Precast prestressed concretecomplements its surroundingsand combats corrosion

A neighboring golf course dictatedthat this pretreatment and waste (disposal facility maintain a lowprofile and blend with thesurrounding terrain.

Precast concrete met the owner’sesthetic requirement. Attractivearchitectural precast concretewall panels in a variety of ribbed,curved and flat surfaces, werechosen for the basin complexbuilding and the two smallerstructures. Because of the highhumidity in this treatment facility,a material was needed that wouldnot only be attractive, but durableenough to withstand the corrosiveconditions, as well as anoccasional wayward golf ball.

Prestressed concrete roof slabsallowed for long clear spans toaccommodate the installation andremoval of the basin equipment.Construction was completedwithin the tight scheduledetermined by the owner in orderto minimize the interference ofgolf course operations.

Architect/Engineer:Black & VeatchKansas City, Missouri

General Contractor:Dugan & Meyers Construction Co., Inc.Cincinnati, Ohio

Owner:Cincinnati Water WorksCincinnati Ohio

(-nent Plant, Pretreatment and

Mill building is corrosion resistantwith prestressed concrete

Engineer:ABAM Engineers, Inc.Federal Way, WashingtonGeneral Contractor:Wright Schuchart Harbor Co.Seattle, WashingtonOwner:Crown ZellerbachCamas, Washington

The design and construction ofthis mill building demonstrates theimportant cost and maintenanceadvantages of precast concrete inbuildings for heavy industries. Aprecast facility of this type canmeet all of the owner’s needs interms of economy, adaptability,schedule and staged installation ofequipment while still providinglong-term durability and fireresistance.

Economy, a fast-track schedule,and the need to withstandcorrosive conditions and heavyloads were decisive factors inselecting precast prestressedconcrete components for the $400

million modernization of this pulpand paper mill.

The fast-track schedule was metby easily installed connections andvertical front erection. Hiddenstructural connections, a smoothinside finish and use of stainlesssteel and a special paint systemfor exposed bracing enhanced theinherent corrosion resistance ofthe prestressed concretestructural elements.

The entire structure provides extraload-carrying capacity allowing theowner to easily relocate heavyequipment. Future expansion willbe economical because existingwalls are removable.

Success = standard components+ technical innovations

Engineer/General Contractor:

Zinc Electrolytic and Melting Plant, Trail, British Colur

Corninco Engineering Services Ltd.Trail, British Columbia

Owner:Cominco Ltd.Vancouver, British Columbia

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Technical innovationsincorporating standard precastprestressed concrete componentswere used to successfully buildthis $9 million automated zincelectrolytic and melting plant.

Because of the potential forsevere corrosion and othermanufacturing requirements,several special design featureswere built into the structure.Standard commercial building andbridge components were used toproduce heavy industrial

( structures resistant to sulphuricacid mist exposure. Otherconsiderations were the detailing of precast units, connections and

attachments to minimize acidcorrosion.

A fast-track construction schedulerequired a straight-forward designwhich would permit rapid erectionwithin the tight constraints of thisconstruction schedule. Allstructures were designed for lowmaintenance and a minimum50-year service life in potentialsulphuric acid mist exposuresranging from low to severe.

A total of 8819 precast concretecomponents (mostly prestressed)were used, including beams,MSHTO girders, columns, doubletee wall panels, floor and roofslabs, special components andtank cells.

Precast concrete has produced amaintenance-free building of goodesthetic appearance at a costcompetitive with alternativemethods.

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Precast concrete achieves strongcorporate image with design flexibility

Architect:Beckstoffer & AssociatesBoston, MassachusettsStructural Engineer:James MacDonald AssociatesBoston, MassachusettsGeneral Contractor:

Phase IDimeo Construction Co.Providence, Rhode IslandPhase IIR. W. Granger & Sons, Inc.Shrewsbury, Massachusetts

Owner:Prime Computer, Inc.Natwick, Massachusetts

Architectural precast concretepanels convey the strongcorporate image required by theowner of this computer research

and development facility.Construction of these threebuildings was completed in twophases, on schedule with the easeof factory manufactured panelsdelivered to the site as needed.

The repetitive, structural bay-sizedpanels were economical toproduce and fast to erect. Theprecast concrete panel systempermitted the desired designflexibility for each building to be adifferent size to satisfy programand site requirements.

In addition, tolerances were easyto control and insulation (exceeding minimum State Energy CodeRequirements) was inexpensive.

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(Prime Computer, Inc., Engineering 2h and Development Facility, Framingham, Massachusetts

Speed of constructionpays dividends

United Technologies, Inc., American Bosch Division, Fuel Injector Assembly Plant, Columbia, South Carolina

Precast prestressed concreteenabled construction to begin,even before designs were finalizedfor this fuel injector assemblyplant. Coordinating sitepreparation and erection is easyto accomplish when using plantmanufactu red prestressedconcrete. Since the contractorrealized how fast these panelscould be erected, he startedgrading another area of the sitebefore the first section of thebuilding was complete. Thisallowed the contractor to staywithin a very tight constructionschedule.

In addition to speed of construction, esthetics and versatility ofmaterials were important to thedesigner. A combination of ribbedand flat panels lend scale to thestructure and also save energy byproviding shade with precastconcrete window panels. Andthese panels may be relocated iffuture expansion is necessary.

