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wiNter 2008

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structural precasteassociatioNatco a t i e wsl et t er s t ru cc t u r l l rer a c t s t a s s o i i N N o N t r u tur a a p p c s a a sso c i

the new parr stand at trent Bridge, Nottingham, with england batting
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Bell & Webster expands into Hoveringham Contents

3 New manufacturing facility for Bell & webster 4 Fastbuild system for ramada Hotel, Barnsley in one of the biggest moves in its 60-year history, Grantham-based precast concrete manufacturer Bell & webster has expanded its operations and set up extensive production facilities in Hoveringham, just outside Nottingham city centre

the chairmans View

by Gerry Feenan

ith the depressing reports on the state of the economy and the winter weather to contend with, we are grateful to the Clegg

Group and Ebor Concretes for providing a front cover image which not only reminds us of happier times but also of next summers Ashes and our hopes for a similar outcome to the 2005 series. The Trent Bridge stand is just one of many projects featured in this issue

he expansion follows the precast manufacturers most

successful trading year to date, with staff and turnover numbers increasing across key market sectors. The new plant in Hoveringham is

tecHNical sectioN 5-6 precast eurocode 2: worked example 5 7 the concrete centre

that illustrate the versatility of precast structures. There is also news from Bell & Webster of their new manufacturing facility at Hoveringham, the latest example of members investing in the future of precast concrete. Congratulations to Buchan Concrete Solutions on receiving an Offsite Construction Award for Best Use of Concrete for their work on the Medlock Primary School in Manchester. There was also recognition for Hanson Building Products who supplied Cobiax flooring to the Newcastle College, Lifestyle Academy project, which received a commendation in The Building Category of the Concrete Society Awards.

spread over seven-and-a-half acres, with two main purpose-built manufacturing buildings and a large outside storage yard. Worldclass building materials supplier Lafarge has formed an on-site partnership with Bell & Webster for the supply of the ready-mixed concrete a self-compacting product called Agilia. One million pounds has been

cobiax goes to college in Newcastle

I would like to take this opportunity to thank Norman Brown for his invaluable contribution as the Associations secretary over the past 18 months and wish him every success in the future.

precast for sustainable school pathfinder project

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salford Hope hospital gets a car park

In the Spotlight A

injected into the Hoveringham plant to provide for new tilting tables, flatbed moulds and self-stressing moulds to create the optimum production environment needed for the companys continuing growth. Production has increased by 50 units a day which means that, combined with the Grantham output, daily production will increase to 140 precast units. Put into perspective, this equates to a 100-bedroom hotel being produced in one week. Two new products will be and increased revenue streams for Bell & Webster. Up until now, the companys acclaimed fast-build rooms system has been used primarily for hotel and student accommodation, but now that capability encompasses social housing, key worker homes, schools, apartments and prison accommodation.
precaster: Bell & webster

visit to the National Motor Cycle Museum in

Birmingham is something special for the enthusiast, but Steve Parker, director Buchan Concrete Solutions, had another very important reason to be there on 28 October. The occasion was the Offsite Construction Awards

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Making a stand at trent Bridge

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product reference Members contact details

when he was presented with the Best Use of Concrete award for Buchans work on the Medlock Primary School in Manchester.

The new plant is spread over sevenand-a-half acres, with two main purposebuilt manufacturing buildings and a large outside storage yard

manufactured at the Hoveringham plant to complement the companys core product base. At the same time, it will also absorb any excess capacity needed for fast-build rooms. These new products an 8m-span floor and an insulated glazed wall panel will open new market opportunities

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tecHNical sectioN

tech

Precast Eurocode 2: Worked examples

by rs Narayanan Freng

reation of the Single Market was a seminal event of the

last decade of the 20th century affecting many aspects of our lives in Europe. By permitting freedom of movement of products and services across this market, it creates huge commercial opportunities for manufacturers of goods and products. This clearly has particular significance to the precast industry. So-called Harmonised Standards for precast products have been written to break down technical barriers to
precaster: structherm
Calculate the reinforcement required in a simply supported rectangular beam 1000 mm deep x 400 mm wide. The applied bending moment in the ultimate limit state is 1800 kNm. The concrete strength is 60 MPa and the cover to the main bars is 60 mm.
Project details Calculated by Checked by Client Job no. Sheet no. Date

