Prec 38
Prec 38
Prec 38
au
NATIONAL NUMBER 38 • OCTOBER 2005
PRECASTER
Precast captures moments in time
“The Heritage Circle” is the culmination of a A crisp, clean concrete finish was Project Details
five year community project which has created integral to the success of the Project name: The Heritage Circle
a striking public artwork in one of Western Heritage Circle, as the artwork Sculptured Wall Panels,
Australia’s premier regional parks, G.O. Edwards relies on image clarity for historical Burswood, WA
Reserve. Innovative in design and enhancing purposes and good “relief” so that Precast Supplier: Delta Corporation Limited
the natural landscape, the artwork celebrates the Principal: Town of Victoria Park
the artwork effectively captures
Town of Victoria Park’s unique indigenous and Sculptor: Smith Sculptors
natural light and shade elements.
colonial history.
Manufacturing the precast panels presented
Comprised of six precast concrete panels
in a circular formation, each panel stands several challenges for WA precast manufacturer,
approximately 2.5 metres tall and 3 metres wide, Delta Corporation Limited. Cast onto an
and weighs approximately 5 tonnes. Each one intricate sculptured fibreglass mould, the
depicts a different theme through a montage precaster’s main concern was that the concrete
of images relating to past life in Victoria would stick to the fibreglass and possibly
Park – Flora & Fauna, Momentous Events & damage the pattern during de-moulding of the
Community, Sport & Recreation, Industries, precast panels.
Transport and Architecture. The panels capture
A trial fibreglass mould was prepared with a
moments in time often long forgotten.
special concrete mix selected to colour match
Initially, through its community committees and the existing limestone sections of the site. Using
staff, the Town provided ideas for the artists, Smith appropriate mould release agents and casting
Sculptors, who scrupulously carved the images techniques the casting process proved correct, One of the six precast concrete panels, which make
into polyurethane blocks. Once carved, the panels meeting with the rapturous approval of the up the montage of images relating to past life in
were sealed and a fibreglass cast was set. sculptors and the Town of Victoria Park. Victoria Park
President’s Column
Amidst a very busy NPCAA As New Zealand’s largest precast manufacturer, We continue our work to promote precast flooring,
agenda, our most recent meeting Stresscrete was the perfect choice for a factory and on our review of the first edition of the Precast
was held in Christchurch New visit, allowing the Australian delegates to Concrete Handbook (which, incidentally, is now
Zealand. The joint meeting with compare notes with their Kiwi counterparts. available on disk from SAI Global). We also
Precast New Zealand (PCNZ) The tour of two of Stresscrete’s projects – the continue to work with Australian Standards on
began with most of the 21 Canterbury Department of Health Board Car Park, reviews of various Standards, with the Australian
NPCAA delegates arriving to a
and the Dressmart Shop and Car Park, showed Safety and Compensation Council on a national
cold and wet Wednesday
us alternative applications of hollowcore and code of practice for both on-site prefabricated
afternoon in the city. By
Thursday morning the sky was reinforced the economies of a precast solution. concrete (sometimes referred to as tilt-up) and
clear, the sun was shining while off-site manufactured concrete (precast), and with
Our thanks to the PCNZ members for their warm Curtin University on precast course material for
the air was crisp and cold, it was a perfect start hospitality and a special thank you to Alan
to a fantastic couple of days. undergraduate engineers.
Kirby of Cement and Concrete Association New
After separate NPCAA and PCNZ meetings, Zealand and to John Marshall of Stresscrete for I also take this opportunity to welcome our
we joined together in the afternoon to their efforts to make our trip one to remember. newest Associate Member – Coates Hire, and
discuss industry issues of relevance to both I would also like to thank our Executive Officer our newest (and first) Professional Associate
organisations, such as the testing of hollowcore Sarah Moore for the effort she put in to make the Member – BDO Chartered Accountants and
performance in areas of high seismic risk. This trip a success. Advisors. Don’t forget to check out the full list of
was further explained by Professor John Mander Members on the back page of this publication.
