Category: Precast Detailing Projects

Precast detailing projects show case precast projects detailed by Tek1 Pty Ltd.
These projects are in Melbourne, Sydney, WA
We have detailed over 10,0000 panels over 12 years.

  • CONCRETE WITH SPECIFICATION DIFFERENCE (N & S)

    CONCRETE:

     (AS 1379 Specification and supply of concrete) A mixture of Cement, aggregates and water with or without the addition of chemical admixtures or other materials.      

    Cement: (AS 3972 Portland or blended cement) A hydraulic binder composed of Portland or blended cement used alone or in combination with one or more supplementary cementitious materials.

    Concrete is defined as follows,

    • Plastic concrete:

    Concrete in the state between completion of mixing and initial set as defined in AS 1012.18 Methods of determining setting time of fresh concrete, mortar and grout by penetration resistance.

    • Hardened concrete:

    Concrete after initial set, as represented by test specimens that have been subjected to a specified process and duration of curing.

    • Normal- Class Concrete:

    Concrete that is specified primarily by a standard compressive strength grade up to 50 MPa and otherwise in accordance with Clause 1.5.3.

    • Special- Class Concrete:

    Concrete that is specified to have certain properties or characteristics different from, or additional to, those of normal-class concrete and otherwise in accordance with Clause 1.5.4.

    SPECIFICATION OF CONCRETE:

    Concrete shall be specified,

    (a) as either

    (1) Normal-class(N), or

    (2) Special-class(S), or

    (b) By strength grade or other readily verifiable parameter by which compliance with the specification can be assessed.

    NOTE: Standard strength grades should be specified wherever possible.

    • NORMAL-CLASS CONCRETE:

    Normal-class concrete shall be specified only by the parameters given in Clause 1.5.3.2(Basic parameter), and shall have the following attributes:

    • A mass per unit volume in the range 2100 kg/m3 to 2800 kg/m3 when determined in accordance with (AS 1012.12.1 Determination of mass per unit volume of hardened concrete) in the saturated, surface-dry condition.
    • Acid-soluble chloride and sulfate contents within the limits given in Clause 2.7, when determined in accordance with Clause 5.5.2.
    • A shrinkage strain not exceeding 1000 × 10−6, when determined in accordance with Clause 5.6 after 56 days drying.

    NOTE: This maximum value of 1000 × 10−6 is consistent with the use for design purposes of a median basic shrinkage strain value of 850 × 10−6.

    • A mean compressive strength at 7 days, assessed in accordance with Clause 5.7, of not less than the values of Grade designation for N20-9MPa, N25-12MPa, N32-16MPa, N40-20MPa & N50-25MPa.
    • A cement complying with (AS 3972 Portland or blended cement) alone or in combination with one or more supplementary cementitious materials.
    • No lightweight aggregate as defined in AS 2758.1 Aggregates and rock for engineering purposes Concrete aggregates.

    Basic parameters of normal-class concrete:

    The following basic parameters shall be specified by the customer:

    • A standard strength grade selected from 20MPa,25MPa,32MPa,40MPa, 50MPa,65MPa,80MPa or 100MPa and designated as one of N20, N25, N32, N40 or N50.
    • The slump at the point of acceptance, selected as one of 20 mm, 30 mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, 90 mm, 100 mm, 110 mm or 120 mm.

    NOTES:

    1. The customer should carefully consider that the specified slump of concrete suits the placement method.
    2. For residential slabs and footings, if the slump is not specified by the customer, the specified slump should be considered to be 100 mm.
    3. The maximum nominal size of aggregate, selected as one of 10 mm, 14 mm or 20 mm. Unless otherwise specified, the default value shall be taken as 20 mm.
    4. The intended method of placement, including relevant details of equipment.
    5. If project assessment is required to be carried out by the supplier (see Note).

    NOTE: If unspecified, it will be assumed that project assessment is not required.

    • If required, a level of air entrainment up to a maximum of 5.0%.