5 Design for flexure reinforced concrete member

Design for flexure reinforced concrete member

5.1 Basis of calculation

It should be noted that there is no limitation on the depth of neutral axis in simply supported members. If desired, the limitation given in BS EN 199211[3], Cl. 5.5 for elastic analysis with limited redistribution may be used assuming zero redistribution. Alternatively, the designer might wish to limit the neutral axis depth to a value that will ensure the yielding of reinforcement at failure. In this example the second option noted has been used.

trade and to facilitate free movement of goods across borders. For structural design these Standards refer to Eurocode 2 (EC2), which thus underpins the whole edifice. Good understanding of EC2 is essential for taking advantage of the new opportunities.

Barnsley builds beds

the 117-bed ramada Hotel in Barnsley was constructed in just 12 weeks, using structherms Fastbuild precast concrete system

5.2 Depth of neutral axis

The depth of neutral axis (x) that will ensure that the tension reinforcement will yield is x = [ecu3 / (ecu3 + esy)]d where ecu3 = 0.0029 esy = (fyk / gS) / Es = 0.0022 Thus x = 0.569d = 0.569 x 905 = 514 mm. Normally the design will be carried out using design aids such as those in Appendix A of the Design manual[1]. A method using first principles is illustrated here.

he Ramada Hotel building was constructed in such a

designed as deep-beam walls to

and simplified site management. Tim Harvey, contracts manager for ISG, commented: Budget was a key consideration for the scheme and Structherm was able to deliver a high-quality product at a competitive price. We were particularly impressed by the companys technical support and in-house design capabilities, providing a highly responsive and consistent service so essential on fast-track projects.

way that follow-on trades were able to commence their works at week 9, meaning a much faster completion time. The building consists of direct decoration party wall and preformed window panels, with solid concrete double-spanning floor beams over two rooms to aid speed of installation. The precast concrete wall panels were

The precast concrete wall panels were designed as deep-beam walls to allow load transfer to the outer edges of the walls, thus concentrating load down the columns and reducing the depth of the support steel

allow load transfer to the outer edges of the walls, thus concentrating load down the columns and reducing the depth of the support steel. As a result, there are worthwhile savings in total steel costs. Bathroom pods were installed in liaison with ISG and Prime Pods as part of the Structherm Fastbuild package, which meant fast installation, smooth coordination

Howard Taylor (then of Tarmac) and I were attending an EC 2 meeting in the late 1990s in Budapest. While sipping tea (or something stronger!), Howard expressed a vision. He thought that the precast industry in the UK would benefit from a publication on EC2 that was modelled on the Green Book
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5.3 Calculation of resistance moment

The stress block is as shown in Figure 5. For x = 0.569d, the moment of resistance of the section Mrc = (0.567nfck) (lx) b (d 0.5 lx) = 0.35 (1 0.3085l) nl bd2fck. If fck = 60 MPa, l = 0.775 and n = 0.95, substituting these values we get Mrc = 3641 kNm.

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tech
Example 5: Design for flexure
As this is greater than the applied bending moment of 1800 kNm, compression reinforcement is not required.

5.4 Calculation of reinforcement

From design tables the depth of neutral axis for the applied moment may be found as 0.251d and the lever arm as 0.875d. The area of reinforcement Ast = (1800 x 106) / (0.87 x 500 x 0.875 x 905) = 5225 mm2. Use 4 no. B32 bars in layer 1 and 3 no. B25 bars and 1 no. B32 bar in layer 2. Note that the notation for calling up has changed to comply with BS 8666: 2005[4].
n acc fck /gC ecu3 = 0.0029 Fc

The Concrete Centre publishes design guidance on a range of concrete applications and techniques. Below is a small selection of our recent brochures; for information on these and other titles available, visit: www.concretecentre.com/publications.

Residential Cellular Concrete Buildings

Cellular structures are particularly efcient for repetitive residential buildings such as apartments, hotels, student residences and prisons. In addition to carrying the vertical and horizontal loads, the concrete walls provide re resistance and compartmentation, acoustic separation, thermal mass, concealed electrical services distribution and minimal nishes to walls.

