate like some cladding materials.
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Designers have a great deal of flexibility in finished 1.3.3 Tilt-up (On Site Casting) E
looks and many concrete producers have specialist
technical assistance for architectural concrete. Figure 1.3.3a
F A
A N
1.2.9 Speed of Construction S C
T H
E O
Concrete panel construction is a faster method of N R
construction than most timber frame methods. Initially E S
it may appear that construction work is slow as the R
panels are cast however the work progresses rapidly
S &
with the erection of the panels and secure lock-up
stage can be achieved quickly.
F R
E
I
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1.3 THE BUILDING PROCESS T D
B
I
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S &
1.3.1 Overview
Building a concrete panel house is not a complex task,
although good planning in the early stages ensures
the elimination of costly mistakes in the latter stages.
S L C
Y O
Trades need to be co-ordinated and made aware of the
required adjustments in method when building with S I
F N
concrete. T T C
N R
E I
M G E
S T
E
Walls are cast either on-site using the floor slab as
a casting bed or off-site in a pre-casting factory.
Tilt-up uses the floor slab as a casting bed. The
A crane is used to lift the panels in place, either panels are then tilted up directly into their final
from the slab or the frame used to transport panels
position. Where space is limited “stack casting” can be N
from the pre-cast factory. I
R
employed. V
Water, power, gas and electrical services need to A
be cast in to walls. Stack casting is the process of casting panels one of N
top of the other, and is a particularly effective process
A
The roof can be constructed in the same manner
when there are many panels needed of the same
as any other construction method.
design, or where smaller panels can be cast on top of
larger panels. W
A M
1.3.2 Wall Casting Process S L
Figure 1.3.3a – Stack Casting
Y L O
S C D
Walls are both the structural and weather tight T A U
elements in one unit. E S L
M T A
There are a number of ways the building could N R
I
progress depending on the casting process employed. G
Walls can be cast:
C
On site – a process called “Tilt-up”.
To use the slab for casting it needs to be large enough
H C
A A
Off site – a process called “Precast” to take the dimensions of the largest panel. If it is N S
N T
not then a temporary casting platform can be made to E -I
L N
extend off the main floor. S
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Once placed, the panels are supported by a cantilever 1.4 TYPES OF CONCRETE WALLS
connection to the floor slab or alternatively are located
in rebates.
The footing under the panel is not necessarily load 1.4.1 Wall Construction
bearing and may be used to support and level
Typical concrete walls consist of 3 main layers to
the panels during construction while the adjacent
produce the final wall.
thickened floor slab may be used to support long term
wall and roof loads. Structural Layer – This layer will be 100-200mm
thick and provides the bulk of the thermal mass
benefits if located inside the insulation layer. The
1.3.4 Precast (Off Site Casting) actual panel thickness will depend on the loads that
are to be supported and panel height.
Panels can be precast on site away from the building
area or off site in a precast factory. Insulation Layer – While the insulation can be placed
either side of the structural layer to make the most of
Precasting allows for walls to be cast in advance of the
the thermal properties it should be placed on the outer
main construction starting and may help in providing
side of the structural layer.
more consistent panels for a contractor inexperienced
in using concrete panel construction methods. External Wythe – This is the weatherproofing layer
and usually the basis of the final cladding. It can be
The panels in the below diagram are supported by
finished in a number of ways to give an impressive
a cantilever connection to the floor slab. Once the
architectural finish.
foundation / floor has cured the props can be removed.
With some plaster systems the external finish may also
be an insulating plaster.
Temporary prop
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1.4.2 Concrete Strapped and Lined 1.4.3 Reid’s™ Nirvana™ System E
While the concrete will assist in moderating Because Nirvana™ is a sandwich panel system with
temperature changes inside the house this type of the insulation on the exterior of the structural layer
F A
construction does not benefit from the thermal mass of it maximizes the benefits of thermal mass. The foam A N
concrete because the insulation layer is on the inside insulation isolates the external temperature and helps S C
T H
face of the concrete. keep the internal temperature stable. E O
N R
E S
Services can be easily provided by fitting them within The Nirvana™ pin is a thermal insulating high strength R
the insulation layer after the panels are erected. connection tying the two layers of concrete together. S &
Conduit for services is placed within the structural
Figure 1.4.2 layer or foam layer during panel casting.
Insulation
F R
E
20-30mm I
T I
Structural /
T D
B
weather
100-150mm
Figure 1.4.3 I
N A
G R
Insulation S &
30-50mm
Weather Structural
50-80mm 100-150mm
Internal plaster
S L C
board lining
Y O
S I
F N
Metal or timber T T C
strapping N R
E I
M G E
S T
E
Internal Face
Nirvana™
N
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V
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N
A
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Designers should select a system that provides the performance required depending on climate, resources, budget
and design constraints.