    (2) SPECIAL- CLASS CONCRETE:

    Concrete other than normal-class concrete shall be specified by the customer as specialclass and, if applicable, by strength-grade. The parameters and attributes that should be specified for special-class concrete should be as set out listed below with reference to Appendix B and Table B1 on AS1379.

    Special-class concrete commonly has the same basic parameters as normal-class concrete with some additions and(or) exceptions. Parameters or attributes that are different from, or additional to, those of normal-class concrete should be included in specification below. If the requirements of specification for any concrete are inconsistent with those for normal-class concrete then the requirements of specification take precedence for that concrete.

    Where any parameter other than strength grade requires the specification of a special-class concrete, or the proportions of the mix are specified, the concrete should be identified by an appropriate code agreed to between the supplier and customer that identifies that particular mix.

    Basic parameter for specification of special-class concrete:

    • It is recommended to select from standard strength grades of S20, S25, S32, S40, S50, S65, S80 and S100.
    • Where concrete is specified as special-class and a strength grade is applicable, the strength grade is designated by the prefix:

    S, for compressive strength grades;

    SF, for flexural strength grades; or

    ST, for indirect-tensile strength grades.

    Where concrete is special-class and any property other than strength grade is Specified as the principal criterion, or the proportions of the mix are specified, it is designated by an appropriate alphanumeric code, agreed between the supplier and the customer, to indicate the criterion.

    • Special-class concrete should be subject to project assessment.
    • Certain concrete exposure classifications may require special provisions for aggregate durability (AS 2758.1 Aggregate & Rock for engineering Purposes.)
    • Any departures from the parameters or composition, or both, of normal-class concrete and any other criteria or limitations shall be specified by the customer in consultation with the supplier.

    NOTE: A summary list of several such parameters, some or all of which may be specified for the production of special-class concrete for a project, is given in Appendix B on AS 1379.

    • Other requirements additional to these parameters may be specified.

  • BEAM Vs COLUMN

    BEAM Vs COLUMN

    BEAM: A beam is a horizontal structural component that resists vertical loads. Its mode of deflection is primarily bending. It transfers loads imposed along its length to its endpoints to walls, column and foundations.

    The beam is structural element that stands against the bending. Mainly beam carries vertical gravitational forces, but also pull the horizontal loads on it.

    (If structural member transfers any load whichever is acting on it through bending, then that element will be refer as a beam.)

    COLUMN: A column is a vertical structural compression element that bears loads mainly in compression. It might transfer loads from a ceiling, floor slab, roof slab to a floor or foundation, it usually transfers loads from superstructure to foundation.

    Column plays an essential role in the entire load transfer system, though many columns are embedded forming part of a wall.

    Columns are commonly used to support beams or slabs or arches on which the upper parts of walls or ceilings rest. Sometimes a column is a decorative element as well as for structural purpose.

    (If structural element transfers the load through compression, it will be called as column.)

    DIFFERENCE BETWEEN BEAM AND COLUMN

    SL.NO

    DESCRIPTION

    BEAM

    COLUMN

    1

    Built

    Without a beam, a structure can be constructed.

    Without a column, a structure can’t be built.

    2

    Support

    They are supported by the column one end or both ends.

    They are directly built from the foundation.

    3

    Weight transfer

    It carries weight of slabs, ceiling. Floor, Roof of a building and transfer it to columns.

    It carries load transferred by beam and ultimately transfer it to footing and ground.

    4

    Classification

    Beams are classified based on their support end condition.

    Columns are classified based on their cross-section shape, material for construction and types of loading.

    5

    Shape

    A beam may be square, rectangular, T-shape, I-shape and H-shape.

    A column may be rectangular, circular, square, t-shape, L-shape and C-shape.

    6

    Simple Terms

    Beam is structural member carrying transverse loads.

    Column is also structural member carrying axial loads.

