concrete pre cast panel by peter spence id: 400213872

Concrete Pre Cast PanelConcrete Pre Cast Panel

By Peter Spence

ID: 400213872

Concrete Pre Cast PanelConcrete Pre Cast Panel

In the construction industry In the construction industry today Pre Cast Concrete today Pre Cast Concrete Panels have become greatly Panels have become greatly used by all types of used by all types of construction from Multistory construction from Multistory Residential, to large Residential, to large Warehouses.Warehouses.

The benefits in using Pre CastThe benefits in using Pre Cast

1.1. Off site manufacturingOff site manufacturing

2.2. Manufacturing under quality Manufacturing under quality controlled conditionscontrolled conditions

3.3. Loading bearing single skin Loading bearing single skin walls that allow greater floor walls that allow greater floor spacespace

4.4. Structural SoundnessStructural Soundness

Design Manufacture Installation

Lifting Point

Grout Holes

Concrete Panel

Slab

Roles of Architect and EngineerRoles of Architect and EngineerIn the Design stage both Architects In the Design stage both Architects and Engineers are involved to developand Engineers are involved to developappropriate drawings for all consultants appropriate drawings for all consultants

Architects are responsible for:Architects are responsible for:Giving the size of each concrete panel Giving the size of each concrete panel Identifying the location of the panels with Identifying the location of the panels with the use of grid markingsthe use of grid markingsDesign of rebates and feralsDesign of rebates and ferals

Engineer is responsible for:Engineer is responsible for:Developing shop drawings for Developing shop drawings for manufacturer manufacturer Detailing each specific component within Detailing each specific component within the panel e.g. reinforcement, concrete the panel e.g. reinforcement, concrete grade, panel thickness, weight etcgrade, panel thickness, weight etcCertification of drawing for structural Certification of drawing for structural adequacy and complianceadequacy and complianceEnsuring panel can support loads and Ensuring panel can support loads and designing accordinglydesigning accordingly


Architect Drawings

Engineer shop drawingsEngineer shop drawingsConcrete Grade

40 MPa

Minimum concrete force at lifting points

Panel Thickness

Panel Volume

Panel Weight

Lifting points specifications

Legend

Panel Area

Propping Specifications

Grout Tubes Specifications

Engineer Approved Stamp


Engineers SpecificationsEngineers Specifications

TILT PROP SPECIFICATION

CODE LENGTH CLOSED MIDDLE FULL WEIGHT

921 2.4m - 3.8m 2.4m - 35kN 3.1m - 32kN 3.8m - 30kN 35kg

912 2.6Mm - 4.4m 2.6m - 35kN 3.5m - 32kN 4.4m - 30kN 37kg

917 4.4m - 6.8m 4.4m - 40kN 5.5m - 23kN 6.8m - 14kN 53kg

914 6.2m - 10.1m 6.2m - 28.5kN 8.0m - 24kN 10.1m - 6.3kN 78kg

The Engineer will specify in drawings each The Engineer will specify in drawings each individual component of the concrete panel. individual component of the concrete panel. These specifications are determined by the These specifications are determined by the load and force the panel will put into the load and force the panel will put into the each components.each components.


Manufacturing Manufacturing The stage of manufacturing is essential to the pre cast development. A Building Contractor may do there own

audit on a Pre Cast manufacture to ensure compliance with all WorkSafe methods and that appropriate Quality Control checks at done at certain stages.

For example Leighton Contractors may inspect La Pre Cast before awarding the supply contract.

Some question supplied by WorkSafe should be answered prior to manufacture

1. Are those involved in the manufacturing of precast panels trained in current procedures and quality control?

• Training should cover industry standards on: manufacturing (including formwork, casting sequences, reinforcement, lifting inserts, concrete placement) and handling of panels

2. What Pre-planning has taken place prior to work commencing?

• Can the builder demonstrate pre-planning of erection?

• Do shop drawings clearly show all information needed to manufacturing? (eg: weight and dimensions of panel, Reinforcement, location of inserts, braces and fixings and concrete strength at lifting points)

Example of shop drawings a manufacture will receive from architect and engineer.


Quality Controller Review Shop Drawings

Carpenters

• Formwork

• Rebates

• Recesses

• Ferrules

Steel Fixers

• Placement of Bar Chairs

• Weld ferrules

• Placement of Reinforcement

• Dowel Tubes

• Lifting Points

Concreters • Pour Concrete

• Vibrate

• Toweling with helicopter

• Apply finishes if needed

Manufacturing Flow Chart


Stage 1 of ManufacturingStage 1 of Manufacturing

Once the shop drawings are reviewed and Once the shop drawings are reviewed and

approved by the Quality Controller they are thenapproved by the Quality Controller they are then

passed on the carpenters to begin the assemblypassed on the carpenters to begin the assembly

of the formwork for the slab.of the formwork for the slab.

The carpenters must ensure that all workThe carpenters must ensure that all work

completed complies with the architect’s drawingcompleted complies with the architect’s drawing

and that all formwork is fixed secure to theand that all formwork is fixed secure to the

pouring surface.pouring surface.