Table 1.4.5
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1.5.4 Cranes E
1.5 FEASIBILITY INVESTIGATION
Cranes will be one of the most expensive pieces of
equipment hired onto the site. To minimise this cost
it is important to plan ahead to try and reduce the size F A
A N
1.5.1 Overview of the crane needed and the time it spends on site S C
T H
As with all methods of construction there must be a E O
Things to consider are: N R
thorough assessment of the site, especially for the sites E S
The load – Weight and dimensions of a panel are R
suitability for concrete construction. S &
key information. An estimate of the dimensions and
While most house designs and sites are suitable for weight will assist the crane hire company to correctly
concrete panel construction this section deals with the assess the most suitable crane for each application.
F R
variables that need to be considered. Typically most residential panels tend to be about 1 to
I E
10 tonnes. Some can exceed 15 tonnes but this is not T I
T D
B
common. I
N A
1.5.2 Site investigation
G R
The following areas require clarification in the
How close can the crane get to the lift load – Lifting S &
capacity of a crane is determined by the distance the
initial site survey to ensure suitability for concrete
load is from the centre of rotation.
construction.
Ground conditions Obstacles the crane has to work around in order to
complete the task – Power lines, trees and buildings S L C
Crane access.
Y O
can all impact on the operation of the crane. Each S I
F N
Longest reach for the crane. T T C
N R
obstacle adds time and complexity to the job. E I
Truck access if casting off site. M G E
The suitability of the ground conditions – Confirm that S T
Casting bed location if casting on site. E
the ground area is big enough to support the weight of
Propping restrictions. the crane moving into position and when working. Also
The following sections give the criteria of what needs check the stability of the ground and identify potential
to be satisfied to ensure suitability of the site. trouble spots such as underground water mains or
N
drains. Crane access on and off site also needs to be I
R
considered. V
A
1.5.3 Geotechnical Investigation Cranes can be set up on sloping ground but they have N
A
to levelled before lifting. The crane operator may need
The ground conditions must be suitable for a house
to bring additional materials and equipment to level
using heavy building materials. Most subdivisions
the crane.
will have been required to have a geotechnical
W
investigation that will highlight any areas of low The impact of the crane operation on the general A M
S L
strength ground and may make recommendations for public – If the operation of the crane results in extra Y L O
maximum permissible bearing pressures. traffic control or loads being lifted over roadways or S C D
T A U
In most normal situations a concrete house will other property then any required authority will need to E S L
M T A
N R
I
not require any different foundation designs be obtained before lifting.
than a timber framed home with a concrete G
floor and will be designed around the standard
maximum bearing pressure of 100kPa.
C
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Typically:
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PART 2 – DESIGN & ENGINEERING A O
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2.1 DESIGNING A CONCRETE HOUSE 2.1.3 Physical Limitations of Concrete E
Concrete has considerable strength, however it can be
chipped easily when shaped into sharp edges.
2.1.1 Overview F A
A N
S C
Designing a concrete house is no more difficult than As long as sharp edges are avoided by using T H
E O
designing for any other building material. appropriate detailing this physical limitation can be N R
Because it can be cast to form almost any shape avoided while still maintaining a large amount of E S
R
concrete offers a great deal of architectural flexibility as flexibility in the design. S &
a primary building material.
Figure 2.1.3
W
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Y L O
S C D
T A U
E S L
M T A
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R = L/k
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2.2.5 Typical Sectional R-values R-Value for Strapped and Lined Concrete Wall E
R-values for various sections can be calculated using Timber strapping is assumed to be a vertical stud at
NZS 4214(int):2002. This standard provides values 600 mm centres. The space between studs is filled
with 30 mm expanded polystyrene sheet. F A
for mainstream building materials as well as formulas A N
and examples for calculating R-values for wall S C
T H
sections. Walls have different R-values for timber and insulated E O
lining so two values are needed and applied in N R
E S
Table 2 of NZS 4218:2004 requires the following proportion to the wall area covered by each. R
minimum wall R-values for buildings of less than S &
300m2 floor area and 30% of wall area in glazing for Figure 2.2.5 – Plan View
the schedule method.
Expanded Poly sheet
Table 2.2.5a 30mm F R
E
I
T I
Climate zone 1 2 3 Structural/weather
T D
B
100mm concrete Condensation
surface
I
N A
R G R
Non-solid 1.5 1.5 1.9 S &
construction
R
0.6 0.6 1.0 Internal gib
Solid construction*
12mm
S L C
Y O
Vertical timber S I
F N
*Solid construction being concrete, masonry, earth wall, solid timber etc.
