CONCAST PRECAST GROUP CIVIL ENGINEERING SOLUTIONS

Transcription

1 CONCAST PRECAST GROUP CIVIL ENGINEERING SOLUTIONS

2 Copyright Concast Precast Ltd 2009 Note: Please note technical information provided is for guidance only, project specific requirements should be discussed at the appropriate time.

3 The Concast Precast Group is a major provider of precast concrete solutions servicing the Irish and UK markets. Founded in 1975, Concast s business has grown through our reputation for delivering quality projects, on time and within budget. Range of projects 2 Our Service 3 Concast has a professional cross functional team with the expertise and state of the art facilities to deliver an extensive range of precast solutions. Concast offers both public and private sector clients a comprehensive service including design, production, transportation and installation on site. Concast provides precast solutions to a wide range of including road and rail projects, multi-storey car parks, office blocks, residential schemes, industrial schemes, sports stadia and power plants. ridge eams 4 TY eams TYE eams M eams Y eams YE eams U eams CSU eams (Concast Super U) ridge ecks 8 Glass Reinforced Concrete (GRC) Omnia Slab Ramp Slabs Retaining Walls 9 Culverts 10 Wingwalls Headwalls Contents 1

4 ocklands Residential Scheme Concast provides multi-storey structural precast concrete solutions for major residential schemes, including luxury apartments, duplexes and townhouses, social-affordable schemes and student accommodation. Concast s design team provides flexible solutions, to suit modern designs. In addition to the structural frame, Concast can provide additional products such as precast balconies, cladding panels, lift-core pods. 2. Sports and Leisure Stadia Concast are a leading manufacturer of sports and leisure facilities including spectator stands which generally incorporate auxiliary facilities such as changing rooms, meeting rooms, conference and exhibition space. 3. Multi-storey Car Parks Precast provides flexible and competitive solutions for all types of multi-storey car parks, from stand-alone car parks, to underground or basement car parks on multi-storey, industrial and residential schemes. 2

5 esign & Planning Concast s in-house designers, work closely with our clients design team to deliver a flexible and innovative solution for every project undertaken. It is essential to identify the most efficient sizes and shapes for components, at an early stage. This ensures structural efficiency and minimises cost. Transport & Installation Concast has a fleet of specialist equipment, to facilitate the transportation and installation of our precast concrete products. Professional crews, complete the installation process on site. Concast is committed to delivering projects on programme and within budget in a safe and efficient manner. Production & ISO Quality Controls Concast has invested heavily in plant and equipment; our modern moulding systems produce a consistently high quality product. Concast has been awarded ISO 9001 Quality Certification, which is independently monitored. Health & Safety Safe working procedures are implemented at all stages of the process from the initial design risk assessment right through to the completion of the safety file. Precast construction keeps the site, cleaner and improves logistics on site. Concast Provide a Quality Service 3

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7 ridge eams Prestressed concrete bridge beams provide a durable, high quality solution for modern road structures. Concast has a dedicated production facility, which manufactures to precise tolerances in compliance with ISO 9001 quality procedures. The high quality steel moulds produce units with an impressive finish, available in a wide range of bridge profiles, which span up to 45m depending on conditions. eam Type Shape Spans Applications TY 5-18m Medium span bridges, car parks, jetties and marine decks. TYE 5-18m Generally used as edge beams to the TY eam. Prestressed technology typically provides slimmer, stronger, lighter, beams and also lowers the cost versus traditional building methods. The speed of installation of precast bridge beams is a key benefit when contractors are planning major road. The prestressed beams manufactured in the facility can also be used in the construction of multistorey car parks,, jetties and marine decks etc. Introducing the Concast Super U (CSU) eam Concast manufactures a wide range of bridge profiles such as the familiar TY, Y, M and U formats etc. U beams are the most widely used beam due to their attractive profile. Concast has also introduced the Concast Super U beam (CSU) with larger spans. The Concast team has designed and developed the Concast Super U beam (CSU) in consultation with engineering firm Mott Maconald. Subsequent to rigorous third party testing and approval, the CSU has been successfully erected on numerous National Roads Authority (NRA) bridge schemes. For larger spans the CSU has significant economic advantages when compared to the standard U-beam, providing a lower cost solution, with faster erection times and greater spans of up to 45m. The familiar and attractive U profile is maintained on the underside of the finished bridge ensuring that the CSU will stand the test of time both from a durability and aesthetic perspective. M 16-29m Provides voided bridge deck for medium and long span road bridge construction. Y 14-31m Medium and long span bridge beams. YE 14-31m Medium and long span bridge beams. YE is generally used as edge beams to the Y eam. U 14-34m Excellent for skewed structures, good with torsion. U beams are popular due to their attractive edge profile. CSU 13-45m Similar in design and profile to the standard U beam, but with greater spanning capabilities. Note: The above table provides a guide only, the Concast design office should be consulted in relation to specific technical requirements for individual contracts. Parapets Precast concrete parapets can be supplied by Concast and fixed on site. Precast concrete removes the necessity for complicated formwork, steel-fixing and pouring which is required for traditional insitu parapets. The required fixings or sockets for projecting bars may be provided as part of the bridge beam and cast in during the production stage. ridge eams 5

