ISSUE 3, OCTOBER 07
Reid On SOLUTIONS IN CONCRETE CONSTRUCTION
Simple Solutions for Panel to Panel Connections
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ach month Reid engineering staff provide lifting designs for a large number of precast construction
projects around the country. Each job
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1. Reid Weldplates – a 10mm steel welding plate with Reid SWIFTLIFT anchor attached to connect concrete panel to steel building work.
in this issue From Derek’s Desk Derek Lawley talks about new developments in concrete
New Products Multiple uses for ECC create opportunities.
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has its own requirements however New
Project Focus •West Coaster makes record
Zealand engineers seem to be using a
concrete panel lift
huge variety of different panel connection
•Large precast bridge beams use Reid Lifting Anchors
designs. Each connection must be individually designed and produced to meet
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the designers needs.
Reidbar - the Versatile Reinforcing Bar System
Reids offer two simple off-the-shelf panel connection solutions for engineers.
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The advantage of using one of Reids solutions are: •
Standard hardware items reduce cost
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Engineering data already available for the products
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Autocad blocks available to drafting persons
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Proven products designed and recommended by the precast specialists
Information on these products is available in the Reid Product Catalogue & Design Guides 07/08. Alternatively, you can contact your Reid Technical Representative who will be able to assist with these products.
2. Reid Cast-In Channels provide fast and easy connection solution that required no welding. Steel channel sections are simply cast into the concrete. T-bolts and brackets are used to assemble the precast components.
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Nirvana Another significant Nirvana insulated concrete panel home is under construction
Engineer’s Report Stitch Jointing details
Code Watch Deaths likely to continue until propping practices improve
Industry Insight •Reids releases new Angle Brackets, Welded Corner Sections and Extruded Rebate Profile Sections. •Reids new 2007/2008 Catalogue is out now!
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Call Reids tollfree on 0800 88 22 12
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FROM DEREK’S DESK
NEW PRODUCTS
Multiple Uses for ECC Create Opportunities Rarely does a product come along that has the potential to change a whole country. The transistor and then the microchip did this for the Electronics Companies but in the Precast Industry things haven’t changed dramatically for the last 40 years since prestress became accepted practice. Bendable concrete promises to change all this. By the end of 2007 Reids expect to have “Bendable Concrete” or ECC as a commercial reality.
Innovative concrete product producers are beginning to explore the potential of using ECC material to improve their products and create a commercial advantage over their competitiors. REIDS have begun to work with several concrete precasters and concrete component companies to assist the production of prototypes .
Floor Units: can be produced with a third of the typical concrete depth used. Savings in weight and material can create a lower overall cost of the building.
Below is a summary of some of the main uses identified.
In our test lab we are already producing un-reinforced structural sections with wall thickness as little as 12mm.
Pipes: can be produced in much thinner sections and with no reinforcing steel.
When used in reinforced sections the strain hardening, ductile properties of the ECC when combined with the reinforcing steel will change the whole design approach for reinforced concrete. The photo below shows the load carrying capacity of normal reinforced concrete beam compared with an ECC beam of exactly the same size and with the same reinforcing.
Water Tanks: these can be produced with approximately half the material use in a standard tank. Additionally no steel reinforcement is required and the lower total weight gives large savings in transport costs.
Streetware Products: an alternative to casting in expensive ductile iron.
The implications for seismic design in New Zealand are huge and we have exciting times ahead in the Precast Industry.
Roof Sections: entire roof sections can be cast in ECC concrete giving an architect the full flexibility of design.
Tensile stress
Derek Lawley, General Manager
Localization
Strain hardening, Multiple cracking
ECC
Concrete
FRC Strain, deformation
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Reids™ Construction Systems www.reids.co.nz
Concrete
ECC
Structural insulated walls: the outer layer of a typical structural insulated wall can be reduced .
For information on any of these products, please contact your Reids Technical Rep. on 0800 88 22 12
PROJECT FOCUS
West Coaster Makes Record Concrete Panel Lift Evan Jones Construction have lifted the largest concrete panels ever in New Zealand. The tilt slab panels were cast on site and lifted into position to create the structure of the new dryer building at the Hokitika Westland dairy site. The main panels were 18 meters in height and 5.7 meters wide with an approximate total weight of 85 tons each. The decision to create such large panels was partly due to the unique nature of the project and short time frame for the project. Bryce Weal from Stiles and Hooker Engineers and Architects was the consulting engineer. They were required to find a unique construction solution for a unique building. Because the building had a very high internal stud height each wall could either be produced as three individual panels or one very large individual panel.
