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C e m e n t a n d C o n c r e t e A s s o c i a t i o n o f Au s t r a l i a
For commercial and industrial buildings
panel
Build a SOLID future
CONCRETE
WALLING
Concrete walls are:
Solid
Durable
Faster to build
Fire-resistant
Termite resistant
Energy savers, and
Will enhance
the appearance of any
commercial or industrial
building
SOLIDconcrete
options
St George Medical Complex,
Kogarah, NSW
Precast and tilt-up construction are now
firmly established throughout Australia
as viable alternatives to be considered
when planning a new commercial or
industrial building.
The use of these construction systems
for commercial buildings is claiming an
increasing share of the construction
market as imaginative architects and
designers apply the method to office
buildings, shopping centres,
warehouses, and other building types.
Precast concrete is a generic term
covering the fabrication of concrete
building components at a location other
than their final position but the term is
sometimes used specifically to refer to
factory-cast panels, whereas tilt-up
refers to the procedure frequently used
to fabricate and erect site-cast wall
elements.
Whether site or factory-cast, construction
almost invariably employs an applied
finish in combinations of textures and
colours, and occasionally, in conjunction
with panels treated by sandblasting or
polishing. Many buildings successfully
use cast-in rebates and other details to
provide modelling of the panels,
increasing their interest and attraction.
The detail is often highlighted by
contrasting or complementary colours
applied after installation of the panels.
Architectural design for the tilt-up
industry has now developed to the stage
where glass, polished stone, metal
panels and cast or fabricated ornamen-
tation are utilised in conjunction with the
concrete panels.
The projects highlighted in this
publication clearly demonstrate that
there is a concrete wall panel solution for
every commercial and industrial project.
The Subiaco Cinema Complex
illustrates that where wall panel shapes,
thicknesses and sizes are impractical
or uneconomical to transport from an
off-site casting facility and the site
layout lends itself to site casting, then
tilt-up construction is a clear winner.
However, where an enhanced cladding
option, such as lightweight glass
reinforced concrete (GRC) or a special
surface finish is desired by the architect,
such as in the St George Medical
Complex, or there is simply a lack of
suitable space for site casting, then the
precast option is the obvious choice.
In each case, the builder and owner
benefit from concrete walls that are
durable, attractive and faster to build
than other construction materials.
3
top Network Ten,
Pyrmont, NSW
centre New Headquarters,
Canningvale, WA
above Officeworks,
Chadstone, Vic
WALLING
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location Arndell Park, NSW
architect Allen Jack and Cottier Architects
structural engineer Woollacots
builder St Hilliers Pty Ltd
WAREHOUSEShowroom and
A sophisticated and adventurous
approach to the use of site-cast tilt-slab
panels has transformed a potentially dull
warehouse with associated showroom
and office areas into a dynamic, well
articulated building.
The project comprises a 2000 m2
warehouse storage area with loading
deck and a 350 m2 office/showroom.
The warehouse is characterised by a
modulated facade to the north and south
which consists of eight bays of 7.5 m
wide x 7.5 m high grey painted tilt-slab
panels, articulated at the 600 mm wide
recessed joints by a series of bright
yellow vertical strips and rain water
elements.
The panels were cast face down
adjacent to the steel portal frame
structure and dowel-connected to the
strip footings in ferrules in the base of
the panels. Panels were connected at
upper levels to cleats plate-welded
onto the steel structure.
5
location Kogarah, NSW
architect Hobbs Winning
structural engineer Wood & Grieve Pty Ltd
builder Fletcher Construction Australia Ltd
precast concrete Precast Concrete Pty Ltd
The complex provides a complete
healthcare service and sets new
standards in facilities and technology
with planning maximising the area
available to ensure five star patient
comfort with a high level of care.
Polished precast reconstructed granite
panels were selected to clad the podium
and sandstone finish GRC panels for
the upper levels. Detail was added to
the precast cladding, particularly at
pedestrian level, to avoid the usual
bland hospital building facade.
The choice of precast cladding for the
podium was influenced by the greater
security and resistance to abuse offered
by the thicker panels. In addition they
are easier to patch in the event of
damage and were able to accept
anti-graffiti treatment.
These precast panels to the podium
feature deep red and black coloured
polished and etched reconstructed
granite in two colours, with the carpark
ventilation louvres integrated into the
panel-module. Podium panels are
generally 2.4 m wide x 5 m high and
150 mm thick.
The precast concrete manufacturer
suggested the use of GRC panels for
the upper levels primarily because he
could supply them earlier than solid
panels due to his plant commitments.
However GRC also offered weight
reductions, which benefited cranage
requirements and cost savings.
MEDICAL COMPLEXSt George
Benson Radiology is a leading private
practice of 16 medical practitioners
operating out of 20 metropolitan and
country locations. The practice’s
requirements for the new building were
specific to the needs of radiology and
the provision of an efficient clinical
service with radiology areas located on
the ground floor and an administration
office area on the level above.
