Site Cast Concrete

Tiltup Construction
Floor Framing
Roof Framing

What is tilt-up construction?

The building's walls are poured directly at
the jobsite in large slabs of concrete called
"tilt-up panels" or "tiltwall panels.
These panels are then raised into position
around the building's perimeter forming the
exterior walls.

Casting Surface
Tilt-up panels are usually cast with the outside
face down against the casting bed.

This allows the use of form liners, rustication strips,

or other highlighting schemes on the outside or
architectural face of the panel.
Face-down casting also places the lifting insert
holes on the inside face of the panel, where they
are easier to patch after the panels are erected.

Usually the concrete floor slab of the building

is used for casting tilt-up panels.

Casting Surface
When the concrete floor slab is used as a
casting platform, it must be on a constant
plane and smoothly troweled.
Smoothness is important because the panel
will reflect any imperfection in the slab.
A smooth surface also helps prevent a
mechanical bond between the panel and floor
slab when lifting.

Tilt up Forms
One of the advantages of tilt-up concrete wall
construction is the savings in form material and labor.
Panel edge forms are commonly made of dressed
timber and nailed to the floor by using two doubleheaded form nails wedged into a drilled hole in the
form and the floor.
Variations, such as putting a wood dowel in the drilled
hole in the floor and nailing to it, are also used.
These drilled holes in the floor can be patched
easily with an epoxy after form removal.

Tilting and Erecting Panels

Tilt-up panels are normally tilted and erected by using
inserts embedded in the panel face that are attached
to the rigging and a crane.
This is called a face lift.
Pickup points have embedded inserts
Panels may be erected by a crane operating on the
floor or from outside the building.
When the crane is operating outside the building, the
operator will be unable to see the lift points as the
panel is being erected
This is called a blind pick.

Tilting and Bracing

Bracing Panels
Prior to tilting, temporary braces are attached to the
panel.
Once erected, the tilt-up panels must be temporarily
braced against wind and other lateral forces until all
final structural connections are completed.
Telescoping pipe braces are commonly used for this
application.
The temporary braces will remain in place until the
roof diaphragm is erected and all structural
connections completed.

Roof & Floor Framing Systems

Site Cast Concrete Floors

One-Way Solid Slab

One-Way Ribbed Slab

One-Way Ribbed Slab

Broadened Joist Ends

Two Way Flat Slab

A two-way floor system spans between beam
on square bays.
The deep spandrel beams and wide columns
become part of the exterior walls.
Two-way floor framing allows for irregularity in
the placement of columns.

Two-Way Flat Slab

Two-Way Flat Plate

Two-Way Flat Slab

The use of a two-way flat plate in this Chicago apartment

building make cantilevered slab edges and balconies easy.

Two-Way Slab & Beam

Two-Way Waffle Slab

Waffle Slab Formwork

Waffle Slab Formwork

Prestressed concrete

Prestressed concrete
Is reinforced by Pre-tensioning or
Post-tensioning high-strength steel tendons .
The tensile stresses in the tendons are transferred to the
concrete, placing the entire cross section of the flexural
member in compression.
The resulting compressive stresses counteract the tensile
bending stresses from the applied load, enabling the
prestressed member to carry a greater load

Prestressing Techniques
Pre-tensioning is accomplished in a precasting
plant before arriving at the job site.
Post-tensioning is usually performed at the
building site, especially when the structural
units are too large to transport from factory to
site.

Pretensioning
Prestresses a concrete member by stretching
the reinforcing tendons before the concrete is
cast.

Pretensioning

Pretensioning (cont)

Post-tensioning

Post-tensioning
Is a method of reinforcing (strengthening) concrete or
other materials with high- strength steel strands or
bars, typically referred to as tendons.
Applications include office and apartment buildings,
parking structures, slabs- on- ground, bridges, sports
stadiums.
In many cases, post- tensioning allows construction
that would otherwise be impossible due to either site
constraints or architectural requirements.