T T C
N R
90mm x 47mm
E I
M G E
The following R-values for concrete walls have Exterior Interior S T
been calculated using the formulas given in NZS
E
4214(int):2002.
They are typical values only and indicate the overall Table 2.2.5b
values that can be expected. N
Material Thickness Stud No Stud I
R
Section (f ) Section (f )
V
1 2
(L)
R-value (L/k) R-value (L/k) A
Concrete 0.1 0.06 0.06 N
Polystyrene 0.030 0.79 0.79
A
Timber 0.047 0.039 -
Air 0.017 - 0.57
Gib 0.012 0.05 0.05 W
R R A M
S L
1 2
R (exterior)
se
= 0.03 S
Total R-value = 1.47
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moisture. This high level of humidity inside a house is E
visible as condensation on the inside of windows and
2.3 WEATHER TIGHTNESS also can occur on the inside of the wall cavity where it
is unseen.
F A
A N
Sources of moisture include: S C
2.3.1 Clause E2 – External Moisture T H
E O
Cooking N R
Clause E2 of the New Zealand Building Code has the E S
Showers R
following stated objective: S &
Unvented LPG heaters
“E2.1 …to safeguard people from illness or injury
Unvented dryers
which could result from external moisture entering the
building.” People
F R
E
I
T I
T D
Refrigeration
Clause E2 states the following functional requirement:
I B
Washing Machines N A
“E2.2 Buildings shall be constructed to provide G R
S &
adequate resistance to penetration by and the High internal humidity will make a home feel and
accumulation of, moisture from the outside.” smell damp. The humidity can be removed using
dehumidifiers or by pumping dryer air in from outside
It should also be noted that Clause E2 essentially but this requires more energy input.
applies to timber framed buildings up to 3 stories or S L C
Y O
10 m high so there are no references in E2 to the Being a hygroscopic material (i.e. a material that S I
F N
draws moisture out of the air), with tremendous T T C
N R
E I
weather proofing of concrete panel walls.
capillary capacity, (the ability to draw moisture in M G E
S T
However, section 9.2.4 of E2 details a control joint for through microscopic pours) concrete will draw in E
a brick veneer that is essentially the same detail used moisture during the night and release it during the day
for panels and is therefore interpreted as an acceptable as the concrete warms up. This moisture can then be
solution for joint sealing in concrete panel houses. vented naturally through open windows or vents.
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All areas within a zone from the foundation base to Reidbar™ – A specialised threaded reinforcing
150mm above ground need to be properly detailed bar available in a range of sizes from 12-32mm. It
and constructed to resist ground water penetration. is compatible with a number of threaded fittings to
simplify steel work and concrete panel connection.
There should also be adequate allowance for the
Seal and Tilt – Specialised bond breaker and curing
drainage of any wall cavities, including insulation filled
membrane which prevents panels sticking to casting
cavities, below finished floor levels but above finished beds.
ground levels.
Swiftlift – Lifing systems for all cast concrete
Design should carefully detail external drains around elements.
the perimeter of concrete houses to prevent free
standing water building up against the panels. Threaded Inserts – High strength metric and
Reidbar™ inserts that are cast in to concrete panels.
An effective solution to bending and rebending
reinforcing starter bars which is not permitted with
Grade 500E reinforcing steel.
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2.5 PANEL HOUSE DETAILING E
S L C
Y O
S I
F N
T T C
N R
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M G E
S T
E
W
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S L
Y L O
S C D
T A U
E S L
M T A
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Reid™ closed cell P.E.F. G
backing rod in panel joint with
Tremflex 834 exterior grade
joint sealant.
C
H C
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Figure 2.5.1f – Plan View - T Plate Connection U T
E
F A
A N
S C
T H
E O
N R
E S
Pryda SBK27 structural bracket R
fixed with Reid™ Hex Screw Bolts S &
F R
E
I
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T D
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Figure 2.5.1g – Plan View - Weldplate Connection
S &
Weld plates should be welded on
the outer edges only to allow panels
to flex.
S L C
Y O
S I
F N
T T C
N R
E I
M G E
S T
E
Welded on angle
W
Flashing over top A M
S L
Y L O
of any parapet
S C D
wall with gap to
prevent capillary
T A U
action E S L
M T A
Flashing under roof N R
I
G
C
H C
A A
N S
N T
E -I
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Reinforcing Mesh
Non structural layer
338 or similar
Internal panel
Reidbar™
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Figure 2.5.1l – Elevation - Mid Floor Conneciton U T
E
Insitu topping F A
600
A N
S C
T H
E O
N R
E S
RB12 Threaded
R
Inserts with
600mm starter
S &
bars @ 300mm
centres.
