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Manchester Metropolitan University
Design, Manufacture & Erection of Precast Concrete Frame
Mark Gilliland, Estimating Manager CCPL
Introduction
Creagh Concrete Products Ltd.
• Core BusinessDesign, Manufacture, Supply & Installation of Concrete, Concrete Products & Aggregates
• Standard Products• Hollowcore flooring• spanTherm flooring• Stairs & Landings• Agricultural products• Small precast • Bradstone• Aggregates, Blocks & Concrete
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Introduction• Bespoke Products
• Wall panels (cross wall)• Sandwich panels• Architectural cladding• Retaining walls• Columns & Beams• Terrace units• Plate flooring• anything else made of concrete
• Recent & Current D&B Projects• Cowes School, Isle Of Wight• Greenwich Student Accommodation, London• Library Building, Univeristy of Roehampton• Apartment Development, Aberdeen• Blackpool MSCP, Blackpool• HMP The Mount, Hemel Hempstead
The process from tender to site
• Tender • 3D Modelling• Design & Detailing• Manufacturing• Logistics• Site Erection
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Case Study – MMU
Project OverviewDesign & Erection• Columns & Beams• Plate flooring & Hollowcore slabs• Wall panels• Stairs & Landings• Terrace units
Creagh Team• Design & Detailing - 5 engineers, 11 detailers• Manufacturing - 60 personnel at 3 sites - Toome, Ardboe,
and Hoveringham• Site erection - 42 personnel
Concrete Statistics• 26,170 tonnes of precast concrete• Heaviest piece 28.7 tonnes• 5936 tonnes of insitu concrete
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Project Overview
Precast package consisted of :-
– 327 columns– 546 beams– 325 wall panels– 55 stair flights– 64 ‘landing’ slabs– 36 terrace units– 753 plate flooring units– 134 hollowcore slabs– 16,333m2 of plate flooring & hollowcore slabs– 2240 pieces
Project Value £6.3M
Floor SlabsPlate Flooring and
Prestressed Hollowcore
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Typical Design – Stage 1Worst case 11.45m effective span Live load during construction 1.5 kN/m2Slab self weight 5.44 kN/m2 (precast + void formers + insitu)Props at maximum 2.4m centresBackpropped a minimum of two levelsGirder designed for buckling to EC3180mm girder depthTop bar H10Bottom bars H6Diag. bars H7
Unpropped Design – Stage 1 5.2m effective span at 3rd floor, no lower floor levels under this areaTo avoid erecting an expensive and time consuming propping system from ground up to this level, an unproppedsolution was designed for these slabs.Girder depth increased to 220mmTop bar H16Bottom bars H6Diag. bars H8
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Typical Design - Stage 2Loading – Live 3kN/m2
- Partitions 1 kN/m2- Finishes 0.44 kN/m2- Ceiling and Services 0.5 kN/m2- Slab self weight 5.44 kN/m2
Minimum Natural Frequency 4Hz
Exposure class XC150 year design life60 mins fire resistanceMovement after installation limited to span / 350 (Non-brittle floor finishes)Long term deflection limited to span / 250
Control of Temporary WorksProp release strategy – permit to load, access and unload
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Stair & Lift Cores
Precast wall panels, stairs and landing slabs
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The Structural Engineer - January 2014
Production
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Site
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17m Circular Column
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Atrium Stair
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Programme
Last piece being fitted 31st May 2013Creagh erecting for 20 weeks on site, to the hour. 2240 precast pieces, steel members in addition to this.
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Summary
• Project ran according to programme
• Main contractor extremely satisfied
• Design and erection by Creagh worked out very efficiently
• High quality concrete elements
Thank you for your attention