Rebar vs Tendons
Rebar is what is called passive reinforcement however;
it does not carry any force until the concrete has already
deflected enough to crack.
Post- tensioning tendons, on the other hand, are
considered Active reinforcing.
Because it is prestressed, the steel is effective as
reinforcement even though the concrete may not be
cracked.
Post- tensioned structures can be designed to have minimal
deflection and cracking, even under full load.

Post-tensioning
Done almost entirely on the job site
High-strength steel strands (tendons) are covered with
a steel or plastic tube to prevent them from bonding
with the concrete
The prestressing of a concrete member by tensioning
the reinforcing tendons after the concrete has set.
Tendon" is defined as a complete assembly
consisting of the anchorages, the prestressing strand
or bar, the sheathing or duct and any grout or
corrosion- inhibiting coating (grease) surrounding the
prestressing steel.

Post-tensioning

Post-tensioning

ADVANTAGES/APPLICATIONS
Allows longer clear spans, thinner slabs, fewer beams
Thinner slabs mean less concrete is required.
Post- tensioning can thus allow a significant reduction
in building weight versus a conventional concrete
building with the same number of floors.
Post- tensioning is the system of choice for parking
structures since it allows a high degree of flexibility in
the column layout, span lengths and ramp
configurations.

Post-tensioned prestressed slab

Types of Post-Tensioning
There are two main types of post-tensioning:

Unbonded
Bonded (grouted)

Post-tensioning Process
Abutments are not needed.
Tendons may be left unbonded or if in a steel
tube bonded with a injected grout.
Most are unbonded.

Bonded post-tension systems

More commonly used in bridges, both in the
superstructure (the roadway) and in cable- stayed
bridges, the cable- stays.
In buildings, they are typically only used in heavily
loaded beams such as transfer girders and landscaped
plaza decks where the large number of strands
required makes them more economical.

Bonded post-tension systems

Typically, a cased hole is drilled into the side of the
excavation, the hillside or the tunnel wall.
A tendon is inserted into the casing and then the
casing is grouted.
Once the grout has reached sufficient strength, the
tendon is stressed.
In slope and tunnel wall stabilization, the anchors hold
loose soil and rock together; in excavations they hold
the wood lagging and steel piles in place.

Unbonded tendon
Is one in which the prestressing steel is not actually
bonded to the concrete that surrounds it except at the
anchorages.
The most common unbonded systems are monostrand
(single strand) tendons, which are used in slabs and
beams for buildings, parking structures and slabs- onground.
A monostrand tendon consists of a seven- wire strand
that is coated with a corrosion- inhibiting grease and
encased in an extruded plastic protective sheathing.

Unbonded tendon (cont)

The anchorage consists of an iron casting and a
conical, two- piece wedge which grips the strand.
In bonded systems, two or more strands are inserted
into a metal or plastic duct that is embedded in the
concrete.
The strands are stressed with a large, multi- strand
jack and anchored in a common anchorage device.
The duct is then filled with a cementitious grout that
provides corrosion protection to the strand and bonds
the tendon to the concrete surrounding the duct.

Construction of Post-Tensioning
In building and slab- on- ground construction, unbonded
tendons are typically prefabricated at a plant and delivered
to the construction site, ready to install.
The tendons are laid out in the forms in accordance with
installation drawings that indicate how they are to be
spaced, what their profile (height above the form) should
be, and where they are to be stressed.
After the concrete is placed and has reached its required
strength, usually between 3000 and 3500 psi ( pounds per
square inch), the tendons are stressed and anchored.
The fact the tendons are kept in a permanently stressed
(elongated) state causes a compressive force to act on
the concrete.

Anchorages in Post-Tensioning
Anchorages are a critical element, particularly in
unbonded systems.
After the concrete has cured and obtained the
necessary strength, the wedges are inserted inside
the anchor casting and the strand is stressed.
When the jack releases the strand, the strand
retracts slightly and pulls the wedges into the
anchor.
This creates a tight lock on the strand. The wedges
thus maintain the applied force in the tendon and
transfer it to the surrounding concrete.