Crosswall Construction
Crosswall is a modern and effective method of construction which uses precast, cellular concrete components to achieve structurally robust, fast, economical medium and high-rise buildings. This publication explains the benets of using crosswall construction and includes case studies of projects which have beneted from its effectiveness. Publication date: 2007 Ref: TCC/03/26 Free PDF download available

x = 0.617d 1000 mm d

lx

z = d 0.5 l x

esy = 0.0022 400 mm

Fs

More iNForMatioN
c) Forces

a) Section

b) Strains (balanced sections)

Figure 5 Flexural design for a rectangular beam

to obtain copies of either: precast Eurocode 2: Design Manual or Precast Eurocode 2: Worked Examples (priced at 45 per copy) please visit www.britishprecast. org, click on publications list or email ec2design@ britishprecast.org
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Whilst structurally these buildings can be considered as simple, the guide addresses the design decisions that are inuenced by the construction process and will overcome reinventing the wheel for standard solutions. Publication date: 2008 Ref: CCIP-032 Price: 45

Precast Concrete in Buildings

The use of precast concrete elements is well established as a construction method throughout the world and provides solutions for a great variety and complexity of layouts, shapes and facade treatments. This publication explains the benets of precast concrete elements for buildings, provides design advice for the project team and showcases projects which have used precast concrete in their construction. Publication date: 2007 Ref: TCC/03/31 Free PDF download available

Design of Hybrid Concrete Buildings - Coming soon

Hybrid concrete construction allows the most appropriate use of in-situ and precast concrete and methods of construction to produce an effective structure. This guide is aimed at the designer and considers a range of hybrid options. It provides design and detailing information for some of the common systems used and structural elements involved. Publication date: due January 2009 Price: 45

coming soon

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produced in the mid-1980s by the Institution of Structural Engineers. He was of course fully aware of my considerable involvement with the Green Book that was written to overcome the difficulties with BS 8110 that were perceived by practising engineers. The Precast Eurocode 2: Design

Manual and Precast Eurocode 2: Worked Examples produced by British Precast fulfil a similar purpose. The Manual guides the reader through EC2 and its National Annex. Design aids are included. Although the original intention was to produce a Manual that included worked examples, it was decided during the development

to split the two. The separate publication Worked Examples complements the Manual and illustrates the application of the code through 13 examples, one of which is a whole building. Together the two companion documents seek to promote understanding of the code and they will assist in dispelling some

of the understandable fears of engineers in coming to terms with a completely new set of Codes and Standards. Although I was the principal author, the publications have been enriched by contributions by others and this is acknowledged fully in the documents.

To download or order hard copies of these documents, where appropriate, visit The Concrete Centre publications library at www.concretecentre.com/publications. For notication of when new publications become available, register for publications alerts at: www.concretecentre.com/register.

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The Concrete Centre Riverside House, 4 Meadows Business Park, Station Approach, Blackwater, Camberley, Surrey GU17 9AB Tel: 01276 606800 www: concretecentre.com

one of the commendations in the Building category of this years concrete society awards is the lifestyle academy of Newcastle college which featured cobiax floor construction

John Perryn Primary School

the new two-storey 8.3 million John perryn primary school, in ealing, west london, replaces a Victorian school that, while still in use, was partly demolished to give some space for the new school to be built

he project was constructed under the Governments

windows. High-level openings are controlled by electric actuators connected to a building management system that controls room temperature, CO2 levels and nocturnal cooling. Solid concrete walls and exposed ceiling soffits provide the buildings thermal mass which works as a heat sink, helping to maintain a consistent temperature through the year. All building materials were obtained from sustainable sources. Piling for the project was carried