8 EAM Properties m am eam g es m am voided ck for and long bridge m tion dium -29m an 34 m eam medium ges and ial m ents 8m m dium an l eam nts for short m ium span nd ial ents 18m TY eam Short and medium span bridges and. Span: 5-18m H Section No Span [m] epth [mm2] Height centroid above soffit Yb Zt (top) [mm3 x 10^6] esign self weight per unit has been taken as 24kN/m3 Zb (bottom) [mm3 x 10^6] Second moment of area [mm4 x 10^9] Approximate self weight [kn/m] M eam Provides voided bridge deck for medium and long span road bridge construction Span m TY M TY TY M SECTION TY PROPERTIES esign self weight per unit has been taken as 24kN/m M TY epth Height centroid Second moment Approximate 5.77 M TY6 Section 11.5 No Span (m) [mm2] above soffit Yb Zt (top) Zb (bottom) of area self weight 6.14 M TY [mm x 10^6] [mm x 10^6] [mm4 x 10^9] [kn/m] M TY8CSU M TY9CSU TY M CSU TY11CSU CSU CSU TYE eam esign self weight per unit has been taken as 24kN/m3 CSU Section Span epth Height cent Edge beam for short and Section CSU11 Span epth Height centroid ist centroid to Second moment Approximate No [m] [mm2] above soffit medium span bridges and No. [m] [mm2] above soffit vertical face of area self weight TY eam CSU Yb Xb Zt (top) Zb (bottom) [mm x 10^9] [kn/m]. [mm3 x 10^6] [mm3 x 10^6] esign self weight per unit has been taken as 24kN/m3 CSU Short and medium TY Section Span epth Web Height centroid Second moment Approximate TYE1 Span: 5-18m CSU No. Height [mm2] above soffit Yb of area self weight TY TYE span bridges and [mm4 x 10^9] [kn/m] CSU M eam H [mm3 x 10^6] [mm3 x 10^6] TY TYE M CSU TY TYE4 Provides voided M TY CSU TYE bridge deck for M TY TYE6 CSU esign self weight per unit has been taken as 24kN/m M medium and 8.92long Span m TY epth Height centroid Second moment Approximate M TYE7 CSU Section No Span (m) [mm2] above soffit Yb of area self weight span road bridge 9.56 M TY TYE8 [mm3 x 10^6] [mm3 x 10^6] [mm4 x 10^9] [kn/m] construction M CSU TY CSU3 TYE Span m M TY M CSU TYE TY CSU TYE CSU CSU esign self weight per unit has been taken as 24kN/m3 M eam TYE eam esign self weight per unit has been taken as 24kN/m3 CSU Section Span epth Height centroid Second moment Approximate CSU No [m] [mm2] above soffit Yb of area self weight epth Height centroid Second moment TY Approximate eam [mm4 x 10^9] [kn/m] Section Span epth Height centroid ist. ce CSU [mm3 x 10^6] [mm3 x 10^6] esign self weight per unit has been taken as 24kN/m3 No. [m] [mm2] above soffit vertic CSU Provides voided bridge deck for Section 1700No Span (m) [mm2] above soffit Yb of area Short and self medium weight TY Section Span epth Web Height centroid [mm3 Section x 10^6] modulus [mm3 x 10^6] Second [mm4 x moment 10^9] Approximate [kn/m] Edge beam for short Yb Xb CSU TY medium span bridges and and long span roadcsu No Height [mm2] above soffit Yb TY of area self weight CSU [mm4 x 10^9] [kn/m] and TY4 medium span TYE bridge construction. U H TY CSU [mm x 10^6] [mm3 x 10^6] TYE U bridges TY and CSU Span: 16-29m M esign self weight per unit has been taken as 24kN/m Span m7.60 TY TYE CSU Section Span M3 epth U Web Height centroid Section modulus Second 491.7moment Approximate TY TYE TY No. Height [mm2] above soffit Yb of area self weight TYE5 M4 U TY [mm x 10^9] [kn/m] H [mm3 x 10^6] [mm3 x 10^6] TY TYE M M5 720U Span m TYE M M M4 U TYE esign self weight per unit has been taken as 24kN/m3 esign self weight per unit has been taken as 24kN/m3 TYE eam Section Span epth Height centroid ist. centroid to TYE9 M M7 960U epth Height centroid Second moment Approximate Second moment Approximate No. [m] [mm2] above soffit vertical face of area self weight Section TYE M6 No 22 Span - 24 (m) M [mm2] above soffit Yb Zt (top) Zb (bottom) of area self weight M U [mm3 x 10^6] [mm3 x 10^6] [mm4 x 10^9] [kn/m] Edge beam for short Yb Xb [mm4 x 10^9] [kn/m] [mm3 x 10^6] [mm3 x 10^6] TYE M M and medium span TYE U TYE U5 M M bridges and TYE M10 U TYE U U Typical 550 Specification TYE TYE Span m TYE esign self weight per unit has been taken as 24kN/m3 U TYE Y eam Section Span epth Height centroid Second moment Approximate TYE U11 No [m] SECTION 1500 Span PROPERTIES [mm2] above 682.2soffit Yb of area self weight esign self weight per unit has been taken as 24kN/m3 TYE Ideal for medium and long span U [mm4 x 10^9] [kn/m] Section [m] Span (m) epth [mm3 x 10^6] [mm3 x 10^6] Height centroid TYE11 Second moment Approximate bridges and TY No eams [mm2] above soffit Yb 4.53 of area self weight TY Zt 4.80 (top) Zb (bottom) [mm4 x 10^9] [kn/m] Concrete earings c/c TY [mm3 x 10^6] [mm3 x 10^6] TY Span 14-31m Transfer cube strength = 35 N/mm2. earings for bridge beams TY Y Typical 7.44 Specification SECTION TY6 PROPERTIES esign self weight 39.38per unit has been taken as 24kN/m Y day cube strength = 60 N/mm2. particular application. As a Section TY Span (m) epth Height centroid Approximate Second moment No TY eams - Y [mm2] above soffit Yb of area self weight (Higher strengths can be accommodated where necessary) closest to the abutment sh TY [mm4 x 10^9] [kn/m] 7.40 Concrete earings 1000 c/c TY Y [mm x 10^6] [mm x 10^6] Transfer cube strength = 35 N/mm2. earings for bridge beams should be considered on the merits of each end of the beam (See sket TY Y Y day cube strength = 60 N/mm2. particular application. As a general rule however, the edge of the bearing the soffit line of prestress Y Y (Higher strengths can be accommodated where necessary) Cement closest to the abutment should be detailed at least 125mm in from the Y esign self weight per unit has been taken 9.86 as 24kN/m Section Span epth Y Height centroid 1300 ist. centroid to Approximate Second moment end of the beam (See sketch below). Cast in items cannot project below Y Cement usually complies with. S Portland. No. [m] [mm2] 17.5 above soffit vertical face of area self weight Y Y Yb Xb Zt (top) Zb (bottom) [mm4 x 10^9] [kn/m] the soffit line of prestressed units Cement [mm3 x 10^6] [mm3 x 10^6] Y The following may also be used: TYE Cement usually complies with. S Portland. Y TYE The following may also be used:. S p.f.a. TYE TYE SECTION PROPERTIES esign self weight per unit has been taken. S as 24kN/m3 - p.f.a. TYE Section Span epth Height centroid ist. centroid to Second moment Approximate TYE TYE No [m] [mm2] above soffit vertical face 9.56 of area self weight Aggregates TYE Yb Xb Aggregates [mm4 x 10^9] [kn/m] E EAM n Properties 6 H H 400 Section No. M2 Span epth 720 Web Height H 200 [mm2] Height centroid above soffit Yb 265.4