and Dr Stefano Pampanin during our tour on the Successful Precast Design Workshops for
following day of the seismic testing facilities at engineers have been held in Sydney, Brisbane, Gavin Stollery
the University of Canterbury. Melbourne, Adelaide and Perth. President
ACN 051 987 181 • ISSN 1037-9908
NATIONAL PRECASTER NUMBER 38 • OCTOBER 2005
Figure 2 (a): Erection of hollowcore (manufactured Figure 3 shows a direct comparison of the Figure 3: Comparison between the composite
by Rescrete Industries) at Sydney Airport, Domestic metal deck flooring composite system with the hollowcore systems to the composite metal deck
Terminal Carpark composite system with precast hollowcore flooring systems (Lam & Uy, 2003)
PAGE 2
NATIONAL PRECASTER NUMBER 38 • OCTOBER 2005
Figure 4: Alternative methods for composite slabs with a typical bay of 9m × 9m. The
hollowcore system comparison showed a typical saving of 50%
over steel weight, number of components and
more significantly on steel surface area when
fire protection and paint treatment are taken
into consideration.
The longitudinal & transverse joint between Optimisation of Shear Stud successful in the design and construction of
the units (Figures 6 & 7) is filled with in-situ Design Capacity office, commercial industrial, hotel, stadium
concrete so that horizontal compressive and car park developments.
membrane forces can be transferred through The use of hollowcore and solid slabs for
the slab. The compressive strength of the composite steel beam design allows the Raised Access Floor
in-situ concrete infill may vary from 20 to optimisation of shear stud design due to the lack
of restriction in positioning the shear studs. No additional finishes may be required to the
40 MPa, but 35 MPa is normally used for top surface of hollowcore units prior to the
design. Shear connectors are pre-welded Elimination of Deflection installation of a raised access floor.
to the steel beams and an adequate amount
of concrete is to be placed and compacted The use of hollowcore and solid slabs Conclusions:
around the shear connectors. The spacing of in composite steel beam design eliminates
the shear connectors is determined from the the difficulties experienced with local deflection This article has presented the use of
of a metal deck solution between steel hollowcore flooring in composite steel
requirements of the shear force interaction
beam supports. – concrete construction and the advantages
along the steel / concrete interface. The sides
over the traditional composite metal deck
of the hollowcore slabs are shaped on the
Fire Resistance flooring system. Research is on-going to
casting bed to the profile shown in Figure 7 to
provide for the transfer of knowledge from the
allow for the transverse shear transfer. The tops Standard precast floors can be supplied with UK to Australia taking account of the subtleties
of the hollow cores in the slabs are typically left a standard fire resistance of up to 4 hours, far that exist in relation to hollowcore manufacture
open at 300mm centres for 500mm in length to superior than metal flooring systems can offer. between the two nations.
permit the placement of tie steel across the slab Available fire ratings are HC150 = 2hrs; HC200
(Figure 8). Research work by Lam et al (2000) = 3hrs; HC250 = 3hrs and HC400 = 4hrs. References:
showed that given the correct geometry and
Immediate Unpropped Working Platform BS 8110: Parts 1 (1997), ‘Structural Use of Concrete:
material properties, full or partial interaction
Code of Practice for Design of Simple Construction,’
between the precast slab and steel beam is British Standards Institution, London.
Once a precast concrete floor is placed on
possible. For typical geometry and serial sizes, Hensman, J.S. and Nethercot, D.A. (2001),
site, it is immediately available as a working
the composite beams were found to be twice as ‘Numerical study of unbraced composite frames:
platform. Steel deck systems by comparison generation of data to validate use of the wind moment
strong and three times as stiff as the equivalent
can present problems in achieving level method of design’, Journal of Constructional Steel
isolated steel section.
surfaces whilst concrete is poured and in Research 57, pp. 791-809.
The advantages of providing access whilst in the wet condition. Lam, D., Elliott, K. S. and Nethercot, D. A.
(2000), ‘Experiments on composite steel beams with
composite beam design No Propping precast concrete hollow core floor slabs’, Proceedings
with precast planks of the Institution of Civil Engineers: Structures and
Propping is not required with the precast slabs Buildings, Vol. 140, pp.127-138.
Steel Economy designed compositely with the steel framed Lam, D. and Uy, B. (2003), ‘Recent Research and
Development in Composite Steel Beams with Precast
building. Large savings can be achieved when Hollow Core Slabs’, Journal of Australian Institute of
The use of precast hollowcore and solid
compared with the large amount of propping Steel Construction, Vol. 37 (2), pp. 1-13.
slabs for composite steel beam design
required with fully in-situ and semi-in-situ Loh H.Y., Uy, B. and Bradford, M.A. (2004),
provides a reduction in the total tonnage of
floor systems. ‘The effects of partial shear connection in the
structural sections compared with the use of hogging moment regions of composite beams: Part 1
non-composite and composite metal deck Diaphragm Action – Experimental study’, Journal of Constructional Steel
steel solutions. Research 60, pp. 897-919.