    IMAGES FOR BEAM AND COLUMN

    EXAMPLE:
    we have a rod of length 5 meter made out of steel and a load “P” to support

    1. We keep the rod on two supports and then place load on top of it. This time the primary mode of load transfer is by bending and thus we call it a Beam.
    2. We keep the rod vertical and apply load Horizontally to it. This time the primary mode of load transfer is also be bending and thus we call it a Beam.
    3. In this case the rod is kept vertically on the floor and the load is placed on top of it. Now the load is being transferred by compression and thus we call it a Column.
    4. We decide to hand the rod from ceiling and hook the load to the other end of the rod. The load in this case being transferred primarily by tension and thus we call it a Tie.

  • Cracking of panels at opening Corners


    Cause
    * During lifting
    * During Transportation
    * During Erection
    * After erection & slab pouring
    Problem
    * where the cracking of panel further affected the waterproofing by damaging the internal stud walls of the building.
    * Reinforcement getting Weak
    * If any interior work will damage due to the weather proof issue.
    Remedies
    * Get concentrate those location & intimate to reinforce team for additional reinforcement
    * Insist to follow the Guidelines from the engineering team
    * Insist Factory to concern the reinforcement for the specific openings
    * Insist Factory & Erection Crew to Follow the standards & guide line when the lifting from the store, during transport & installation the panel
    * During transportation take care all panels sitting on ‘A’ frame to be vertically supported on 2 points & if any additional support should only be for lateral purposes. Insist to follow the transportation guidelines
    * The Grouting must be taken care on time for the panel with openings Coordinators to advise if any special cases if needed.

  • CONSIDERATRIONS-LIFT SHOP DRAWINGS FOR PRECAST

    The important things to be considered in lift shop drawings for precast is listed below:

    1. Core Setout.
    2. Door Opening.
    3. Recess at the bottom of lift door.
    4. Landing Call Buttons penetrations.
    5. Controller Box Penetrations.
    6. Service Penetrations and internal platform box.
    7. Lifting Eye Placements & capacity.

         1. CORE SETOUT:

    1. Lift Core Panels Setout in Concrete plan and structural plan should match with lift core details.
    2. If any thickness of panels change keep inside dimensions unchanged, because inside dimensions are dictated by lift manufacturer’s drawings. Panels thickness change must affect only the outside dimensions of lift core.
    3. Propping method – Lift Cores are generally erected first. Higher level slab may not have been poured when lift core goes up. Hence propping of lift core need to have some special attention.

    2. DOOR OPENING:

    1. The door opening width and height of lift in lift drawing should match with architect and structural drawings.
    2. Make sure that the height of lift door opening in lift drawing are measured from FFL or SSL.
    3. Minimum Header height should maintained Discuss with interested parities if there any doubt.
    4. Always consider the RL’s difference between FFL and SSL while  the opening height are finalized. FFL and SSL are usually different

    3. RECESS AT THE BOTTOM OF LIFT DOOR:

    1. The recess at the bottom of lift door (as per door sill detail) is provided for door frame installation. Make sure we take this into consideration
    2. The door sill details are not same for all projects we need to confirm the depth and width of recess at the bottom of lift door before start the detailing.
    3. If the door sill height recess is wrongly provided (i.e. Measured from SSL instead of FFL) then there will be a problem in installation of lift door frame.
    4. The provided recess depth should start from the end of clear opening of lift door.
    5. Make sure that the Door sill details provided in lift drawings are measured from FFL or SSL.

    4. LANDING CALL BUTTONS PENETRATIONS:

    1. Penetrations for landing call buttons, fire switch and other electrical purpose are to be placed as per lift manufacturer’s drawings.
    2. First confirm the view direction of lift drawing (viewed from landing i.e. Outside) and precast Setout. It will clear the location of the lift call buttons and other penetrations.
    3. Ensure the height of penetrations provided in lift drawings are measured from FFL or SSL.
    4. There will be penetrations of different diameter according to its purpose i.e. call buttons, electrical, fire switch etc. so concentrate more on size and location of penetration while detailing.
    5. Penetration locations and size may vary according to the respective floor entrances so refer the details from correct floor entrance which is given in lift drawings.  