Primary Capital Programme initiative, designed to improve the standard of the countrys primary schools and is a Pathfinder project. Main contractor Willmott Dixon looked at other methods of construction before opting for precast concrete because of factors such as fire resistance, flexibility, high quality (eliminating finishing trades) and instant working platform. Buchan Concrete Solutions was then selected to
precaster: Hanson

develop a bespoke design. With its 14 classrooms, the new building also includes a Childrens out by Roger Bullivant who installed 122 piles using a mix of continuous helical displacement and continuous flight augurs. For RBL south east operations manager, Jamie Bain, it was a very satisfactory job:We were on site for just five days and completed the contract on time. On the back of it, we have won two more The pre-cast concrete frame was erected by Buchan in just 35 working days on site, a remarkable achievement. But a greater claim to fame is the emphasis placed from the start on sustainability, as shown by the following: 90% of the demolished school building was recycled or used as piling mat material. A sustainable drainage s ys te m (SUDS) wa s constructed. A large ground-source heat pump was installed to minimise energy consumption and carbon emission levels. Buchan Concrete Solutions contribution involved supplying The prefabricated concrete panel system gave all the benefits of the fast, economical, pre-finished system, reducing programme time and waste without jeopardising future internal flexibility. Natural ventilation to all classrooms was made possible by using stack ventilation chimneys working in conjunction with a large proportion of openable and erecting 177 precast concrete units for external and internal walls, stairs, landings and beams a total of 426m 3 plus hollowcore floor slabs. Precast panels weighing up to 14 tonnes, 190mm thick and 4m high were made in a range of lengths and delivered on a just-in-time basis. On average 16 units (equivalent to 125m2) were erected each day, using a ten-man erection team.
precasters: roger Bullivant & Buchan concrete solutions

Cobiax slabs for a better lifestyle A

mong the factors of merit singled out by the judges The Academy provides a new facility for Newcastle College about the Lifestyle Academy Departments of Hair and Beauty, Sports and Fitness, Food and Hospitality, and Travel and Tourism. The Colleges desire for a highly sustainable building and future flexibility along with tight financial constraints led to the choice of concrete for the following reasons: Using Cobiax slabs, without downstand beams, enabled overall floor-to-floor height to be significantly lowered relative to normal steelframe slabs. In turn this minimised cladding costs. Programme savings from the speed of construction of the Cobiax slabs, which need no further work (i.e. no time required for hanging services and ceiling tiles). which is on the south-east corner of Newcastle Colleges Rye Hill Campus, west of Newcastle city centre was the use of Cobiax floor construction, which: Reduced the foundation loads and the amount of concrete required Guaranteed a high-quality exposed slab soffit to most of the structure Used the thermal mass of the exposed structure to reduce heating demands and improve the sustainable nature of the building Minimised transportation costs, by using Hanson Building Products factory in Washington, which benefited the highly sustainable approach taken.

Cost savings by eliminating the need for ceilings.

Centre which will provide childcare for children up to three years old. In addition, it will facilitate provision of community/parent support including a childminder network, parenting classes, crche and health visitors clinic.

The Colleges desire for a highly sustainable building and future flexibility along with tight financial constraints led to the choice of concrete...

acknowledgement Abridged from an article that first appeared in CONCRETE magazine, Vol.42, No.10, pp.2526, November 2008. Reprint permission granted by The Concrete Society.
photos: rMJM

school projects for Willmott Dixon and a leisure centre, he added.

The pre-cast concrete frame was erected by Buchan in just 35 working days on site, a remarkable achievement. But a greater claim to fame is the emphasis placed from the start on sustainability

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product Reference
tarmac precast concrete ltd charcon specialist products Bell & webster concrete ltd Buchan concrete solutions Hanson Building products roger Bullivant ltd

ebor concretes ltd

products Foundation Units and Piles Composite and Double Tee Floors Staircase and Stair Units Structural Wall Units Beams and Columns Frames Multi-Storey Car Parks Grandstands and Terracing Specialised Building Systems

From the front cover:

precaster: scc

Hope Hospital Multi-Storey Car-Park B

uilt for Salford Hospital possible by the use of only one centre of the building. Trust, this SCC Ltd designcross-over ramp, situated in the build project provides parking for 1136 vehicles on its Hope site. The car park is just part of a massive current redevelopment plan and will provide the muchneeded space to progress with the overall expansion plan. Built on part of an old surface park, it provides parking on six levels and uses a sloping deck arrangement to maximise the spaces available. This was made Although the car park could be considered as essentially a basic design, the client was keen to produce a gateway building as the site is close to the M602, which is one of the main arterial routes into Manchester city centre. This was achieved by the development of an original concept design, provided by

H. K. Ryder Architects, and by u s i n g ce r t a i n m a te r i a l s throughout the development. One in particular is the grey ship-lapped cladding, which was used to good effect on the service cores. In addition, galvanised steel edge-on-edge mesh in a random pattern forms the floor-to-floor screening, broken at floor level by a prominent white concrete aerofoil, giving the building a strong horizontal emphasis.