The carpenter is responsible for:The carpenter is responsible for:

1.1. Erecting formworkErecting formwork

2.2. Placement of formwork for rebatesPlacement of formwork for rebates

3.3. Attachment of ferrules in the formworkAttachment of ferrules in the formwork

4.4. Any recesses in the concrete panelAny recesses in the concrete panel

Once Work is completed the Quality ControllerOnce Work is completed the Quality Controller

reviews all work so compliance to drawings andreviews all work so compliance to drawings and

specificationsspecifications

Carpenters RoleCarpenters Role

Formwork

Rebate

Ferals in Formwork


Stage 2 of ManufacturingStage 2 of ManufacturingAfter the Quality Controller approves Stage 1 of manufacturing the Steel Fixers complete their

job.

At this stage all the relevant details in the concrete are place within the section of the concrete

slab. All specifications are detailed by the engineer in the shop drawings

Stage 2 comprises:

1. Placement of bar chairs

2. Placement of Reinforcement mesh, lifting points and dowel tubes

3. Tiring together of bar chairs, reinforcement mesh and lifting points

4. Welding of ferrules


Welding Ferrules Tiring of Reinforcement Dowel Tube

Stage 3 of ManufacturingStage 3 of Manufacturing

Stage 3 of manufacturing comprise another Quality ControlStage 3 of manufacturing comprise another Quality Controlinspection. The inspection at this stage should include:inspection. The inspection at this stage should include:

A check of the identification number of the panel A check of the identification number of the panel Confirmation of panel sizeConfirmation of panel sizeVerification that all structural components, including Verification that all structural components, including reinforcement, inserts and casts-in plates, all with comply reinforcement, inserts and casts-in plates, all with comply with shop drawingswith shop drawings

The steps involved at during stage 3 of manufacturing areThe steps involved at during stage 3 of manufacturing are

11 Pour concrete Pour concrete 22 Vibrate Vibrate 33 Detach reinforcement tiresDetach reinforcement tires44 Allowance for grout hole in panel. Allowance for grout hole in panel. 55 Trowelling by HelicopterTrowelling by Helicopter66 Appling finishesAppling finishes


Pouring Concrete

Vibrating

The Finished PanelThe Finished Panel

Concrete Slab Dowel Tube

Lifting Points Rebate and Ferrule Locators


DeliveryDelivery

After manufacturing has taken place the After manufacturing has taken place the panels are delivering to site on a truck. panels are delivering to site on a truck. Trucks bringing the panels to site must be Trucks bringing the panels to site must be certified and comply with all regulationscertified and comply with all regulations

The Trucks delivering pre cast panels The Trucks delivering pre cast panels need to have:need to have:

1.1. Ladder for access to trayLadder for access to tray

2.2. Hand RailsHand Rails

3.3. Loads secured to tray by chain Loads secured to tray by chain

4.4. Carrying loads not to be over specified Carrying loads not to be over specified limitlimit

If delivery trucks don’t have the above they willIf delivery trucks don’t have the above they will

not be allowed onto site to drop off pre castnot be allowed onto site to drop off pre cast

panelspanels


Propping And AnchoringPropping And Anchoring

Props on the pre cast panel are attached before its Props on the pre cast panel are attached before its set into position. The ideal position for the props to be set into position. The ideal position for the props to be attached at the panel is to be 2/3attached at the panel is to be 2/3rdrd the height. The the height. The engineer will specify where the attachment need to be engineer will specify where the attachment need to be placed.placed.

Its Recommended that:Its Recommended that:

1.1. Two Props/braces minimum per panel be used for Two Props/braces minimum per panel be used for stability and load transferstability and load transfer

2.2. Props should be fixed prior to lifting panelProps should be fixed prior to lifting panel

3.3. Anchoring system be adequate and support the loads Anchoring system be adequate and support the loads from above. from above.

4.4. Anchoring foundation should be firm and not moveAnchoring foundation should be firm and not move

AttachmentsAttachments

Props are attached to the panel by the ferrules Props are attached to the panel by the ferrules inserted during manufacturinginserted during manufacturing

Dynabolts are used to anchor the propsDynabolts are used to anchor the props

Propping

Anchoring


Fixing Panel Fixing Panel

Once propping has been attach to the panel, the panel is then lifted into position by a crane. Once propping has been attach to the panel, the panel is then lifted into position by a crane. A crane either on site or on the delivery truck will move the concrete panel into positions.A crane either on site or on the delivery truck will move the concrete panel into positions.

Dowel Pins should already be placed within the concrete ground slab. The crane Operater Dowel Pins should already be placed within the concrete ground slab. The crane Operater with the help of a Spotter and Labourers will put the panel into position. The Dowel pins fit with the help of a Spotter and Labourers will put the panel into position. The Dowel pins fit into the dowel tubes which were cast into the panel at manufacturing stage. into the dowel tubes which were cast into the panel at manufacturing stage.

Once panel is in the correct position the props are anchored and grout holes and dowels Once panel is in the correct position the props are anchored and grout holes and dowels tubes filled with grouting solution. tubes filled with grouting solution.

Concrete Slab with Dowel pins Grout Hole in Panel Panel fixed into position


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Specified Corrugated Finish Trowelling Helicopter

concrete pre cast panel by peter spence id: 400213872

Documents

concrete pre cast panel

dimensions of panel

pre cast concrete panels

concrete strength

concrete placement

pre cast manufacture

pre cast development

appropriate drawings