F R
E
I
T I
T D
Pre-stressed planks 90 x 90 steel angle fixed with Liebig
AS15/15 structural anchors @
I B
1000mm centres. N A
G R
S &
S L C
Y O
Figure 2.5.1m – Elevation - Top Plate Conneciton S I
F N
T T C
N R
E I
M G E
S T
Truss
E
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2.5.2 Window and Door Detailing 2.5.4 Lifting and Handling of Panels
Joinery suppliers have an extensive catalogue of By planning for lifting during the design process
extrusions that are available for window and door considerable time and cost savings can be made over
details. Most major suppliers will have Autocad the duration of the project.
drawings that can be used to determine the casting
Engineers from Reid™ Construction Systems are
rebates needed to install the joinery.
available to consult with designers over the best size
The architect should consult directly with the joinery and shape for panels.
supplier’s technical support for further details.
Panels that are difficult to lift because of shape or
strength issues will require more work on site to
Figure 2.5.2
handle. Planning the lifting in advance will allow
better budgeting and may reduce crane hire time
significantly.
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Although any Grade 500 steel can be used in a panel The following table shows the savings in bar length E
Reid™ Construction Systems recommends the use when using Reid™ Grout Sleeves.
of Reidbar™ for panel reinforcing. Reidbar™ has a Table 2.6.5
continuous thread that makes it compatible with a
Lap Bar Grout Sleeve Bar F A
range of components that are used for easy, fast and Bar Size (mm) A N
Distance (mm) Embedment (mm) S C
strong connections between panels. 12 600 110 T H
E O
16 800 140 N R
Care needs to be taken that adequate steel is added E S
to panels where large voids reduce the ability to install
20 1000 174
R
25 1250 234 S &
reinforcing.
32 1600 328
2.6.4 Ductile Mesh There is a dramatic saving in bar length not only in the
difference in embedment but because of the need for F R
E
Ductile mesh is currently under development. I
T I
Check with Reid™ Construction Systems for further
the bar to overlap with Drossbachs. Therefore, when T D
B
compared to the use of Drossbach, tubes Reids™ I
N A
information.
Grout Sleeves are a far more economic solution in bar, G R
grout and time.
S &
2.6.5 Structural Reinforcing Steel
Further information regarding Reids™ Grout Sleeves
Connections
can be obtained from the Reidbar™ Design Guide.
Structural connections between panels is done using
S L C
lapped or sleeved reinforcing bar. 2.6.6 Concrete Cover Y O
S I
F N
Reid™ Grout Sleeves create connections that T T C
N R
E I
When designing Nirvana panels it is recommended
achieve the full strength of Reidbar™ with minimum that the non-structural layer of the panel be at least M G E
S T
embedment. 50 mm thick. E
Figure 2.6.5 In exposed sea spray zones it is advisable to increase
non structural panel thickness to 70 mm for additional
50mm ID Drossbach tube protection.
N
I
R
2.6.7 Galvanising V
A
Reidbar™ and Reidbar™ fittings can be ordered hot N
dipped galvanised from suppliers and can be used with A
minimum concrete cover.
600mm lap
(50 x Bar
RB12
diameter)
Grout Volume 2.6.8 Structural Drawings W
Grout
= 1000ml A M
Sleeve All Reidbar™ fittings can be easily included on S L
Y L O
structural drawings by using AutoCAD blocks which S C D
are available from Reid™ Construction Systems T A U
E S L
engineering department. M T A
N R
I
2.6.9 Further Information
G
120 to 150mm
Further information can be obtained from the
(10 x Bar diameter) Grout Volume = 200ml
Reidbar™ Design Guide (2004) which details products C
and connection systems that allow faster construction H C
A A
times and improved connection strengths for reinforced N S
As shown above the two main solutions for connecting
N T
panels are grout sleeves and Drossbach tubes.
concrete structures.
E -I
L N
Specific enquiries can be made directly to the Reid™ S
Engineering Department.
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PART 3 - CONSTRUCTION
Because of the need to install services as the panels Detailed structural drawings
are being cast the head contractor on a concrete panel
project has a far greater role co-ordinating sub trades Shop drawings of the panels
than in a timber frame house.
Contract specifications
All trades must be aware of the method of construction
and the consequent adjustments that need to be To avoid confusion during the building process it is
made to provide services in a concrete panel building. a good idea to provide written documentation for all
Ducting and service boxes must be installed into the communications.
panels before any concrete is cast.