9 CSU bridges eam and Ideal for long span bridges YE Span: 13-45m eam Edge beam for medium and long span bridges and Edge beam for Ideal for long span bridges Span: 13-45m Span: 14-31m U eam Ideal for medium and long span bridges Spans: m Y eam Ideal for medium and long span Ideal for medium CSU eam bridges and and long span Ideal bridges for and long span bridges Span: 13-45m Span: 14-31m YE eam Span: 14-31m Edge beam for bridges medium and long U span eam bridges and Ideal for medium Span: and long 14-31m span bridges Spans: m ridge eams Y eam Ideal for medium and long span RIGE EAM Span: 14-31m Section Properties YE eam CSU eam medium and long span bridges and Span: 14-31m U eam Ideal for medium YE eam Edge beam for medium and long span bridges and. Span: 14-31m and long span RIGE EAM bridges Spans: m Section Properties RIGE EAM Y eam Section Properties CSU eam Span: 14-31m Ideal for long span bridges Span: 13-45m YE eam Edge beam for medium and long span bridges and U eam Ideal for medium and long span Spans: m Y eam U eam Ideal for medium and long span bridges. Span: 14-34m CSU eam Ideal for long span bridges. Span: 13-45m No - [mm2] above soffit Yb CSU Zt (top) 800 Zb (bottom) 1000 c/c [mm x 10^9] [kn/m] [mm3 x 10^6] [mm3 x 10^6] CSU Transfer cube strength = 35 N/mm2. Y Y day cube strength = 60 N/mm2. CSU Y (Higher strengths can be accommodated where necessary Y CSU Y CSU Y Cement Y CSU esign self weight Cement per usually unit has M complies been taken eam with as. 24kN/m3 S Portland. Y CSU The following may Section Span (m) epth Height centroid ist. centroid to Second Provides also be used: moment voided Approximate CSU No - [mm2] above soffit vertical face. S p.f.a of area self weight Yb Xb bridge deck for CSU c/c [mm4 x 10^9] esign self weight per unit has been taken as 24kN/m3 [kn/m] [mm3 x 10^6] [mm3 x 10^6] medium and long CSU13 epth Height centroid Second moment Approximate Aggregates Section No Span (m) YE1 14 -[mm2] 16.5 above 700 soffit Yb Zt (top) Zb (bottom) of area self weight span road bridge CSU Comply with. S Concrete aggregates from Natural S [mm3 x 10^6] [mm3 x 10^6] [mm4 x 10^9] [kn/m] esign self weight per unit has been taken as 24kN/m3 YE2 CSU construction CSU Section Span (m) epth Height centroid ist. centroid to Second moment Approximate No - eams CSU3@ [mm2] CSU16 YE3 above 18 soffit vertical face of area self weight Span m Yb 1000 CSU5 c/c Xb [kn/m] [mm3 x 10^6] [mm [mm4 x 10^6] x 10^9] Prestressing Strands CSU17 YE YE1 14 CSU Comply with. S with Class 2 relaxation. YE CSU CSU YE mm dia. standard at 209 kn max. initial force YE3 18 CSU CSU19 YE YE CSU YE5 23 CSU YE YE TolerancesTY eam 25 CSU YE CSU YE Unless specifically Short agreed and otherwise, medium beams will be made t YE8 28 CSU the full tolerances span shown bridges in Tp and specification. Clause 1710 CSU CSU (or.s Part 1, Clause and ). CSU CSU SECTION PROPERTIES esign self weight per unit has been Span taken m as 24kN/m3 CSU epth Height centroid Second moment Approximate Section No Span (m) [mm2] above soffit Yb of area self weight [mm3 x 10^6] [mm3 x 10^6] [mm4 x 10^9] [kn/m] U esign self weight per unit has been taken as 24kN/m3 U TYE eam epth Height centroid Second moment Approximate Section No Span (m) U7 [mm2] above soffit Yb 1100Zt (top) TY eam Zb (bottom) of area self weight [mm3 x 10^6] [mm3 x 10^6] [mm4 x 10^9] [kn/m] Edge beam for short Short and medium span U U and medium span bridges and commerical