C. H. Goodchild BSc, CEng, MCIOB, MIStructE

J. Glass BA, Dip Arch, DipBRS, PhD, ILTM

A guide to choosing and using combinations of precast and in-situ concrete for better value structural frames

Best Practice Guidance forHybrid Concrete Construction

1

1. Executive summary 2

2. Introduction 3

3. Why use Hybrid Concrete Construction? 5

4. Best Practice Guidance for Hybrid Concrete Construction 9

5. Achieving best practice 16

6. Case studies 28

Ipswich Town Football Club: North Stand 28

Toyota (GB) Headquarters 34

West Car Park, West Quay, Southampton 39

Whitefriars, Canterbury 47

7. Conclusions 51

8. References and further reading 52

Appendix: Background research 53

A.1 Context 53

A.2 Best Practice Guidance for Hybrid Concrete Construction research project 55

A.3 Structural design 61

Best Practice Guidance for Hybrid Concrete Construction

Contents

Published by The Concrete Centre on behalf of industry sponsorsRiverside House, 4 Meadows Business Park, Station Approach, Blackwater, Camberley, Surrey GU17 9ABTel: +44 (0)1276 606800 Fax: +44 (0)1276 606801

TCC/03/09 Published September 2004 ISBN 1-904818-09-9Price Group L © The Concrete Centre

All advice or information from The Concrete Centre is intended for those who will evaluate the significance and limitations of

its contents and take responsibility for its use and application. No liability (including that for negligence) for any loss resulting

from such advice or information is accepted by The Concrete Centre or their subcontractors, suppliers or advisors. Readers

should note that The Concrete Centre publications are subject to revision from time to time and should therefore ensure that

they are in possession of the latest version.

Front cover: Inland Revenue, Nottingham, interior of building.

Photo: Martine Hamilton-Knight/Built Vision. Architect: Michael Hopkins & Partners.

British Precast is the trade federation representing the UK precast and concrete masonry industry. The Structural Precast

Association is a member of British Precast and is supporting this publication. Website: www.britishprecast.org Tel: 0116 253 6161.

CONSTRUCT is an association of member companies dedicated to the task of improving the construction efficiency of in-situ

concrete frames and associated structures. For further details contact the Secretary on 01276 38444.

Acknowledgements

The Advisory GroupJohn Caine Curtins Consulting Engineers

Norman Brown ABC Structures

Clive Budge British Precast Concrete Federation

Mike Downing Downing Associates

Charles McBeath whitbybird

Rob Moura Ascon/Edmund Nuttall

Chris Packer HBG Construction

Mahesh Parmar Anthony Hunt Associates Ltd

Martin Southcott The Concrete Centre

Russ Wolstenholme W S Atkins for DTI

Interviewees and Participants at WorkshopsMatthew Allen Sir Robert McAlpine Design Group

Roger Bailey Tarmac Precast Concrete Ltd

Graham Beardwell Ove Arup & Partners (M&E)

Andy Butler Stanhope plc

Peter Carruthers Sir Robert McAlpine Ltd

Ian Cordingley Upton McGougan Consulting Engineers

Mike Crook HOK Sport

Ian Curry AMEC

John Cutlack Jan Bobrowski & Partners

Brian Cutler Independent Consultant

Phil Doyle Sheppard Robson Architects

Chris Edwards HBG Construction

Adrian Falconer Ove Arup & Partners

Jim Farley Sir Robert McAlpine Ltd

Ian Feast Hammerson plc

Andy Fereday Miller Construction

Jack Gabrielcyzk Taylor Whalley Spyra

Tony Giddings Argent Group

Kevin Gill Gill Associates

Ray Hull Byrne Brothers Ltd

Rob Jones Davis Langdon and Everest

Simon Lake Toyota GB

Suqlain Mahmood Sir Robert McAlpine Design Group

Bob Martin Bison Concrete Products

Gavin Murgatroyd Gardiner & Theobald

Dominic O’Neill Fitzroy Robinson

Robert Reed HBG Construction

Martyn Reeve Sir Robert McAlpine Ltd

Peter Rogers Stanhope plc

David Rose Ipswich Town FC

Peter Stackhouse Lyons Sleeman & Hoare

Thierry Suc Upton McGougan Consulting Engineers

George Tootell CV Buchan

Dennis Vittle The Marble Mosaic Company Ltd

David Walker Trent Concrete Ltd

Russell Woby Hoopers Architectural Services

Researchers on ‘Hybrid ConcreteConstruction for the UK Market’Ghassan Aouad University of Salford

Bousmaha Baiche Oxford Brookes University

Peter Barrett University of Salford

Pal Chana BCA (formerly of Imperial College)

Charles Fowler RPEG, University of Reading

Colin Gray RPEG, University of Reading

Rod Webster CiD

Dedicated to Gerry Shaw.

The Concrete Centre acknowledges and appreciates the support given by many individuals,companies and organisations. These include:

3

Introduction 2

Introduction

Hybrid Concrete Construction (HCC) combines all the benefits of precasting (e.g.

quality, form, finish, colour, speed, accuracy, prestressing) with all the benefits of in-situ

construction (e.g. economy, flexibility, mouldability, thermal mass, continuity, durability,

and robustness). HCC can answer client demands for lower costs and higher quality by

providing simple, buildable and competitive structures that offer consistent performance

and quality.

To date, the use of HCC has been confined mainly to bespoke structures. Some of these

structures achieved cost savings of up to 30% over more conventional structural frames.

Naturally, the concrete industry was eager to identify how this order of saving might

be achieved consistently and more widely. As well as responding to the challenges

laid down by the Latham 2 and Egan3 reports, wider use of hybrid structures would

significantly improve the productivity and therefore competitiveness of the whole UK

concrete frame industry.

With this in mind, the Reinforced Concrete Council was successful in gaining government

support, through the Department of Trade & Industry Partners in Innovation (PII)

scheme, to carry out a research project entitled ‘Best Practice Guidance for Hybrid

2

1 Executive summary

Executive summary

Hybrid Concrete Construction (HCC) is about providing best value in structural frames.

HCC provides simple, buildable and competitive structures that answer client demands

for better value. It meets industry requirements for increased prefabrication, increased

off-site activity, safer and faster construction and consistent performance.

Despite the challenges thrown down by the Latham2 and Egan3 reports and their

successors, the UK has been slow to realise the benefits of HCC. One of the barriers to

HCC’s more widespread use was found to be the lack of comprehensive guidance, a

situation which this publication aims to change.

Based upon work carried out under a PII research project, this publication demonstrates

how to achieve best practice. The guidance explains the benefits that result from:

■ early involvement of specialist contractors

■ using a lead frame contractor

■ using best value philosophy

■ holding planned workshops

■ measuring performance

■ trust

■ close co-operation – with an emphasis on partnering.

The guidance is supported by case studies and shows that although there are intense

periods of co-ordination during the design phase, there are tremendous rewards on site

and in use. Best value is achieved through communication and measured in terms of

buildability, construction speed, aesthetic, quality, environmental and whole-life cost

benefits.

HCC can achieve very significant cost savings and give rise to some very satisfied

clients. This publication is intended to show how this can be achieved.

Figure 1 Gatwick office project

Showing precast floor beams onto

in-situ beams and columns.Photo: J Doyle