Know what must Have the correct specifications and Foundations will be prepared no differently for a
be achieved drawings concrete panel house than a timber frame building
Be experienced, trained or have with consideration needed to be given to the size and
Know how to do it access to expertise for the tasks load of the building.
required.
Have the resources, plant and
Be able to do it
materials needed.
Have in place the appropriate quality
Know if it is done 3.2.2 Ground Floor Slab
control measures and able to assert
right
them.
Concrete slabs are often used as the casting bed onsite
Be willing and able to commit for the
Want to do it tiltup projects. To ensure the best finish on panels
duration of the project.
care must be taken when pouring the slab to obtain a
Be able to record and document the
smooth level finish on the slab.
project as it progresses, obtain all
Have appropriate
necessary tests and certifications,
support systems However, where a timber frame building needs the
hold regular progress meetings with
the client. slab to be poured for bottom plate fixing, external
concrete panels can be placed first and the concrete
foundations poured into the internal structure.
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3.2.3 Post Tensioned Floors 3.2.5 Reidform™ Formwork L D
O U
G C
In a traditional concrete floor the control of concrete Reidform™ is a formwork system using laminated U T
E
shrinkage is done either by saw cutting or use of a veneer lumber (LVL) and specially designed brackets.
cast in crack inducing system. This does not eliminate Contact a Reid™ Representative for more information.
cracks but controls where they occur.
Figure 3.2.5 F A
A N
Post tensioning is the process whereby the floor S C
T H
is placed under compressive stress in the hours E O
immediately following casting. This eliminates N R
E S
shrinkage cracks and the need for saw cuts. R
S &
This is particularly useful where architectural concrete
floors are specified or where r igid tile overlays are used
and reflective cracking is a risk.
F R
E
I
T I
T D
Reid™ Construction Systems can advise on methods of
producing post-tensioned floors using Reidbar™. I B
N A
G R
S &
Figure 3.2.3
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3.4.10 Hardening State Figure 3.4.12a
E
Once concrete begins to harden walking on it will not
leave imprints.
F A
A N
At the beginning of this stage concrete strength will S C
T H
be low but will continue to harden over an extended E O
period.
N R
E S
R
S &
3.4.11 Cracking
F R
Plastic cracking in concrete occurs within a few hours
I E
of placing before it has gained sufficient strength to
T I
resist shrinkage and settlement. T D
B
I
N A
This cracking happens before the concrete has had a G R
S &
chance to bond with the reinforcing. The role of steel
generally is to control the extent of cracking rather
To prevent plastic shrinkage use chemical evaporation
than to prevent it. To prevent cracking, reinforcing
retardants (such as Seal and Tilt) or fine misting water
must be pre or post tensioned.
sprays so that panel faces do not dry on hot or low S L C
Y O
Concrete can suffer from two types of cracking: humidity days when there is wind. S I
F N
T T C
Pre-setting cracking Drying Shrinkage: In many applications, drying N R
E I
M G E
S T
Hardening cracking
shrinkage cracking is inevitable as they are E
tensile stress cracks caused by water evaporation.
Control joints need to be placed in the concrete to
predetermine the location of drying shrinkage cracks.
3.4.12 Pre-setting Cracking Concrete will continue to cure and shrink for up to 2
N
years. I
R
This cracking is the result of:
V
Figure 3.4.12b A
Plastic settlement N
A
Plastic shrinkage
Formwork movement
W
Plastic settlement cracks show as surface cracks soon A M
S L
after placing and will usually follow lines of reinforcing Y L O
S C D
or sudden changes in concrete thickness. These cracks T A U
E S L
are caused by insufficient compaction during placing M T A
and will get larger as the concrete dries and shrinks. N R
I
G
Plastic shrinkage: Cracks appear as parallel lines or
as crazed lines (like a drying mud pond). It is caused
by rapid moisture loss from the surface of the concrete C
H C
allowing the top to shrink before any strength is A A
gained. The underlying concrete will remain moist and N S
N T
not shrink so these cracks generally will not show on Shrinkage cracks from corners are normal and not E -I
L N
the other face. structural problem. S
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E
F A
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S C
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E O
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E S
R
S &
F R
E
I
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B
Each pin is set to the collet depth. Step 5: Structural concrete layer is cast I
N A
G R
S &
S L C
Y O
S I
F N
T T C
N R
E I
M G E
S T
E
N
I
R
Completed panels ready for erection. V
A
N
3.5.2 Off-site Precasting A
Casting off site can be done in a precast yard in
exactly the same way as on-site casting however due
W
to the limitations of casting bed space and demands
A M
on time it may be necessary to complete the panel S L
Y L O
casting process in one day. S C D
T A U
This can be done only if the structural layer is cast first E S L
so that lifting can be done as soon as the concrete has M T A
gained enough strength. N R
I
G
The width of the panel is limited to about 3 m due to
the height limits of transportation regulations.