Large Precast Bridge Beams Use Reid Lifting Anchors Stahlton Precast produce concrete “Super T “ beam sections for use in bridges and infrastructure projects. At present the products are being supplied to Northern Gateway Alliance and the State Highway 20 upgrade. Because of the size and weight of these beams the lifting, transportation and placing of them can be awkward and time consuming. Super T beams can range in length from 22 meters to 32 meters. The larger units weigh 54 tons Previously these beams had strand wire cast into the concrete to produce lifting hooks. This practise however had several disadvantages. The strand was not always accurately cast into the beam and hence sometimes the beams were difficult to evenly lift by crane. By casting large 20 ton foot anchors into the beams Stahltons have been able to overcome these problems. Other advantages of using REID cast in anchors have been; • Easier on site storage of units because they can now be stacked • Easier on-site handling • Faster placing • No swing or rolling of the beams with lifting by crane Other precast beam producers have also used cast-in anchors to replace cast-in strand type hooks in new Zealand. Specify REID cast-in anchors on your next job to get the maximum efficiency on your project.
The factors that lead to the decision of producing large panels were cost, time and simplicity of construction. The construction company wanted to get the structure up as high and fast as possible. By lifting larger panels they lowered crane costs and also reduced the scaffolding and labour costs associated with joining and stabilizing multiple wall panels. The lifting design was provided by Reid Construction Systems who calculated and provided the correct positions for the lifting anchors to be placed in the panels. The job required eight 10-Ton Reid Swiftlift anchors embedded in the 40MPA concrete. All panels were lifted off the bed and walked on the crane hook to the site before lifting into position. From start to finish the panel lift took half and hour. Once in place the panel was temporarily supported in its resting place by four custom fabricated props. Crane driver was Arthur Gillman from Evan Jones Construction.
Video footage of this lift can be viewed on the Reids website www.reids.co.nz/reidsvideos/
For information on any of these products, please contact your Reids Technical Rep. on 0800 88 22 12
Reids™ Construction Systems www.reids.co.nz 3
REIDBAR - THE VERSATILE * Micro alloyed seismic grade 500E reinforcing bar to AS/NZ5 4671:2001
FLANGE NUT
GROUT SLEEVE
COUPLER
THREADED INSERTS
Available in all sizes.
Available in all sizes.
Available in all sizes.
Available in all sizes except RB32.
Reidbar nut with integral washer.
For full strength connection between Reidbar and HD reinforcing.
For full strength connection between Reidbar reinforcing
Features:
Features:
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Bolting situations
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Holding down plates
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Rockbolting bearing plate fixing
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Reids™ Construction Systems www.reids.co.nz
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Does not need surrounding concrete for strength of connection
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Eliminates lapping of reinforcement
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Allows connection of reinforcement to precast units
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Eliminates protruding starter bars allowing for easier and safer transportation
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Eliminates bending/ rebending of 500E grade reinforcement
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Easier and safer work areas.
Features: •
Does not need surrounding concrete for strength of connection
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Eliminates lapping of reinforcement
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Allows connection of reinforcement to precast units
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Eliminates protruding starter bars allowing for easier and safer transportation
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Eliminates bending/ rebending of 500E grade reinforcement.
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Easier and safer work areas.
For casting into concrete to provide high strength anchorage of Reidbar starter bar. Ideal for thin wall panel construction in base and midfloor connections where starter bar connection is required. Features: •
Eliminates protruding starter bars allowing for easier and safer transportation of precast units
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Eliminates bending/ rebending of 500E grade reinforcement
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Easier and safer work areas
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Allows connection of reinforcement to precast units
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Pullout capacity in concrete equal or greater than bent out starters in similar situation
For information on any of these products, please contact your Reids Technical Rep. on 0800 88 22 12
REINFORCING BAR SYSTEM Bar sizes: 12, 16, 20, 25, 32mm Bar surface finish: Black Bar, Hot-dip Galvanised from selected steel stockists Fusion-bonded Epoxy*
Bar available from all leading steel merchants. *Upon request
NUT AND HALF NUT
FOOT PLATE
WING NUTS
REID BRACE
Available in all sizes.