U U bridges and U Span m U U TY eam U U Span m17.06 U U Short and medium span U U bridges and commerical. Span m 400 esign self weight per unit has been taken as 24kN/m3 esign self weight per unit has been taken as 24kN/m3 epth Height centroid Section esign modulus self weight per Second unit has moment been taken Approximate as 24kN/m3 Section Span (m) epth Height centroid Section Section No Span (m) Span (m) epth Second moment Approximate No - [mm2] above soffit Yb [mm2] Height above of area centroid soffit self Yb weight Second of area moment Approximate self weight Provides [mm4 x 10^9] No - [mm2] above soffit [kn/m] Yb [mm3 x 10^6] [mm3 x 10^6] [mm4 of x area 10^9] Concrete voided 1000 c/c self [kn/m] [mm3 x 10^6] [mm3 x 10^6] weight bridge deck CSU c/c [mm x 10^9] Transfer for cube [kn/m] 13.75strength = 35 N/mm2 SECTION Y PROPERTIES esign self weight 43.42per unit has been taken as 24kN/m37.44 [mm3 x 10^6] [mm3 x 10^6] medium and Y2 800CSU day long epth Height centroid Second moment Approximate cube strength = 60 N/mm2. Y3 Section No Span (m) 900 Y [mm2] above soffit 700 Yb Zt (top) Zb (bottom) of area self weight span road bridge 8.99 CSU (Higher strengths can be accommo [mm3 x 10^6] [mm3 x 10^6] [mm4 x 10^9] [kn/m] Y construction 970 CSU Y Y5 CSU CSU Span m Y6 1200CSU8 Y Cement 8.99 CSU Y7 CSU Y CSU Cement usually complies with. S. 1 Y8 CSU CSU CSU10 Y The following may also be used: CSU CSU11 Y S p.f.a. CSU CSU12 Y TY eam CSU CSU CSU13 Y Short and medium CSU span bridges Aggregates and CSU CSU Comply with S Concrete ag SECTION CSU16 PROPERTIES CSU esign self weight per unit has been taken as 24kN/m CSU Section Span (m) epth Height centroid ist. centroid to Second moment Approximate No CSU CSU [mm2] above soffit vertical face of area self weight Yb Span m CSU c/c Xb [mm4 x 10^9] [kn/m] Prestressing Strands CSU [mm3 x 10^6] [mm3 x 10^6] YE CSU Comply with. S with Class YE CSU mm dia standard at 209 kn ma YE YE SECTION esign self weight per unit has been taken as 24kN/m3 YE PROPERTIES esign self weight per unit has been taken as 24kN/m TYE YE Section Span (m) epth Height centroid ist. centroid 16.70to Second moment Tolerances eam epth Height centroid Second moment Approximate Approximate Section No Span (m) [mm2] above soffit Yb of area self weight YE No [mm3 x 10^6] [mm2] [mm3 x above 10^6] soffit [mm4 x 10^9] vertical [kn/m] face Edge beam of area self weight YE Yb Xb Unless for short specifically agreed otherwise c/c and U [mm4 medium x 10^9] span [kn/m] [mm3 x 10^6] [mm3 x 10^6] the full tolerances shown in Tp sp U bridges and SECTION YE PROPERTIES esign self weight per unit has been (or.s taken as 24kN/m Part 1, Clause an U U YE epth Height centroid Second moment Approximate U Section YE3 No Span (m) [mm2] above soffit Yb Span of m area self weight U YE [mm x 10^6] [mm x 10^6] [mm x 10^9] [kn/m] U U YE U YE6 U YE U YE Typical Specification U esign self weight per unit has been taken as 24kN/m Section Span (m) epth Height centroid TY Second moment eam Approximate No - U9 [mm2] above soffit Yb of area self weight Typical Specification: Concrete Transfer cube strength = 35N/mm 2 ; 28 day cube strength = 60N/mm 2 (Higher strengths can be accommodated where necessary) Note: Technical data is provided as an illustrative guideline only, variations will occur. Project specific parameters must be referred to the Concast design team for analysis. of area self weight Concrete Typical Specifica M eam H