Step 4: When concrete is set the foam layer is placed C
over the pins and pressed down. Steel work, ducting H C
A A
and lifting anchors are set ready for the structural layer N S
N T
casting. E -I
L N
S
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Step 1: Foam panels are pre-cut, marked and Step 3: Foam insulation sheets with pins in place
punched with the connector pins. are positioned while the concrete is still wet and not
hardened.
The finish float of the structural layer does not need Step 4: Outer layer steel is placed and concrete cast.
to be towel finished.
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Step 5: The panel is completed with the final E
screed and troweling.
F A
A N
S C
T H
E O
N R
E S
R
S &
F R
E
I
T I
T D
B
I
N A
3.5.3 Panel Erection G R
S &
Panel erection is the same process for on or off-site casting.
S L C
Y O
S I
F N
T T C
N R
E I
M G E
S T
E
N
I
R
V
A
N
A
Step 1: Footing prepared. In this case the floor will Step 2: The wall line is marked and stop blocks set
be in-filled after the panels are erected. to assist with panel location.
W
A M
S L
Y L O
S C D
T A U
E S L
M T A
N R
I
G
C
H C
A A
N S
N T
E -I
Step 3: Levelling shims are placed to level the Step 4: Panels are lifted into position. L N
panels. S
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Stops are used to position panels on wall lines. Step 6: Floor and foundations cast to complete and
all temporary supports removed once concrete has
cured.
4 Conclusion
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NIRVANA PANEL (CROSS SECTION) FOR EDGE LIFTING ONLY
APPLICABLE FOR SINGLE LEVEL WALL PANELS HOWEVER ALWAYS CHECK WITH REIDS ENGINEERS FOR DESIGN APPROVAL
C P
TOP EDGE NIRVANA PINS AT 600 crs BOTTOM EDGE A
T R
FOAM INSULATION
CS25/40 BAR CHAIRS TO SUIT MESH
REINFORCING MESH 338 (EXPANDED HIGH D ENSITY POLYSTYRENE)
GLUE TAB TO INSULATION
A O
L D
O U
G C
U T
E
NOTE: IF PANELS ARE TO BE FACE LIFTED DUE TO SIZE AND SHAPE, PLACE THE 50mm LAYER AT A N
THE BOTTOM AND THE 100mm LAYER ON TOP. REF. PAGE 23 <CONCRETE PANEL HOUSE GUIDE> S C
T H
E O
MINIMUM 100mm STRUCTURAL LAYER-PLAN VIEW MINIMUM 50mm EXTERNAL LAYER-PLAN VIEW N R
NOTE :
NOTE: E S
*REID SEISMIC MESH OR REIDBAR TO SUIT, WITH 40mm GAP TO BOXING
* MESH 338 LEAVE 20mm GAP TO BOXING R
S &
*LIFTING ANCHORS, HANGER BAR, SHEAR BARS TO ENGINEERS DESIGN
*REID THREADED INSERTS OR GROUT SLEEVES TO ENGINEERS DESIGN * CUT INSULATION TO SUIT PANEL DETAILS
* AT WINDOW AND DOOR CORNERS, USE REID ANCHOR 1FA240 SET AT
*NIRVANA PINS SET APPROX. 100mm FROM EDGES, AND 600mm GRID PATTERN
45°, APPROX. 40mmin
*AT WINDOW AND DOOR CORNERS, USE RE ID ANCHOR 1FA240 AT 45°,APPROX.
40mm in
TOP EDGE TOP EDGE
F R
E
I
T I
T D
B
I
N A
G R
S &
ANCHOR
HANGER BAR.
TO SUIT
S L C
Y O
S I
F N
T T C
WINDOW WINDOW
N R
E I
M G E
S T
E
N
I
R
V
A
N
A
W
A M
S L
Y L O
S C D
T A U
E S L
BOTTOM EDGE
GROUT SLEEVE OPTION
BOTTOM EDGE CONNECTOR PINS M T A
N R
I
THREADED INSERT OPTION
SUGGESTEDLAYOUT: (DECIDE IF CONCRETE LAY ERS WILL BE POURED SEPARATELY OR AT THE SAME TIME) G
*PLACE FORMWORK, THEN APPLY REID BONDBREAKER TO CASTING SURFACE
*FIX LIFTING AND STRUTURAL COMPONENTS TO FORMWORK AND PLACE REID SEISMIC MESH
*PLACE CONCRETE
OPTION FOR POURING SEPERATE STRUCTURAL LAYER OPTION FOR POURING BOTH LAYERS CONTINUOUSLY
1. PLACE NIRVANA PINS INTO WET CONCRETE (SET THE DEPTH TO SUIT 1. PRE CUT THE INSULATION AND BOTH MESH SHEETS TO CORRECT
C
INSULATION AND EXTERNAL CONCRETE LAYER) SIZE
H C
A A
2. WHEN CONCRETE HAS SET, PUSH THE INSULATION SHEET OVER 2. AFTER POURING THE STRUCTURAL LAYER CONCRETE, PLACE THE
THE NIRVANA PINS. REMOVE ANY LOOSE FOAM
N S
INSULATION SHEETS AND LAY THE MESH ON TOP
3. PLACE EXTERNAL LAYER COMPONENTS AND MESH. POUR CONCRETE
N T
3. PUSH THE NIRVANA PINS THROUGH THE INSULATION SHEETS, TO THE
E -I
CORRECT DEPTH
4. PLACE COMPONENTS AND MESH, CONTINUE CONCRETE POUR
L N
DISCLAIMER :
S
YOUR ENGINEER MUST APRROVE OR REVISE DETAILS TO SUIT YOUR PARTICULAR DESIGN
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Nirvana Details Guide
REIDFORM FOR WI NDOW AND DOOR OPENINGS: PLAN VIEW
REID CORNER
BRACKETS EFICB
TIMBER REIDFORM
TO SUIT
SIDE FILLET
OPTIONAL TIMBER FILLET FOR NAIL FIXING REID FOAM REBATE 75X20
ASSEMBLE: DISMANTLE:
1. FIX CORNER BRACKETS 1. REMOVE CORNER BRACKETS & ANY JAMB
2. CHECK SQ & FLUSH BRACKETS
3. FIT REIDFORM JAMBS FULL HEIGHT 2. TAP JAMBS FREE & REMOVE
4. OVERLAP HEAD & SILL FILLETS 3. REMOVE OTHER BRACKETS & PULL THE HEAD &
SILL FREE
NOTE :
REIDFOA M WINDOW AND DOOR BLANKS AR E AVAILABLE AS AN OPTION, BUT CAN ONLY BE USED ON STEEL
CASTING BE DS WITH R EIDS SWIFT FORM RELE ASE BOND BREAKER. PRICE ON APPLICATION.
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NIRVANA WALL DETAIL
PLANING FOR SERVICES: POWER AND WATER (STRUCTURAL LAYER POURED FIRST) C P
A
T R
A O
WHEREVER POSSIBLE USE THE INTERNAL TIMBER WALLS FOR SERVICES L D
LIGHT SWITCH OPTION : USE REMOT E CONTROL LED WALL S WITCH TO OPERATE LIGHTS. (THIS O U
ELIMINATES WIRES IN THE CONCR ETE WAL LS) AVAILABLE FROM MOST ELECTRICAL SUPPLIERS G C
U T
E
20-30mm ELECTRICAL CONDUIT OR TO SUIT
F A
REID SEISMIC MESH
A N
S C
T H
338 MESH
E O
N R
E S
R
S &
F R
E
I
T I
T D
B
I
N A
G R
S &
N
I
R
V
A
N
A
FOAM INSULATION
C
H C
A A
N S
DISCLAIMER :
N T
YOUR ARCHITECT MUST APRROVE OR REVISE DETAILS TO SUIT YOUR PARTICULAR DESIGN
E -I
L N
S
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NIRVANA EXTERNAL WALL TO FLOOR DETAIL
DRAINAGE SCORIA
RB12TI AT 600crs
THIS AREA OF FLOOR POURED
(REID THREADED INSERTS)
AFTER PANELS HAVE BEEN ERECTED
650
POLYTHENE TO SUIT
REID SWIFT
SHIMS TO SUIT 100mm FOAM INSULATION
DISCLAIMER :
YOUR ENGINEER MUST AP RROVE OR REVISE DETAILS TO SUIT YOUR PARTICULAR DESIGN
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NIRVANA INTERNAL CORNER PANELS
C P
A
OPTION A PLAN VIEW
T R
A O
L D
O U
PRYDA STRUCTURAL BRACKET SBK30 G C
U T
OUTSIDE FACE E
3 REID HEX SCREW BOLTS HSB12/100
REID BACKING ROD BRCC
TO SUIT, AND REID DM10
SEALER F A
GIB B OARD(GLUE FIX) A N
S C
T H
E O
METAL CORNER MOLDING N R
FLEXIBLE PLASTER/PAINT E S
R
S &
S L C
Y O
S I
REID BACKING ROD BRCC TO SUIT.
FLUSH FILL WITH REID DM10 OPTIONAL F N
T T C
SLIGHT MOVEMENT IS PROBABLE AT THIS JOIN
N R
E I
M G E
S T
E
CRACK INDUCER W
A M
FLUSH FILL WITH REID DM10
S L
REID BACKING ROD TO SUIT. Y L O
PRYDA STRUCTURAL BRACKET SBK29 S C D
REID DM10 FLUSH FILL OR
T A U
LEAVE AS RECESS 3 REID HEX SCREW BOLTS HSB12/100
E S L
M T A
N R
OUTSIDE FACE
I
G
DISCLAIMER:
YOUR ENGINEER MUST APRROVE OR REVISE DETAILS TO SUIT YOUR PARTICULAR DESIGN
C
H C
A A
N S
N T
E -I
L N
S
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NIRVANA WINDOW AND DOOR DETAIL OPTION
WINDOW DETAILS
Joinery suppliers have an extensive
catalogue of extrusions that are available HEAD
REID SCREW HIF 6-100
for wi ndow and door details. Most major REIDSTRIP
suppliers will have Autocad drawings that 60X1.5
can be used to determine the casting REID BACKING ROD TO SUIT
rebates needed to install the joinery.
REID SWIFTFOAM SWFOAM 750
The architect should consult directly with DRIP GROOVE
the joinery supplier's technical support for
further details. SILICON FIX ALUM ANGLE TO HEAD
(SILICON SEAL J AMBS WITH REIDS DM10)
Install to the window manufacturers
instructions
SILL
REIDSTRIP
60X1.5
DOOR DETAILS
REIDSTRIP
60X1.5 REID BACKING ROD TO SUIT
CONCRETE FLOOR
DISCLAIMER :
YOUR ARCHITECT MUST APRROVE OR REVISE DETAILS TO SUIT YOUR PARTICULAR
DESIGN
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MESH DETAIL: AT WINDOW AND DOOR OPENINGS
C P
A
HEAD
POLYSTYRENE CRACK INDUCER REIDSTRIP 60X1.5 WHITE PVC
T R
A O
L D
O U
G C
U T
E
338 MESH
F R
E
STRUCTURAL I
T I
T D
CONCRETE LAYER SEISMIC MESH
100mm THICK USE RSM 2008
I B
125mm THICK USE RSM 2508 N A
SILL
150mm THICK USE RSM 30010 G R
S &
REID ANCHOR 1FA240 AT 45 TO EACH CORNER
MIN.40mm
S L C
Y O
S I
F N
T T C
N R
E I
REID SEISMIC MESH
M G E
S T
E
338 MESH
N
I
R
POLYSTYRENE CRACK INDUCER REID STRIP 60X1.5 WHITE PVC
V
A
N
A
DISCLAIMER :
YOUR ENGINEER MUST APRROVE OR REVISE DETAILS TO SUIT YOUR PARTICULAR DESIGN
W
A M
S L
Y L O
S C D
T A U
E S L
M T A
N R
I
G
C
H C
A A
N S
N T
E -I
L N
S
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Nirvana Details Guide
NIRVANA WINDOW DETAIL OPTION
REID SWIFTFOAM
SWFOAM750
REID SW IFTFOAM
REID TR IM SILL SWFOAM750
REID DM10
SEALER
SPOT GLUE
DISCLAIMER:
YOUR AR CHITECT MUST APRR OVE OR R EVISE DETAILS TO SUIT YOUR PARTICULAR DESIGN
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TIMBER TRUSS TO NIRVANA WALL DETAIL
OPTION A
C P
A
T R
A O
L D
O U
G C
U T
E
PRYDA TIMBER TRUSS
F A
A N
S C
T H
TIMBER CEILING BAT TEN OR SIMILAR
E O
N R
E S
R
CEILING TO SUIT
S &
* PRYDA TIM-CON BRACKET TCF 130
* ONE BRACKET TO ONE SIDE OF TRUSS REID SPLIT DRIVE ANCHORS TO SUIT
(UP T O 12KN UPLIFT)
F R
* REID SCR EW BOLT HSB12/100 (BOLT
ONLY TO STRUCTURAL INTERNAL
I E
CONCRETE)
T I
* 15 PRYDA NAILS 30X3.15 TO TIMBER T D
B
I
N A
G R
S &
OPTION B
S L C
Y O
S I
F N
T T C
N R
E I
PRYDA TIMBER TRUSS
M G E
S T
E
PRYDA SHEET BRACE ANCHOR SBA
(WITH PRYDA NAILS 30X3.15mm)
C
H C
A A
N S
N T
E -I
L N
S
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