Architect/Engineer:Piedmont Engineers, Architects &

Planners, Inc.Greenville, South Carolina

General Contractor:Metric Constructors, Inc.Charlotte, North Carolina

Owner:United Technologies Diesel SystemsColumbia, South Carolina

Prestressed concretegoes underground, providescatalyst for 90-acre development

Architect:Zimmer Gunsul Frasca PartnershipPortland, OregonStructural Engineer:kpff consulting engineersPortland, OregonGeneral Contractor:Donald M. Drake Co.Portland, OregonOwner:Multnomah CountyPortland, Oregon

Prestressed concrete provided thecatalyst for redeveloping a 90-acrelandfill in Multnomah County,Oregon. The inherent durabilityand strength of prestressedconcrete allowed the county tobury a 186,000 sq. ft. (17,280 m2)vehicle maintenance andoperations facility 30 ft. (9 m) inthe ground and begin the massivereclamation project. This solutionalso minimized the visual impactin a neighborhood of existing andproposed residential and openspace uses.

Unique double tee wall panels,weighing up to 65,000 lb. (29 t),provided the stability needed inthis substantially below-gradefacility. The 44 ft. (13 m) highpanels were designed for 42 lb.per. cu. ft. (680 kg/rn3)equivalentfluid pressure, as required by thesoils consultant’s specifications.Double tees used in the secondfloor accommodate a specifiedlive load of HS2O highway loadingor 250 psf (12 kPa). Hollow-coreslabs were used in the roofsystem. Solar panels on the southside of the roof provide almost allthe facility’s air conditioning needsand about half of its heating andhot water requirements.

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Construction time reduced,easy expansion guaranteed

GCA, Burlington Division Plant, Andover, Massachusetts

Architect.Jung/Brannen Associates, Inc.Boston, MassachusettsStructural Engineer:Weidlinger AssociatesCambridge, MassachusettsGeneral Contractor:Vappi & Co., Inc.Cambridge, MassachusettsOwner:GCA CorporationBedford, Massachusetts

Construction of this computermanufacturing, testing andassembly facility was completedthree months early by using plantmanufactu red architecturalprecast concrete panels. Each ofthe seven structures can be easilyexpanded by simply resetting theprecast panels which make up theexterior walls.

Beginning with a three-storyadministration building, single-story test and assembly modulesfollow in sequence of manufacturing operations. The modules,interconnected by service cores,create a production floor thatcovers six acres. Insulated precast concrete panels were themost economical choice for thisproject.

Quality control is assured withpanels that are produced at theplant and transported to theconstruction site in sequence. Thevertical ribbed texture of the architectural precast panels creates adistinct look when contrasted bybands of horizontal glass.

Increase fire resistance,cut construction costswith precast prestressed concrete

Precast prestressed concrete metthe owner’s requirement for anatural material that wouldcomplement the environment andbe a showplace in keeping withhis reputation as a leader in theindustry. It ws also a system withinherent construction cost savings.

Additional fire protection requiredin many industrial buildings wasnot a cost factor to the owner ofthis facility. Hollow-core floors in

the manufacturing areas featurebuilt-in fire resistance and easilymet local fire codes. Thesecomponents also eliminate theneed for scaffolding and much ofthe on-site labor costs associatedwith other building systems, thus

reducing the owner’s overallconstruction costs.

Manufacturing areas were cladwith 10 ft. (3.05 m) wide, doubletee panels with a 24 in. (609.6mm) deep tee for dramatic effect.Double tees allowed exteriorconstruction to proceed quickly, sothat interior finishing couldcontinue during the winter months.The wall panels featured aninterior core of insulation providingan overall U’ value of less than0.10. As with any structure, andcertainly a manufacturing facility,durability and maintenance costsare major considerations. Durableprecast prestressed concrete willrequire little maintenance to retainits interior and exterior surfaces.

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Welch Allyn, Inc. Office and Manufacturing Facility, Skaneateles Falls, New YorkArchitect/Engineer:Stetson-Dale, Architects & EngineersUtica, New York

General Contractor:John Luther & Sons Co.Rochester, New York

Owner:Welch Allyn, Inc.Skaneateles Falls, New York

Low maintenance, low energy costswith insulated precastconcrete panels

Architect/Engineer/Contractor:Oscar J. Boldt Construction Co.Schofield, Wisconsin

Owner:Mid-Wisconsin Beverage, Inc.Wausau, Wisconsin

Ten days after construction began,the precast concrete exteriorwalls of this office and bottlingplant were erected. These durablepanels were manufactured off siteand were ready to erect just asthey were delivered.

By using load-bearing insulatedprecast panels, the owner savedon more costly site-cast buildingsystems. The insulated core of theload-bearing prestressed elementscould not have been economicallyachieved using site-cast methods.

Minimal maintenance and reducedenergy costs will continue to savethe owner money for years tocome. And, fire resistant precastconcrete provided the owner witha fire rating that also saved himmoney on insurance costs.

Mid-Wisconsin Beverage, Inc., Office and Bottling Plant, Wausau, Wisconsin

Combine exterior beauty withenergy efficiency

Architect/Engineer:Facilities Design Department,

General Mills, Inc.Minneapolis, Minnesota

General Contractor:Burkey Construction Co.Reading, Pennsylvania

Owner:Izod, Ltd.New York, New York

This single-story warehouse anddistribution center featuresexposed aggregate panelscombined with the energyefficiency of insulated prestresseddouble tees.

In just eight months, precastprestressed concrete constructionwas completed. The exterior wallsare prestressed double tees with acentral core of insulation whichkeeps energy costs down. Stems

of the double tees face outward,providing interesting contrast tothe flat exposed aggregate panels.The smooth side of the double teefacing the interior of the buildingare easy to clean and will requirelittle maintenance in the future.

Combining exterior beauty’withenergy efficiency is easy toachieve using standard precastprestressed concrete components.

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presiressed concrete InSIJtUte201 NORTH WELLS STREET/CHICAGO, ILLINOIS 60606

Address Correction Requested IDEAS Number 21/Editor: Catherine M. Kielas 7.84

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David Crystal, J. G. Distribution Center, Reading, Pennsylvania(