Post-Tension Anchorage

Hydraulic Jack (Ram)

Smaller Hydraulic Jack

Post-tensioning
Is Post-tensioned members tend to shorten
over time due to elastic compression,
shrinkage, and creep.
Adjoining elements that would be affected by
this movement should be constructed after the
post-tensioning process is completed and be
isolated from the post-tensioned members
with expansion joints.

PRECAST CONCRETE FRAMING

SYSTEMS
Pretensioned Framing Systems

Types of Precast Concrete

Types of Precast Concrete

Types of Precast Concrete

Double & Triple Tees

Double & Triple Tees are primarily used for
applications that require exceptionally long spans such
as parking decks, bridges, swimming pools,
gymnasiums and industrial building walls.
The pieces are cast in forms rather than extruded by a
machine.
Double and triple tees exceed fire codes and require
virtually no maintenance.
The tee sizes vary from 8' - 12' wide and 20" - 40"
deep.

Double Tee Construction

Double Tee Installation

Double Tee Floor

Double Tee Detail

Inverted tee beams

Inverted T

Double Tee Wall Parking

Structure

Hollowcore slabs

Hollowcore slab
A hollowcore slab is a precast, prestressed concrete
member with continuous voids provided to reduce
weight and, therefore, cost and, as a side benefit, to
use for concealed electrical or mechanical runs.
Primarily used as floor or roof deck systems,
hollowcore slabs also have applications as wall panels,
spandrel members and bridge deck units.

Hollowcore slab
In most cases, the slabs are cast on long line beds,
normally 300 ft to 600 ft long.
Slabs are then sawcut to the appropriate length for the
intended project.

Hollowcore Detail

Hollowcore Slab

Hollowcore Slabs

Hollowcore Slab

Methods of Manufacturing
Two basic manufacturing methods are used for
the production of hollowcore slabs.
Dry cast or extrusion system
Stationary, fixed forms

Dry cast or extrusion system

A very low slump concrete is forced through the
machine.
The cores are formed with augers or tubes with the
concrete being compacted around the cores.

Stationary, fixed forms

Higher slump concrete used.
Sides are formed either with stationary, fixed forms or
with forms attached to the machine with the sides
being slip formed.
The cores in the normal slump, or wet cast, systems
are formed with either lightweight aggregate fed
through tubes attached to the casting machine,
pneumatic tubes anchored in a fixed form or long
tubes attached to the casting machine which slip form
the cores.

Hollowcore Sizes

Hollowcore Size

Advantages to Hollowcore Slabs

Hollowcore slabs are most widely known for providing
economical, efficient floor and roof systems.
The top surface can be prepared for the installation of
a floor covering by installing non-structural fill
concretes ranging from 1/2 inch to 2 inches thick by
casting a composite structural concrete topping.
The underside can be used as a finished ceiling as
installed, by painting, or by applying an acoustical
spray.

Advantages to Hollowcore Slabs

When properly coordinated for alignment, the voids in
a hollowcore slab may be used for electrical or
mechanical runs.
For example, routing of a lighting circuit through
the cores can allow fixtures in an exposed slab
ceiling without unsightly surface mounted conduit.
Slabs used as the heated mass in a passive solar
application can be detailed to distribute the heated air
through the cores.

Structural applications
Hollowcore slab provides the efficiency of a
prestressed member for load capacity, span range,
and deflection control.
In addition, a basic diaphragm is provided for resisting
lateral loads by the grouted slab assembly provided
proper connections and details exist.

Other applications
Fire resistance
Depending on thickness and strand cover,
ratings up to a 4 hour endurance can be
achieved.
Excellent sound transmission characteristics
associated with concrete.
Weather resistant

HOLLOWCORE DETAILS
Structural Connections

Hollowcore NonBearing Detail

Hollowcore Bearing Detail

Hollowcore Bearing Detail

Hollowcore Detail

Hollowcore Detail

Hollowcore Walls

Residential Construction
Spandeck is a
patented
garage floor
system which is
produced in
Salt Lake City,
Utah.

Residential Construction

Two-Foot Widths
Offer Clear Spans
Up to 36' Without
Additional Bearing