As the radiology function did not require
the use of windows at ground level, it
was a challenge to articulate the
precast panels. The boxiness of the
building is minimised by the use of
shallow concave lines cast into the
panels which meet or disappear behind
parapet walls. The painted precast
panels range from 8.1 m high x 3 m wide
to 6.4 high x 3 m wide and are 150 thick.
The largest panels weight 7.8 tonnes.
Shadow lines and deep reveals add
dimension to the flat panels.
7
CENTRElocation North Adelaide, SA
architect Ursini Architects Pty Ltd
structural engineer Ginos & Associates
developer Macnificent Pty Ltd and Mr P H Ong
precast concrete Hicrete Precast Pty Ltd
Benson Radiology
Location Pyrmont, NSW
Architect Nettleton Tribe
structural engineer Tierney & Partners
builder A W Edwards
precast concrete Rescrete Industries Pty Ltd
TENNetwork
Network Ten wished to consolidate their
headquarters and production on one
site and after an 18-month search
selected a site in Saunders Street,
Pyrmont nearby the Glebe Island Bridge
and expressway viaduct.
Polished red/brown precast concrete
panels were selected as cladding for
TEN’s new 5-level headquarters as a
finish that will not readily show the dirt
from the high concentration of road
traffic in the area.
The precast concrete cladding panels
are 170 mm thick to allow for the inset
grooving that patterns the polished
surfaces. The concrete mix contained a
reddish alluvial stone, together with
coloured sand, off-white cement and a
colouring oxide. The panels are
supported via haunches from the floor
slabs with all reinforcing black while
restraint connections are stainless steel.
Precast concrete is used as cladding
for levels 3 to 5 whilst brickwork is used
below level 3.
In the event of the building changing
use and the two-storey height of studio
space being converted into two levels
of offices there is provision in the
structure to include this area of floor
slab. As well, the solid precast cladding
panels have a pattern of joints that
reflects the window openings in the
fenestrated panels so that it would be
possible to cut window openings in the
solid panels, for future building recycling.
9
location Subiaco, Perth, WA
designer Campion Design Group
structural engineer Sinclair Knight Merz
builder Mervon Pty Ltd
tilt-up accessories Reids
The design brief for this four-screen,
900-seat complex includes basement
parking for 200 cars, a 550 m2
showroom and a 120-seat restaurant on
the ground floor. Tilt-up construction
was selected as the most cost-effective
solution for the project given the site
conditions, Careful planning by the
designer, builder and structural
engineer allowed the loadbearing wall
panels to be stack cast on-site on the
basement slabs and suspended ground
floor slab. Panels were generally 175 mm
thick and 3.6 m wide x 12 m high. The
14.5 m high x 400 mm thick portal
arches for the entrance foyer were also
cast on-site.
The prominence of the corner site in
Subiaco called for a distinctive image
for the complex and the designers
looked to the Art Deco style which
predominated in cinema design in the
1920’s and 30’s. External and internal
detailing and the selected colour scheme
all reflect the Deco style.
CINEMA COMPLEXSubiaco
location Northbridge, WA
designer and project manager Tom Brooking
structural engineer Wood & Grieve Engineers
concrete sub-contractor DTMT Contractors
Tilt-up concrete panels, some weighing
32 tonnes, were cast on-site as cladding
to the insitu concrete structure of this
entertainment complex. The Metropolis
City Concert Club provides a venue for
live performance artists and dance
parties with four levels of bars and
lounges overlooking the main stage.
The potential of concrete has been
exploited both structurally and visually
to complement the sophisticated
interior finishes. Beams, columns,
balconies and floor profiles have been
modelled internally while the external
face of the tilt-up panels has been
detailed by grooving and insets and
given a paint finish.
The 125 mm thick and 12 m high tilt-up
panels were stack cast adjacent to the
structure on a scratch slab and were
erected prior to the construction of the
internal structure, shimmed and dowel-
connected to the strip footings via
ferrules in the base of the panels. These
connections were subsequently grouted.
Panels were connected at upper levels
by cast-in ferrules to the insitu columns.
The many unusual features of the
structure of this entertainment venue
reinforce the high-tech image which
derives from the finishes, lighting effects
and sound quality. The tilt-up external
walling provides an enclosure which was
not only fast and economical to build
but has the advantage of providing
excellent sound attenuation and fire
resistance.
11
VENUELive Entertainment
location Notting Hill, Victoria
architect John R Brogan & Associates
structural engineer K J Klopter & Dobos
builder Farro Developers
BBC Hardware has now built fourteen
Hardwarehouse stores across Australia
as well as one in Auckland, New Zealand
using tilt-up construction techniques for
the cost benefits and efficiency the
system provides. The stores rely on the
distinctive use of colour, towers and
graphics to transform what might be a
bland shed into a noticeable and
attractive shopping destination.
The BBC Hardwarehouse at Notting Hill
has a floor area of 9200 m2 and stocks
over 40 000 line items. To accommodate
such a large operation over 130 concrete
panels were cast on site either 2.7 or
3 m wide and some exceeding 9 m in
height. The panels are loadbearing and
support the roof trusses whose 75 m
span is broken by a central row of steel
columns. Panels of clear acrylic roof
sheeting are used alternating with metal
sheeting to provide a source of natural
lighting within the store, The roof framing
braces the structure.
Externally 400 x 450 mm applied and
modelled string courses provide relief
to the expanse of panel as well as the
opportunity to change the colour of the
paint finish.
RETAIL STOREBBC
location Chadstone, Victoria
concept architect Woods Bagot
structural engineer David Novak & Associates
builder Construction Engineering
precast concrete SA Precast Pty Ltd
Officeworks is a chain of supermarket-
style suppliers of office equipment
whose market presence is reinforced
by a distinctive corporate livery based
on colourful and crisp graphics.
The building, which is a simple box with
a partial mezzanine for offices, is
constructed of loadbearing precast
concrete panels. On the east, west and
south walls, which will always be visible,
the panels are detailed with strong
grooving to appear panelised and are
170 mm thick. On the north wall, next to
which there may be future development,
the panels are not grooved and therefore
only 150 mm thick. Special portico
panels which carry the signage are
300 mm thick.
The 170 mm thick panels are 3.6 x 8.4 m
and weigh approximately 12.5 t while the
150 mm thick panels are 2.5 x 8.4 m.
The project was built within an extremely
tight time frame with working and shop
drawings produced in four weeks and
only nine weeks allowed for construction.
The precast panels and roof steel
erection was completed in four weeks.
A time saving factor was the excellent
surface quality of the precast panels
which were cast in steel moulds and
required little or no patching prior to the
application of the paint finish.
This type of loadbearing precast
concrete construction provides an
economical structure which, in the
hands of an imaginative designer, can
be transformed into eyecatching
commercial premises.
Officeworks 13
location Huntingwood, NSW
architect Peter Hunt Architect
structural engineer Miller Milston & Ferris
builder Liberty Bell Constructions
precast concrete Rescrete Industries Pty Ltd
Architectural Glass Projects design and
manufacture large scale glass
assemblies for facade glazing as well as
components such as revolving doors.
They required increased space for their
head office and manufacturing facilities
and were conscious of the need to
upgrade accommodation and staff
working environment, and to have
premises whose appearance suggested
the sophistication of the product.
The office component of this develop-
ment is naturally a showcase for their
glazing systems while over 1650 m2
of machine finished 200 mm thick
prestressed precast hollow-core panels
provide 3- and 4-hour rated fireproof
cladding to the steel framed 2500 m2
warehouse. The panels are used
horizontally and the smooth machine
finish was chosen as it proved an ideal
base for a colour banded paint finish.
The 150 mm ground slab extends into
the warehouse where steel portal frames
at 9 m centre support the hollow-core
wall panelling. The portals span 29.5 m
with the curved roof members fabricated
from steel plate.
The clean and precise detailing of the
facades is offset by the colour scheme
of blue and white banding which is used
predominantly on the machine-finished
hollow-core panels.
PROJECTSArchitectural Glass
To comply with the low-cost construction
budget the external loadbearing
concrete wall panels of these offices
were cast on site and erected using
tilt-up construction techniques. The
brief called for a building with clear
efficient planning that would readily allow
internal modification and be capable of
being easily extended. It has been
designed with two wings extending
from a central services core with a print
works in a separate building to avoid
possible problems that may be caused
by noise and vibration.
The greenfield site with unhindered
access and a regular floor plan, lent itself
admirably to the on-site construction of
the two-storey-high tilt-up wall panels.
Careful planning of casting locations on
the ground floor slab allowed panels to
be poured adjacent to their ‘stood’
position, avoiding the need to ‘walk’ the
panels and the associated requirement
for heavy cranage.
The wall panels were supported on
erection pads with grouted dowel
connections into the panels. A 50 mm
wide ledge was provided internally in all
panels at first floor level. Dowel bars
were screwed into cast-in ferrules in the
panels and then cast into the first floor
slab allowing the panels to cantilever
above the first floor slab to resist
negative wind loads.
15
location Canning Vale, WA
architect Spowers Architects
structural engineer Barwood Parker Australia
builder Doric Constructions
tilt-up concrete V & L Carlino
HEADQUARTERSNew
SPONSORED BY:
Cement and Concrete Association of Australia
Locked Bag 2010 St Leonards NSW 2065
For technical enquiries fax 1300 360 298
Email [NSW, ACT, QLD]: inquiry_n@ccaa.com.au
Email [VIC, SA, WA, NT, TAS]: inquiry_s@ccaa.com.au
Australian Pre-Mixed Concrete Association
Locked Bag 2011 St Leonards NSW 2065
For precast flooring and panel manufacturers contact the NPCAA
National Precast Concrete Association Australia
8–10 Palmer St North Parramatta NSW 2151
Website: www.npcaa.com.au
ISBN 876 304 057 June 1998 G78 De
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