Available in RB12 and RB16 sizes as stock item.
Available in RB12 and RB16 and RB20 sizes.
Available for all bar sizes.
Available in remaining sizes on request.
A flange nut with the benefit of wings for hand tightening.
Ideal for diagonal roof wall
The footplate has end stops that prevent it being screwed onto Reidbar past the end flange of the fitting.
Used for formwork with Reidbar for insitu concrete casting.
Features:
The full Reidbar nut will achieve the full bar strength. Features: •
Use for bolting plates and fitments to Reidbar
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Use half nuts as a lock nut for secure connection
bracing applications.
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Use standard Reidbar with fittings for easy connection and tensioning to structural steelwork
Features: •
Use for anchorage of Reidbar in concrete
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Use with Reidbar for tie-back applications
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Used to substitute a standard hooked end anchorage
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Easy to detail and install
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Uses off shelf
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Eliminates congestion of bent bar anchorages
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May be fitted after other reinforcement in place to ease construction
componentry
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For information on any of these products, please contact your Reids Technical Rep. on 0800 88 22 12
Reids™ Construction Systems www.reids.co.nz 5
Nirvana House Waiwera, Auckland
NIRVANA
liaised with Doru Indries at Atlas Precast where the panels were made. Reids prop hire service was also used to temporarily brace the panels and again Cameron Gilmour provided the safe propping design. Paul from P J Construction was most appreciative of the excellent level of support from Reids Construction Systems with this project and is keen to do another Nirvana insulated home when the opportunity arises. Another significant Nirvana insulated concrete panel home is under construction. Going north over the Waiwera bridge, this house sits prominently above the estuary. Site access was difficult and some design aspects were challenging, so good teamwork was essential. Reids provided initial information on the
advantages of insulated concrete panels, the flexibility of panel design shape and various panel connection details to assist the architect and engineer. Panels were kept smaller in size to overcome tight truck and craneage access. There were a lot of retaining walls required and precast panels proved to be an efficient solution. Reids worked closely with the builder at the early planning stage, discussing technique and logistics and also
Stitch Jointing & Precast Panels
Architect: Engineer: Builder: Crane Hire:
Wayne Houston Nancekivell Cairn Ltd. P J Construction Tranzcrane Warkworth
Precast:
Atlas Silverdale
Contact your Reids Technical Representative for more information on this product. Phone 0800 88 22 44.
ENGINEER’S REPORT
Eliminate overlapping reinforcement during casting and placing. Joining precast wall panels by means of a cast insitu vertical “stitch joint” is a common detail in precast construction. While on paper the engineering detail may look logical, construction can be difficult for the precaster & contractor producing these types of detail.
The drawings below detail the new design configuration.
For further advice on this specification contact Terry Seagrave on 09 920 4346
The difficulty lies with projecting horizontal reinforcing that overlap between panels and make placing difficult and time intensive for the contractor especially when wall panels need to be placed by crane. To overcome the construction difficulties REIDS have design details that use REIDBAR to eliminate the need to have overlapping reinforcement during casting and placing. One large benefit of this detail is lower formwork and shuttering costs associated with molding the traditional precast panel.
STITCH JOINT USING REIDBAR SYSTEM
Additionally this new design detail will create on-site efficiencies and lower costs. The new detail uses Reidbar couplers and Reidbar footplates.
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Reids™ Construction Systems www.reids.co.nz
Other stitch jointing details available upon request.
For information on any of these products, please contact your Reids Technical Rep. on 0800 88 22 12
CODE WATCH
DEATHS LIKELY TO CONTINUE UNTIL PROPPING PRACTISES IMPROVE TODAY MODERN CONSTRUCTION TECHNIQUES NOW INCORPORATE A LARGE AMOUNT OF PRECAST AND CAST ON-SITE TILT SLAB CONCRETE PANELS AND COMPONENTS. THESE CONCRETE COMPONENTS NEED TO BE PROPPED TO SECURE THEM WHILE THEY A FINALLY FIXED INTO THE BUILDING STRUCTURE.