10 ridge ecks Concast manufactures various forms of bridge deck including glass reinforced concrete (GRC) panels and omnia plates. These panels replace the need for temporary shuttering and hence increase the speed of construction. A thorough testing and transparent quality control procedure is in place, as the units must be sufficiently durable to last the lifespan of the bridge. Glass Reinforced Concrete (GRC) GRC slabs are glass fibre reinforced concrete panels, which are used to span the short distance between bridge beams on site. They can be provided in various profiles such as corrugated or flat to suit the supporting beam design. They are light, durable and relatively inexpensive. GRC decks are recognised as an industry standard which are widely used on bridge beam projects. Omnia Slab Omnia slabs are a thin layer of solid concrete slab with a projecting lattice exposed to bind with an insitu concrete layer, poured later on site. It is suitable to span the short distance between bridge beams. Precast Ramps Concast has provided ramp slabs on a number of major throughout the country. These are solid reinforced slabs used on pedestrian bridges or similar instances. Typical span up to 7 meters, depending on the depth of the required unit. ridge ecks 8

11 Retaining Wall Units Concast s retaining wall units are an efficient means of bulk storage and the retention of materials. The precast concrete units are generally free-standing and can be dismantled or relocated if required. Concast manufactures various types of retaining walls, including: Single or double heel wall units, of varying heights to form a load-bearing wall. They can be loaded from one or both sides. Retaining wall with insitu heel, the precast wall unit is cast with exposed projecting steel in the heel of the unit, the concrete is then poured on the projecting steel on site. Twin walls, ideally suited for basements and embanking of materials. The twinwall comprises of two panels connected by a cast in steel lattice, the unit is then filled with insitu concrete, to form a single unit. Single Heel ouble Heel Twin Walls In-Situ Heel Retaining Wall Units 9