Precast floor slabs are structurally grouted to National Precast Concrete Association Australia
Speed of Erection provide a floor with full diaphragm action as (2003) Hollowcore flooring: technical manual.
required in most multi-storey frames. This can New South Wales Government (1998) Construct
Time-consuming activities such as propping, New South Wales: Seizing opportunities to build a better
be achieved without a structural topping.
shuttering and concrete pouring may be virtually construction industry, New South Wales Government
eliminated. Using a precast floor, a large volume White Paper.
Finished Soffit
of work is carried out off-site and saves what Standards Australia (2003) AS2327.1 – 2003,
Precast floors are manufactured on high quality Composite structures – Part 1: Simply supported beams,
can be a complex and time-consuming site Standards Australia.
operation subject to the vagaries of the climate. steel beds and are suitable in appropriate cases
for direct decoration.
Reduced Site Operations Precast Concrete Handbook
Factory Engineered Components
The use of hollowcore and solid slabs in
composite steel beam design greatly reduces Precast floors are factory produced, being Everything you
the amount of in-situ concrete work on site. manufactured in an environment which is more need to know
The ability of hollowcore slabs to provide readily controlled than a building site. Quality about Precast.
bay centres of 7.5m and greater, far exceeds control systems are properly implemented and Now available
that provided by a metal deck solution. This are independently examined on a regular basis on CD-ROM.
enables a reduction in the number of steel under the quality assurance scheme.
Call Standards
members for a building and consequently on Product Application Australia on
site programme time. In addition, the provision 1300 65 46 46
of factory welded shear studs on the steel Composite steel beam design offers an now to order
beams removes the stud welding operation economic solution whenever a steel frame is your copy!
from the site critical path. being considered. It has been proven
PAGE 4
NATIONAL PRECASTER NUMBER 38 • OCTOBER 2005
PAGE 5
Smartfloor provides a smart solution
for Brisbane Mater Hospital
An 11 storey carpark taking shape at form composite structural sections.
South Brisbane is the first building to The thickness of the topping slab varies National Precast Concrete
incorporate a precast, prestressed and with span and loading. The topping slab, Association Australia
post-tensioned concrete beam shell reinforced with steel mesh, develops a
CORPORATE MEMBERS
developed by Queensland Precaster, diaphragm action that provides strong
Asurco Contracting n [08] 8240 0999
Precast Solutions. resistance to lateral loads. The system
Bianco Walling Constress n [08] 8359 0666
is lighter than conventionally reinforced
Delta Corporation n [08] 9296 4111 (WA) or [08] 8363 4817 (SA)
Due for completion in late 2005, the new concrete floors of equal capacity and Duggans Concrete n [03] 6266 3204
$22.5million Water Street carpark will provides long, unobstructed spans, Georgiou Group Precast n [08] 92099200
provide an additional 1018 parking spaces which in return make it possible to Girotto Precast n [03] 9794 5185 (VIC) or [02] 9608 5100 (NSW)
for staff and visitors to the six hospitals reduce beam column and footing loads, [07] 3265 1999 (QLD)
that form the Mater Hospital complex. providing further economies all round. Hicrete Precast SA n [08] 8260 1577
Hollow Core Concrete n [03] 9369 4944
Site access was a high priority issue for This flooring system is a formwork-free Humes (NSW) n [02] 9832 5537
builder Watpac, because the construction solution that is suitable for any project, Paragon Precast Industries n [08] 9454 9300
floor plate took up the entire site which with spans up to 8 metres, off-site quality Precast Concrete Products n [07] 3271 2766
didn’t leave an area for site offices, controlled production, and offering Precast Solutions n [07] 3807 4511
materials etc. The constricted site immediate access for sub trades below. Precast WA n [08] 9332 6310
conditions made the selection of off-site It becomes an immediate safe working Reinforced Earth n [02] 9910 9910
manufactured structural components platform, with minimal reinforcing to Rescrete Industries n [02] 9627 2666
a necessity. tie and mesh to place. Its low sound Rocla Building Products n [02] 9928 3552
SA Precast n [08] 8346 1771
transmission and excellent fire rating,
Precast concrete provided the answer, Sasso Precast Concrete n [02] 9604 9444
combined with its extremely cost efficient
not only in reducing on-site construction attributes make it hard to go past in any
Structural Concrete Industries n [02] 9411 7764
but also in providing a clean, attractive, rational structural selection process.