Recently a new version of NZS3101(2006) has been released. This now requires more rigorous performance from the drill in anchors used for any structural application. Most propping jobs across the country don’t have any specific fixing design carried out to ensure the propped component will remain standing under storm conditions. REIDS now provide a complete design service including prop specification, positioning plan, fastener specification and printed job plan. Many construction companies across the country are now taking full advantage of the opportunity to remove risk and guesswork. By using a professional service they can reduce responsibility and have as much insurance against the possibility of an accident and the associated liability.
When the Precast Handling Code of Practice was published in 2002 it was intended that additional costs were not be imposed on builders by requiring a qualified engineer sign off propping designs for individual panels on a project. However with the number and frequency of fatalities and accidents happening New Zealand regulatory authorities here may have to consider adopting the practices in Western Australia and the USA whereby specific designs are required for all components temporarily propped.
By their very nature these components are large and extremely heavy. The potential for accidents is always present when working with such large and heavy components. Just recently in June and July 07 two people were killed when working with large precast components.
What many people do not realize about the correct use of props is the high degree of engineering that needs to go into both the design and positioning of these props for safety.
Twelve walls dangerously blown over due to poorly engineered propping designs.
Firstly the props should be manufactured to a specific engineered design that takes into account the allowable axial load in compression before the props will buckle. The steel grade, wall thickness and weld quality of the props must all be of the highest standard.
Secondly the correct specification of prop and positioning needs to be determined by a competent trained person as required by the Precast Handling Code of Practice. Wind loads are a key factor that can vary dramatically depending on the exposure of the site. During construction the wind loads on panels are likely to be the most severe loads the components will receive during their entire service life. In areas of wind funneling in valleys and near cliffs then extra design allowances must be made.
A complex set of errors-poor site preparation and incorrect propping.
For information on any of these products, please contact your Reids Technical Rep. on 0800 88 22 44
Reids™ Construction Systems www.reids.co.nz 7
NEW PRODUCTS
Reid Swiftform just got three times more powerful! Video footage of this system can be viewed on the Reids website www.reids.co.nz/reidsvideos/
1x Casting On Site Reids new Angle Bracket allows simple and fast securing of Swiftform systems of all sizes to concrete surfaces. This allows the Swiftform system to be used for on-site casting of concrete panels.
2x Super-easy Setup for Windows New Welded Corner Sections provide the fastest, the most accurate system for creating window formwork setups. The system comprises aluminium extruded corner sections and Reids Formwork Jointers.
ALSO New Extruded Rebate Profile for window and door rebate casting.
3x Stack Casting Just Got a Whole Lot Simpler! Reids new Angle Bracket can be paired to create a simple and robust stack casting system that incorporates the Reid Swiftform Extrustion Formwork systems.
New Product Catalogue Call 0800 88 22 12 to request a free copy REIDS HAVE RELEASED OUR NEW PRODUCT CATALOGUE FOR 2007/2008
320 pages of detailed Product Design Guides and Product Catalogues, this is a must for all precast and tilt-up industry persons, engineers and specifiers.
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Auckland Head Office & Sales 64A Diana Drive, Glenfield Auckland, New Zealand PO Box 101-517, NSMC, Auckland, NZ Tel: +64 9 920 4360 Fax: +64 9 920 4364 Call Free: 0800 88 22 12 Reids™ Construction Systems 8 Email:
[email protected] www.reids.co.nz
Hamilton
Wellington
21A Kaimiro Street Hamilton Tel: 07 849 0643 Fax: 07 849 0642
Unit 2/1 Gough Street, Seaview, Lower Hutt Tel: 04 568 4505 Fax: 04 568 0098
Tauranga
Christchurch
80 Glenlyon Avenue Tauranga Tel: 07 543 3806 For Fax: information 07 543 3807 on
any of these
125 Wrights Road, Addington, Christchurch Tel: 03 338 3844 products, please Fax: 03 338 8846 contact
Email REIDBAR Information
[email protected] Swiftlift Information
[email protected]
www.reids.co.nz
your Reids Technical Rep. on 0800 88 22 12