Making a Stand at Trent Bridge

A
s part of the 8.2 million improvements carried out at Trent Bridge by Clegg Construction, Ebor Concretes supplied precast The total order of just under 300K was received in mid-September 2007 and all units were produced between the end of September and late November. Deliveries began in early November and were completed just before Christmas 2007. With a very tight and limited construction period between the end of the 2007 season and the start of the 2008 season, the project was completed on time and the stand was officially opened by The Duke of Edinburgh on the first day of the Test Match against New Zealand in June 2008.
precaster: ebor concretes

Built on part of an old surface park, it provides parking on six levels and uses a sloping deck arrangement to maximise on the spaces available

concrete terrace units and stairs for both the new stand generally referred to as the Parr Stand and an extension to the front of the Fox Road stand. (The existing Fox Road stand terracing had been supplied by Ebor some years earlier.) Both the new stand and the Fox Road extension were constructed under the same contract and the jobs ran in parallel. All 340 terrace units and around 200 step blocks plus two flights of stairs and associated landings were manufactured at Ebors Ripon factory.

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thorp precast ltd

s.c.c. ltd

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spa Members

Bell & webster concrete limited Alma Park Road, Grantham, Lincs, NG31 9SE Contact: Roy Spurgeon Tel: 01476 562277 Fax: 01476 562944 Email: roy.spurgeon@eleco.com Web: www.eleco.com/bellandwebster

ebor concretes limited PO Box 4, Ure Bank Top, Ripon N.Yorks, HG4 1JE Contact: Paul Whitham Tel: 01765 604351 Fax: 01765 690065 Mobile: 07872 901339 Email: paul.whitham@eborconcrete.co.uk Web: www.eborconcrete.co.uk

s.c.c. limited Kenwood Road, Off Station Road, Reddish, Stockport, Cheshire, SK5 6PH Contact: Peter Crofts Tel: 0161 432 7700 Fax: 0161 432 4847 Email: reddish@sccltd.co.uk Web: www.sccltd.co.uk

Buchan concrete solutions limited Kings Lane, Byley, Middlewich Cheshire, CW10 9NB Contact: Neil Gibbons Tel: 01606 843500 Fax: 01606 842215 Email: neil.gibbons@buchanconcrete.co.uk Web: www.buchanconcrete.co.uk

Hanson Building products (Floors and Precast Division) Birchwood Way, Cotes Park Industrial Estate, Somercotes, Derbyshire, DE55 4NH Contact: David Chamberlain Tel: 01773 600247 DD Fax: 01773 600290 Office Email: David.Chamberlain@Hanson.com Web: www.hanson.co.uk

tarmac precast concrete ltd Tallington, Stamford, Lincs, PE9 4RL Contact: Kevin Bourne Tel: 01778 381000 Fax: 01778 348041 Email: kevin.bourne@tarmac.co.uk Web: www.tarmac.co.uk

charcon specialist products Marions Way, Coventry Road, Croft Leicester, LE9 3GP Contact: James Gadher Tel: 01455 288275/276 Fax: 01455 285284 Mobile: 07774 223575 Email: James.Gadher@aggregate.com Web: www.aggregate.com

roger Bullivant limited Walton Road, Drakelow, Burton-on-Trent Staffs, DE15 9UA Contact: Steve Parker Tel: 01283 525045 Fax: 01283 512233 Email: marketing@roger-bullivant.co.uk Web: www.roger-bullivant.co.uk

thorp precast ltd Apedale Road, Chesterton, Newcastle-Under-Lyme Staffordshire, ST5 6BN Contact: Harvey Thorp Tel: 01782 561155 Fax: 01782 561156 Email: Harvey@thorpprecast.co.uk Web: www.thorpprecast.co.uk

A product group of the British Precast Concrete Federation Limited

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STRUCTURAL PRECAST ASSOCIATION 60 Charles Street, Leicester LE1 1FB. Tel: 0116 253 6161. Fax: 0116 251 4568