Ultrafloor n [02] 4932 4433 or [03] 9614 1787
and economical structural solution. The Westkon Precast Concrete n [03] 9312 3688
“The combined use of formwork and precast ASSOCIATE MEMBERS
precaster delivered a complete precast
Ability Building Chemicals n [03] 9457 6488
package with their innovative Smartfloor concrete components has given us the perfect
Actech International n [03] 9357 3366
prestressed precast floor system. The result. The main benefit of this system is
Barossa Quarries n [08] 8564 2227
Beamshell system was also used, where speed. We expect to save about five to six
Baseline Constructions n [02] 9080 2222
precast prestressed ‘shell’ beams act weeks on this project”. Blue Circle Southern Cement n [02] 9033 4000
compositely with the in-situ topping and John Earnshaw, Project Manager, Construction Cathay Pigments Australasia n [02] 9150 6666
the precast flooring planks to create an and Project Management Australia Pty Ltd. Cement Australia n [07] 3335 3096
economical two-way structural system. Coates Hire Propping n [02] 8723 6300
The result is a system that offers Degussa Construction Chemicals n [02] 8811 4200
considerable savings in structural depth Grace Construction Products n [07] 3276 3809
Hallweld Bennett n [08] 8347 0800
compared to one-way flooring systems.
Hilti (Aust) n 13 12 92
By reducing beam depth to the minimum
Huntsman Composites n [08] 8347 4666
the system affords a clean, almost LW Contracting n [02] 4735 6716
level, soffit that aids the even spread of OneSteel Reinforcing n [02] 8424 9802
lighting. It is noticeable in carparks where Ramset Fasteners n 1300 780 063
there are deep beams that the beams Reid Construction Systems n 1300 780 250
cut off the lighting at night, leaving dark RJB Industries n [03] 9794 0802
areas that can seem threatening. When Sika Aust n [02] 9725 1145
staff work late shifts, as at the Mater, Smorgon Steel Reinforcing n [03] 9279 5549
this factor is of real importance in itself, A level soffit aids the even spread of lighting Sunstate Cement n [07] 3895 1199
Xypex Australia n [02] 6040 2444
and is a positive and lasting benefit of
PROFESSIONAL ASSOCIATE MEMBERS
this flooring system, something which Project Details
BDO Chartered Accountants & Advisors n [02] 9286 5850
is sometimes not considered when Project name: Mater Hospital Complex OVERSEAS MEMBERS
selecting a carpark structural system. Water Street Carpark, Cem–FIL International n [66 2] 3660240
South Brisbane Golik Precast Ltd (Hong Kong) n 852-2634 1818
The precast flooring system measured
Precast Supplier: Precast Solutions Pty Ltd Halfen-Deha Pte Ltd (Singapore) n 02 9642 8396
up in other areas as well, having been
Redland Precast Concrete Products n 852-25900328
developed to meet an increasing demand Principal: Mater Misericordiae
Health Services
for precast and prestressed concrete
Brisbane Ltd The information provided in this publication is of a general nature and should
components, where time and cost not be regarded as specific advice. Readers are cautioned to seek appropriate
savings compared to conventional forms Project Manager: Construction & Project professional advice pertinent to the specific nature of their interest.
Management (Aust)
of construction, are required. The two- Pty Ltd Published by
way structural spanning capabilities lend
themselves well to any project, having
Architect: Peddle Thorp Architects National Precast Concrete
the flexibility to fit any building plan, Structural Engineer: Cardno Alexander Browne Association Australia
unlike one-way spanning systems. Precast Design Bruce Lemcke 1/184 Old Canterbury Rd
Engineer: Engineering Summer Hill NSW 2130 Australia
The system, once complete, consists Construction Manager: Watpac Australia Pty Ltd PO Box 396 Summer Hill NSW 2130
of a fully bonded concrete topping to Tel [02] 9799 3421 Fax [02] 9799 8423
Email: info@npcaa.com.au
Executive Officer - Sarah Moore
PAGE 6 www.npcaa.com.au