12 10 Concast s concrete box culverts are used for conveyance of fluids such as stormwater, stream crossings and sewage as well as for short-span bridges and underground access. Precast box culverts are produced in a controlled environment allowing a high degree of quality and uniformity. Concast also provide wing walls and head beams, which can be used to guide fluids through the box sections.

13 Culverts and Trenches In addition to a standard range of box culverts, Concast can also provide non-standard sizes to suit your requirements. U shaped culverts (or trenches) are also popular, when access is required from the top of the culvert. Lids can be cast separately for these units, which allow the user to have the culvert covered over or accessible, as required. These lids are often used when pipes or other equipment stored within the culvert/trench may require maintenance. Final design and wall thickness is dependent upon the project specific design criteria, which can be reviewed by our design department. Culverts and Trenches 11

14 The Concast Precast Group provide complete precast concrete solutions for a wide range of sectors including: Retail and office parks Concast provide multi-storey precast frames for retail or office buildings. Typically the floor plan maximises the open plan requirements, which consist of columns, beams, stairs, floors, wall panels with external precast cladding. Leisure and Sports Stadia Concast typically provide terraced stadia seating units, wall panels, raker beams, columns, beams, flooring and stairs. Residential modern housing and apartments Residential schemes are ideally suited to precast concrete cross wall construction, consisting of load bearing and non-load bearing wall panels, floors, stair cores and lift shafts, balcony and cladding panels. Multi-storey car parks Concast have extensive expertise in multi-storey car parks, consisting of multi-storey precast concrete columns, beams, spandrel panels, planters, flooring, stair cores and cladding panels. Civil Engineering Solutions Concast provide precast solutions for road, rail, harbour and sewage treatment structures. The types of precast products provided include bridge beams, column and beams, culverts, retaining walls and other bespoke items. 12

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16 + 44 (0) (0) info@concast.ie Registered Head-office: Concast Hazelhatch Newcastle Co. ublin