    5.CONTROLLER BOX PENETRATIONS:

    1. Controller box may need a recess or in some cases could be a penetration.
    2. Ensure the location of the control box from the panel edge, we need to maintain the sufficient gap from the edge of the panel.
    3. Ensure the sufficient cover from reinforcement with the penetrations

    6. SERVICE PENETRATIONS AND INTERNAL PLATFORM BOX:

    1. Ensure the Hatch opening / exhaust opening need to be accessible for the whole lift for installation & service.
    2. In some case there will be an internal recess requirement to allow for attaching temporary platforms inside the lift for servicing the lift. Make sure these recesses are same RL and opposite.

        7. LIFTING EYE PLACEMENTS & CAPACITY.:

                 For the whole lift is closed by 2 types of lids One by cast-insitu lid and another by precast lid. If we have the precast lid, we need to consider the following things

    1. Connection between the vertical precast & lid
    2. Slope for the water drain
    3. Finish of the face of the lid
    4. Lifting Eye & Hooks for the Lift car & accessories fixing
    5. Ensure the Capacity & size of the Hooks from the lift design.

  • HOB AND ITS TYPES

    HOB
    Hob is projection or recess on the top of slab, which is made up of concreate or sometimes precast. It will act as a base or foot for the precast panels and balustrade which are to be placed above the actual SSL (Structural surface level) and a locating guide sometimes with weather proof.

    HOB TYPES

    1. Weather proof Or Stepped Hob:
          This type of hob has projection from slab SSL, which is used to separate inside (living spaces) and outside (balconies and wet areas) of the building to resist water to enter the building. It has recess at the outside of the building on top of the hob, which means top face has step along the outside of building. Refer Section A-A for weather proof hob.

    2. Flat hob:
         It is also projection type hob, but top face is in full width flat without step. Usually, it will locate between either inside-inside or outside-outside area. Refer Section B-B for flat hob.

    3. Recess hob:
             It is further back from SSL or ditch or recess on slab. It will also act as weather proof. This hob needs some gap clearance on the higher side to make easily sit precast on it. Refer Section C-C for recess hob.

    4. Balcony hob:
              Balcony hob also be the projection type; it is used to outside of the building in outermost wall to resist spill of water or use as balustrade. Balustrade purpose hob have considerably higher than the all-other hobs. Refer Section D-D Balcony hob.

    5. Model hob plan drawing:

  • Types of Brace (Prop) Plan

    Brace are used for temporarily support precast concrete elements until the permanent fixing are made.
    1. Single storey (Drop-in) panel propping
    2. Double storey (Spin-up) panel propping
    3. Panel higher than double storey propping
    4. Panel to panel propping
    5. Edge Propping
    6. Spandrels propping

    1. Single storey panel propping:
          Single story panel are normally used 2 props a panel. Some times more than 2 props are used based on panel design.

    2. Double storey panel propping:
                    Double story panel are normally 2 props placed 200mm below the underside of slab. Some times more than 2 props are used based on panel design.


    3. Panel higher than double storey panel propping:
           This type of panel needs two level of propping. Two props on the below level and two props on the above level. If there is a slab in above level the propping system will pass through the below level slab by providing a pocket on the slab

    4. Panel to panel propping:
            Provide ferrule in the opposite panel Or Adjacent panel for propping. Especially this kind of propping system are applicable for lift and stair core area, where there will be no slab to support the prop.

    5. Edge Propping:

        These types of propping are used for column and some panel having cantilever. Provide ferrule in the edge of the panel.

    6. Spandrels propping:
            These types of propping are used for spandrels. Provide ferrule at the top of panel. Where the ferrule will be connected with the member which hold the propping system.

    Model brace plan drawing: