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T h e S h o c k e y P r e c a s t G r o u p

PARKING STRUCTUREDESIGN GUIDE2008/2009

Edition

Parking Structure Design Guide2008/2009 Edition

Introduction

48’ Bay System

Parking Structure Aesthetics

The AltusGroup

Shockey Parking Structure Specifications

Glossary

• WhyPrecast?• WhyShockey?

• OptimalLayout• Openness• RampWalls• DrySystem

• Colors,Features,Textures• CaseStudies • CalvertSt.ParkingStructure • WashingtonNationalsBallpark ParkingStructure • GaylordNationalHarborResort &ConventionCenter

• C-GRID®ReinforcedDoubleTeesfor ParkingStructures

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219 Stine Lane

Winchester, VA 22603

540.667.7700

www.shockeyprecast.com

NOTE: Thedetailsshowninthisdesignguideareintendedtobehelpfulinthepreparationofcompleteproject plans. These details are not to be used asworkingdrawings.Workingdrawingsanddetailsmustbepreparedandapprovedbyqualifiedprofessionalscertifiedinthejurisdictioninwhichtheprojectistobebuilt. Shockey acceptsno responsibility for anyerrorsoroversightsintheuseofthismaterialorinthepreparationofplans.Thispublicationisintendedforusebyprofessionalpersonnelcompetenttoevaluatethe significance and limitations of its contents andable to accept responsibility for the application ofthe material contained herein. Special conditionsandspecific local requirementsonyourprojectwillrequirespecificevaluationandpracticalengineeringjudgmentbytheproject’sEngineerofRecord.

©TheShockeyPrecastGroup2008.AllRightsReserved.

FairfaxCountyJudicialCenterParkingStructure,Richmond,VA

InTroducTIonAsthecostofrealestatecontinuestorise,ownersanddevelopersareingreaterneedofparkingsolutionsthatprovidesmartandcost-effectiveanswerstoavarietyofcommercial,residential,municipal,andinstitutionalparkingneeds.Inadditiontothepracticalissuesrelatingtoparkingavailabilityandcost,theseownersandgoverningbodiesareplacinganincreasedemphasisonaesthetics.Today’sparkingstructuremustbeconvenientlylocated,low-cost,andcomplementthesurroundinglandscape.

Inthischapterwewillexplorethenumerousbenefitsprecastconcreteoffersforowners,designersandgeneralcontractors,including:

• Speed-to-market

• Durability

• Sustainability

• 50-YearLifeExpectancy

• IntegratedProjectDelivery

• IncreasedValuefortheOwner

• OpennessandSecurity

Why Precast?Whyaremoreownersanddesignersselectingprecastconcreteasthematerialofchoicefortheirparkingstructureprojects?Theanswerissimple.Precastconcreteisahighlydurable,economicalandversatilebuildingmaterialthatoffersincomparablevalueandflexibility.Itsshorterectiontimeandabilitytoreducetheoverallconstructionscheduleappealtoownersandgeneralcontractors.Fordesigners,precastopensthedoortoaworldofliterallylimitlesspossibilitiesforproviding“signature”solutionstotheirindividualparkingneeds.

Speed-to-MarketThedecisiontodesignwithprecastconcretecarrieswithitamyriadofadvantagesovercast-in-place(CIP)concreteorothertraditionalconstructionmaterials.OneoftheforemostbenefitsofusingprecastratherthanCIPconcreteisthattheprecastmanufacturingprocessisunaffectedbytemperatureoradverseweatherconditions.Precastconcretecomponentsarefabricatedinacontrolledplantenvironment,whichmeansthatvaluableprojecttimeisnotlostwaitingforacceptableweatherconditions.

Typicalprecastparkingstructurecomponentssuchasdoubletees,columnsandinvertedteebeamscaneasilybeerectedatanaveragerateof12piecespercraneperday,andcanbeerectedinweatherconditionsthatwouldbeproblematicforthefullerectionofsteelcomponentsorCIPconcrete.Precastconcrete’sfastererectionmeansfollow-ontradescanbeginworkmorequicklyandtranslatestoanoverallconstructionschedulethatmaybeseveralmonthsshorterthanthatofaprojectusingCIPconcrete.

Forgeneralcontractors,thisschedulereductionresultsinaneconomicadvantageduetosignificantlyreducedoverhead(generalconditions)andincreasedavailabilityofthefirm’screwsforotherprojects.

The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM IntroductIon 3

durabilityOneofprecastconcrete’sforemostadvantagesisitsdurability.Plant-castprecastproductsaretypicallymoredurablethanfield-placedconcreteinpartbecauseofthecontrolledenvironmentinwhichtheyaremanufactured.Thelowwater-cementratiousedinprecastconcretecreatesadenserproductthatdoesnotallowpenetrationofchloridesandotherharmfulelementsaseasilyasfield-placedconcrete.ThePrecastPrestressedConcreteInstitute(PCI)PCIHandbook6thEditionreportsthatstudieshaveshown“acceleratedcuringmakesprecastconcretemoreresistanttochloridesthanfield-curedconcrete.”

TheShockeyPrecastGroupcanuseflyash,silicafume,slagcementandothercementitiousmixturestohelpreducethewater/cementratiooftheconcretemix,increasedensity,reducealkalisilicareactivity,andincreasethelong-termstrengthanddurabilityofourprecastconcretecomponents.Theuseofcorrosioninhibitorsandgalvanizedorepoxy-coatedreinforcingintheprecastconcretecanfurtherincreasedurability.Topreventcorrosionofconnectionsandtomaximizethelifespanofaparkingdeck,TheShockeyPrecastGroupusesstainlesssteelflange-to-flangeconnectionsinthedrivingsurfacewherethemajorityofnormalwear-and-tearwilloccur.

SustainabilitySilicafume,flyash,andslagcementareallconsidered“green”productsandtheiruseaspartoftheoverallconcretemixcanaddLEEDpointstoaproject.

50-Year Life ExpectancyInaccordancewiththeLife-365ServiceLifePredictionModel™,usingslagwithacorrosioninhibitorinournormalconcretemixtures,itcanbeshownthatwitha1.9”covertosteelinourhorizontalprecastcomponents,TheShockeyPrecastGroupisabletoprovideparkingstructuresthatmeeta50-yearlifeexpectancy.

Intheeventaprimaryflangereinforcementisusedthatcannotcorrode(suchastheC-GRID®carbonfiberreinforcingsystem),durabilityofthedoubleteeswillbesignificantlygreaterthanthatofdoubleteesreinforcedwithweldedwirefabric.

Pleasenotethatachievinga50-yearlifeexpectancyiscontingentuponpropermaintenanceasoutlinedinPCI’sMaintenanceGuide,includingimmediaterepairofcracksandtimelyreplacementofjointsealantstomaintainprotectionofconnections.

Integrated Project deliveryStructuralprecastcomponentscanbeerectedinarelativelyshortperiodoftimebecausetheyinterlocktosupportoneanother.Simplerinstallationrequiresfewercrewmembers,whichtranslatestolesstraffic,congestionandwasteonthejobsite.Forthegeneralcontractor,acleanerandsaferjobsitemeanslessriskandmoreassuranceofasmoothandsuccessfulprojectflow.AndbecauseTheShockeyPrecastGroupmanufacturesanderectsitsprecastcomponents,thegeneralcontractorcanrelyonasolesubcontractorforprojectcompletion.

Increased Value to ownerFortheowner,the“speedtomarket”ofprecastmeansfasterdeliveryofthefinishedparkingstructure,whichcanresultinsignificantcostsavingsandtranslatetoafasterreturnoninvestment.Thedurabilityandlongevityofaprecastparkingstructurealsoequalsabetterlong-terminvestmentfortheowner.Aspreviouslystated,theinherentquality,strengthanddensityofprecastconcreteproducedbyTheShockeyPrecastGroup,combinedwith

4 IntroductIon The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM

aregularmaintenanceprogram,canresultinaparkingstructurewithatypicallifecycleof40-50years–fargreaterthanthetypicallifecycleofaCIPparkingstructure.Fortheowner,thisrepresentsasignificantreturnontheinitialinvestment.

openness and SecurityAnyonewhohaseverparkedinadimly-lit,closed-inparkinggarageunderstandsperfectlytheaestheticandsecurity-relatedadvantagesofaprecastparkingstructure.Theuseoflong-spanprecastdoubleteesandarchitecturalload-bearingspandrelsorload-bearingwallsallowdesignerstocreateparkingstructureswithwidebaysthatgivepatronsanincreasedsenseofvisibilityandsecurity.Theendresult?Morepatronsarelikelytousetheprecastparkingstructurethanadimly-lit,closed-inCIPparkingstructure.

Why Shockey?

The Shockey PedigreeWhychooseTheShockeyPrecastGroup?TheShockeypedigreeissynonymouswithquality,integrity,anddoingajobrightthefirsttime.Ourhistorystretchesbackmorethan100years,encompassinggeneralcontracting,designbuildandprecastconcreteservices.

In1896,HowardShockeystartedawagon-repairbusinessinWinchester,Virginia.ThebusinessgrewtoincludegeneralcontractingandHoward’sreputationforqualityconstructionanddo-it-right-the-first-timeattitudequicklyputhiscompanyindemandforcustomhomebuilding.Today,manyofthehomeshebuiltattheturnofthecenturyarestillstanding;monumentstohislegacyofhardwork,integrity,anddedication.Howardpassedthatlegacytohissons,andinthe1930s,JimShockeyjoinedhisfatherinthebusiness.HewaslaterfollowedbyhisbrotherRalph.In1947,thecompanybecameknownasHowardShockeyandSons.

In1955,ShockeyopenedasmallmanufacturingfacilityforprestressedconcreteasadivisionofCrider&Shockey,itsformerready-mixconcretecompany.Oneyearlater,ShockeyBrothers,Inc.becamethethirdShockeyoperatingcompany.In1999,thecompanychangeditsnametoTheShockeyPrecastGroup.Today,TheShockeyPrecastGrouphascompletedmorethan3,000precastprojectsthroughouttheMid-Atlanticregion,includingtheserecentnoteworthyparkingstructures:

• CalvertSt.ParkingStructure,Annapolis,MD

•D.C.NationalsBallparkParkingStructures,Washington,D.C.

•GaylordNationalHarborResort&ConventionCenterParkingStructure, OxenHill,MD

• JohnPaulJonesArenaParkingStructure,Charlottesville,VA

•CarilionHealthcareRiversideParkingStructure,Roanoke,VA

• ShadyGroveMetroStationParkingStructure,ShadyGrove,MD

• FairfaxJudicialCenterParkingStructure,Fairfax,VA

TheShockeyPrecastGroupisachartermemberofthePrecast/PrestressedConcreteInstitute,aswellasbeingaPCI-CertifiedPlantandPCICertifiedErector.ShockeyPrecastmanagementhasheldleadershippositionsinMAPA,the


Shockey Bros, Inc. casting yard, circa 1960s.

Shockey Bros., Inc. – prestressing double tees, circa 1960s.

PCIchairmanship,variousPCItechnicalcommittees,andonthePCIIndustryAdvisoryGrouptotheNationalBuildingInformationModelingStandardInitiative.TheShockeyPrecastGroupisalsoamemberoftheAltusGroup–acollaborationofprecastersdedicatedtoadvancingtheuseofC-GRID®carbonfiberreinforcing.

Sole SourceTheShockeyPrecastGroupprovidestheOwner,DesignerandGeneralContractorwithasinglepointofcontactforthefullrangeofprecastactivitiesfrominitialcoordinationanddesignthroughturnoverofthebuildingtotheowner.With50+yearsintheproductionanderectionofprecastconcrete,TheShockeyPrecastGroup’sexperienceintheparkingstructurearenaisunmatchedintheregion--makingustrulyThe Partner of Choice.

TheShockeyteamassiststheOwnerorGeneralContractorthroughtheentiredesignandconstructionprocessstartingwithearlybudgetinginformation.Westrivetobepartoftheearlydesignprocess,providingexperience-basedbudgetsinsupportofspecificprojectplanstoassisttheOwnerorGeneralContractorinlong-termfinancialforecastingofprojects.Asplanningcontinuesanddetailsofthestructurebecomemoredefined,weassistindefiningthecostofaprecaststructurebyofferingacomprehensiveproposalfortheproject.

TheprojectproposalincludesadetailedengineeringandproductionschedulethatenablestheOwnerorGeneralContractortomeetprojecterectionneeds.TheShockeyPrecastGrouptypicallyassiststheOwnerandGeneralContractorbyprovidingqualitycoordinationeffortstotheteamthroughoutthedesigndevelopmentprocess.

Shockey’steamincludesfield-experiencedcoordinatorswhospecializeinonsitemanagementofpre-erectionactivitiestofacilitateasmoothtransitiontotheerectionphaseoftheproject.Ourtransportationcoordinatorsensurethesitelogisticsdetailsareplannedwellinadvancetoallowforuninterruptederectionoftheprecast.Aftererectioniscompletedorhasadvancedtoasafedegree,ourFieldCoordinatorsprovideearlyaccessto


The Shockey Precast Group Winchester Plant

thestructureforfollow-ontrades.Thistimelyonsitecoordinationminimizesdisruptionsoffieldactivitiesandreducestheoverallprojectconstructionschedule.

Duringerectionofthebuilding,TheShockeyPrecastGroup’sfieldfinisherscompletetheonsitework--enablingtheprecastportionofthestructuretobecompletedwithinamonthoferectioncompletion.Thisquickresponseallowspunch-listreviewofthestructuretoproceedwithoutdelay.Finally,uponcompletionoftheprecastwork,weprovideanindustry-leadingmanualforcareandmaintenanceofparkingfacilities,alongwithawarrantyofourwork.Ownerswhofollowthecyclicmaintenanceactivitiesoutlinedinthismanualandwhohavetrainedpersonnelresponsibleforthecareoftheirparkingstructurewillensurethestructuremeetsorexceedstheservicelifeobjectives.TheShockeyPrecastGroup’sfieldrepresentativesalsoprovideexperience-basedassistancetotheownersonanas-neededbasisduringparkingstructureoperations.

Fromdesigndevelopmentthroughon-lineoperations,TheShockeyPrecastGroupprovidesone-stopserviceforalltheactivitiesnecessarytobringanewparkingstructuretoreality.

design Assist ProgramIn1996,legislationwaspassedthatenabledthefederalgovernmenttoenterintodesign-buildcontracts.Sincethattime,therehasbeenadramaticriseinthenumberoffederally-fundeddesign-buildprojects.Asaresult,theneedforspecialtysubcontractorstosupportthissignificantincreasehasneverbeengreater.

TheShockeyPrecastGrouptypicallyseekstobecomeinvolvedinthedevelopmentofprojectsthatarelessthan15%designed.EarlyinvolvementinthedesignprocessenablesTheShockeyPrecastGrouptohelpourcustomersmakesound,informedchoicesthatbestservethefinancialandaestheticneedsoftheowner.

Design Assistance ServicesTheShockeyPrecastGroupprovidesthefollowingdesignassistanceservicestoourcustomers:

1. Prepareandupdatebudgetestimates.

2. Participateinconstructabilityreviews.

3. Supportvalueengineeringoptions.

4. AttendmeetingswiththeA/EDesignTeamasrequired.

5. ProvideassistancetotheA/EDesignTeamintheformofconstructiondetails,loading

concepts,productsamples,anddrawingsfromsimilarproducts.

6. Participateinregularphone,written,andemailcommunicationswiththeA/EDesign

Teamduringthedevelopmentofthedesignthrough100%ConstructionDocuments.

7. UseBIMProcesstoprovide3Dprojectmodels.


FrequencyTheShockeyPrecastGroupprovidesdesignassistprogramserviceswiththefollowingfrequency:

1. AtCoreandShell100%DesignDevelopmentDocuments.

2. At10%,50%,and100%ConstructionDocuments.

Building Information Modeling (BIM)“ABuildingInformationModel(BIM)isadigitalrepresentationofphysicalandfunctionalcharacteristicsofafacility.Assuchitservesasasharedknowledgeresourceforinformationaboutafacilityformingareliablebasisfordecisionsduringitslife-cyclefrominceptiononward.

AbasicpremiseofBIMiscollaborationbydifferentstakeholdersatdifferentphasesofthelifecycleofafacilitytoinsert,extract,updateormodifyinformationintheBIMtosupportandreflecttherolesofthatstakeholder.TheBIMisashareddigitalrepresentationfoundedonopenstandardsforinteroperability.”—NationalInstituteofBuildingSciences

TheShockeyPrecastGroup’sEngineeringdepartmenthasplayedanintegralroleinthedevelopmentofBIMfortheprecastindustrythroughitspartnershipwithTEKLAStructures.ThiscommitmenttoremainingattheforefrontofBIMtechnologyhasmadeTheShockeyPrecastGroupinstrumentalintheadvancementanduseofBIMthroughouttheprecastindustry.Forourcustomers,TheShockeyPrecastGroup’sextensiveknowledgeanduseofBIMtechnologymeanswecanmaximizetheeffectivenessofthisvaluableintegrationtooltoensuresmoothprojectflowandopenteamcommunication.

Safety: First at All LevelsTheShockeyPrecastGroupiscommittedtoprovidingasafeandhealthfulworkenvironmentforallouremployeesandotherswhomaywork,visit,orenterourfacilitiesorjobsites.Itisourpolicytoconductbusinessinamannerthatoffersmaximumprotectiontoeachandeveryemployeeandanypersonthatmaybeaffectedbyouroperationsandbusiness.Wewillmakeeveryefforttoprovideaworkingenvironmentthatisfreefromanyrecognizedorpotentialhazard.ThecommitmentisbestdescribedbytheShockeymaxim–Safety: First at all levels.

Thegroundworkforasafeandsuccessfulprojectisestablishedlongbeforethefirstpieceofprecastisdeliveredtothesite.TheShockeyPrecastGroupisproudofitsthoroughpre-constructionplanningandsafeexecutionofallworkactivities.Shockeymanagersandfieldoperationsexpertsmentallybuildtheproject,anticipatingasmanyissuesaspossiblethatcouldadverselyaffecttheprogressoftheworkonsite.Thoroughon-sitereviewofaccessrequirementsforthecraneandtruckstransportingtheprecastarediscussedlongbeforethefirstlayeroftopsoilisdisturbed.

Duringtheprojectproposalstage,theFieldOperationsManager,withassistancefromTheShockeyPrecastGroup’sEstimatingDepartment,usesavailablecontractdocumentstodeterminethesafestandmosteconomicalmethodforerectingtheprecast.TheFieldOperationsManagerdeterminesrequiredaccessforthecraneandestablishesthesizeofthecrane,lengthsofboom,andboomconfigurationrequiredtosafelyerecttheprecastwellwithinthecrane-specifiedcapacities.Anaccesssketchshowingtherequiredcranepathisprovidedwitheachproposal.Additionally,thecranegeometry(length,width)andthemaximumcranebearingpressureareprovidedsotheownercandeterminecostsfor


providingstabilizedcraneaccessandastablebasecoursetosupportthetrucksprovidingprecastdeliverytothesite.

ErectionoftheprecastisperformedbyerectorsQualifiedunderPCI’sErectorCertificationProgram.PCI-QualifiedErectorsmustundergoarigorousauditoftheirerectionoperationsatleasteverysixmonths.Anydeficienciesfoundduringtheauditsareimmediatelycorrected.Follow-upauditsensurecontinuedcompliancewiththissafety-orientedCertificationProgram.

Duringthedesigndevelopmentstageofallawardedprojects,theprecastdesignengineerusestheerectionplantodetermineifadditionalerectionbracingisrequired.Theprecastdesignengineerevaluatesthestabilityofthepartiallyerectedstructuretoensureitcanwithstandthemostsevereweatherconditionsatanypointduringerection.Ifadditionalerectionbracingisrequired,theerectionbracingplanwithspecifiedbracingdetailswillbeincorporatedintotheerectionplanforthestructure.Thedesignanalysisanddetailswillbesealedbytheprecastdesignprofessional.

Internalpreconstructionmeetingsbetweentheerectionforemanandtheprecastdesignprofessionalsandon-sitepreconstructionmeetingsbetweentheGeneralContractor,InspectionAgencies,andtheEngineerofRecord,areheldtoensurethatallaspectsofprecasterectionarefullyunderstoodandagreedupon.Thisincludesin-depthdiscussionsonprecastconnectionsandrequirederectionbracing.

Apre-erectionsurveyoftheCIPconcreteorsteelsubstructuresupportingtheprecastiscompletedwellinadvanceoferectionsoanyrequiredmodificationsorrepairstotheCIPorsteelcanbeaccomplishedwithoutaffectingtheerectionstartdate.ErectioncommencesonlyafterassurancefromtheEngineerofRecordthattheCIPhasachievedrequiredstrengthorthesteelstructureisreadytoacceptprecast.

Theerectorisrequiredtodevelopasite-specificSafetyPlanforeachproject.Thisplancontainsacompletehazardanalysisandfallprotectionplanningfortheproject.Priortostartoftheerection,theerectioncrewisfullybriefedontheSafetyPlanandunderstandsthesafetyconstraintsoftheproject.Thisincludeshandlingofthetypesofprecastproductsfortheproject.Allprecastdeliveredtotheprojectarriveswithashippingandhandlingtagattached.Thistagoutlinesthespecifiedmethodoferectingthepanelandgivesanyspecialhandlinginstructionsforrotatingorrollingtheprecast.Weeklyfollow-upsafetymeetingssometimesreferredtoas“ToolBoxTalks,”areheldonsiteforthedurationoftheproject.

Duringerectionoftheprecast,theerectionforemanisresponsibleforsafetyontheproject.TheforemancontinuallyobservestheworkofthecrewtoensurecompliancewiththepublishedSafetyPlan.PropersafetymarkingofthesiteismaintainedinaccordancewiththeSafetyPlanandtheforemanensuresthatnon-erectionpersonnelremainoutsidetheerectionarea.Onlywhentheproperlydocumentedturnoveroftheerectedstructurehasbeencompletedwillnon-erectionpersonnelbeallowedtoperformworkonthestructure.



JohnPaulJonesArenaParkingStructure,UniversityofVirginia,Charlottesville,VA

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Bay SizeTheShockeyPrecastGroup’s48’baymoduleuses12’widedoubletees,whichresultinthemostcost-effectiveuseofprecastcomponents.Basedonthe12’doubleteewidth,thishandbookwillofferapossible“typical”parkingstructurelayout.Wheneverpossible,limittheuseofnon-standardteewidthsorbaysizes,asthiswillinfluencethecost.Thebaysizeyouchoosemayresultinverydifferentspandreldimensions,floortofloorheights,drainageplansand/orsupportingwallsystems.

drainageForownersanddesigners,assuranceofaproperdrainagesystemisoneofthemostimportantconsiderationsinthedesignofaparkingdeck–bothforthehealthandlifeofthedeckaswellasforthecomfortandconvenienceofitspatrons.Theuseofa“drysystem”forwashesthatdirectwatertowardthedrainisconsideredsuperiortotheuseofCIPconcretepourstrips.WhileCIPtoppings,suchasthoseusedinpourstrips,typicallyfeaturea3,000psiconcretemix,theconcreteusedforaprecastdrysystemwillusea6,000psimix.Sincetheprecastdrysystemisproducedinacontrolledplantenvironment,itismonitoredbythePCIQualityControlprogram.ThequalityofCIPwashcastingsmaynotbecontrolledinthesamemanner.

Designedcorrectly,aneffectivedrainageplanwillhelppreventwaterfrompondingorcausingprematuredegradationtothejointinterfaces.Generally,drainsarelocatedattheinteriorbays,atalternatinggridlines.Oneeconomicalwaytoprovideproperdeckdrainageisto“warp”thedecksurface.Warpingoccurswhenthedeckperimeterisheldataconstantelevationandtheinteriorbaysarealternatelyraisedandlowered.Warpingisgenerallynotcauseforconcernregardingcrackingofthedoubleteesurface,providedthewarpisheldtoalimitof.175inchperfootofwidthfora60’longtee.PleasereferencePCIJournalJanuary/February2003,page35forstandardindustrypractice.Thefollowingdiagramprovidesanillustrationofthisconcept.

The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM 48’ Bay 11

48’ BAY SYSTEM

12 48’ Bay The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM

Whilewarpingofthedecksurfaceisanoptionworthconsidering,itisalsopossibletoalternatelyraiseandlowertheperimeterofthedeckequallywiththeinteriorbays,resultinginatwo-waydeckcrossslope.Thiseliminatestheneedforwarpingteesbut,inturn,tendstobelesscosteffective.Theamountofcrossslopealongthelengthoftheteewilldependonthedecksystemandbaysizechosen.Eitheroptionispossibleandmayormaynotbesuitabletothedesigninquestion.

Afewimportantdrainagefacts-

• TheShockeyPrecastGroupcastspre-manufactureddrainunitsintotheflangesofthedoubleteesthatprovidecosteconomyandbettersealingqualitycomparedtofieldinstalledvarietiesandeliminatesfieldcuttingandinstallation.

• TheShockeyPrecastGroup’s“totalprecast”decksurfacedoesnotrelyontheuseoffieldtoppedCIPconcrete.Thisrepresentsasubstantialadvantageoverotherprecastsystemsandprovidesbetterdurabilityandlowercosts.Italsominimizesthechanceforwaterinfiltrationattheprecastinterface.

• TheShockeyPrecastGroupcandivertwatertowardthedrainusingoneofthreepossiblesystems:precastcurbs,monolithicprecastwashes,orCIPwashes.

• Locatinghandicappedparkingspacesshouldincludeconsiderationofmaximumallowableslope.

drainage considerationsThemovementofwaterfromthedecksurfaceisillustratedbelow.Theslopingofthedeckstructureenablesthewatertobedirectedtostrategicallylocateddrains.Thisslopinghasaverysignificanteffectonstructureframing.Therefore,earlydeterminationiscriticalandvitaltofloorheights.

High point

Bay width

High point Low point w/ drain

Interior bay

Bu ilding perim eter Constan t elevation

Approx . 60 ’

Concep t of Warping

ma x .175 inch per

Arrows indicate direction of water

flow

Concept of Warping

Expansion JointsUndernormalseasonalheatingandcoolingcycles,concretewillexpandandcontract.Thisinturngeneratesin-planeforcesanddisplacementsthatmustbeaccountedfor.Expansionjoints,whencorrectlylocated,allowtheseeffectstooccurwithoutadverselyaffectingtheprecastjointsandconnections.Dependingonthedeckconfiguration,expansionjointsshouldbelocatedamaximumof300feetapart.Theexpansionjointisfrequentlylocatedatthejointbetweentwoteesatacolumngridlineandshouldbelargeenoughtoaccommodatethecombinedthermalmovementoneachhalfofthestructure.Thelocationoftheshearresistingelementsalsoplaysaroleindeterminingthelocationofexpansionjoints.If,forexample,a300’longdeckcontainedstiff,shear-resistingelementsonbothends,itmightbeadvisabletointroduceanexpansionjointsomewhereinthemiddleofthedecktohelp“relieve”thebuildupofstressattheends.Thisisbecauseshearelementsactas“pointsoffixity”andwillacttorestrainthedeck,therebycausingconnectionforcestoexceedreasonablelimits.Itisessentialtorememberthatexpansionjointsalsoservetointerruptthelateralforceresistingsystem,which,forthepurposesofdesign,effectivelycreatestwoseparatebuildingstructures.Eachbuildinghalfmustcontainsufficientlateralloadresistingelements.


Typical Framed Level Drainge Plan


General LoadingAparkinggaragemustsatisfyavarietyofloadingrequirements.Inadditiontotheirownselfweight,parkinggaragesaredesignedtoresistuniformvehicularloadsof40psfortheapplicationofa3,000poundsactingonanareaof20squareinches(typicalsizeofthebaseofatirejack).Ifhigherloadingcriteriaareneededtoresistfiretrucksorotherlargevehicles,specialprovisionsmayberequired,includingthedeepeningofelementsortheadditionofreinforcing.Otherloadsincludewindorseismic,asdeterminedbytheapplicablebuildingcode.

Seismic/Wind considerationsParkingstructurestypicallyutilizeshearwallstoresistthelateralwindorseismicforcesprescribedbylocalbuildingcodes.Dependingonlocationandsiteconditions,thedesignloadswillvary,aswillthenumberorsizeofshearwallsneeded.Shockeyengineersalwaysperformacomprehensivelateralloadanalysisofeachbuildingthecompanydesigns.LoadsfromthisanalysisarethengiventotheEngineerofRecordforverifyingtheCIPfootingandwalldesigns.

Whenpossible,itisadvantageoustoprovideshearwallslocatedalongthelineoframpwallswithanadditionalwalloneachendoftherampasshowninthefigurebelow.Anotheroption,dependingontheprescribedloads,istooffertheshearwallswith“punched”windowopeningstoprovideadditionallightandopenness.Horizontalrampwallscanbeusedtoprovidetherequiredlateralstabilityparalleltotheramp.Thesewallshaveopeningstoprovidelightandopenness.

Wallsshouldbelocatedinawaythattakesmaximumadvantageofthesurroundingdeadloadelements.Shearwallsthatsupportdoubleteesorinvertedteebeamswill“engage”moredeadload,whichhelpstocounteractthewalloverturningmoment.Whenoverturningmomentsarelargerthandeadloadresistingmoments,aconditionknownas“netuplift”onashearwallelementoccurs.Thisrequiresthedesignofhold-downdevicesorconnections,which,inturn,increasescost.

SincethedesignoftheCIPfootingsandwallsistheresponsibilityoftheEngineerofRecord,itisimportantthatsufficientthoughtbegiventoshearwallplacementearlyinthedesignprocess.TheShockeyPrecastGroupisableandqualifiedtoworkwiththeprojectengineerstohelpdeveloprational,economicalandpracticalload-resistingsystemsthatwillprovidesuperiorbuildingperformance.

Shea r walls

Possible Stair shafts

Shear Wall Layout

Floor-to-Floor HeightThefloor-to-floorheightofaparkingstructuredependsonavarietyoffactors,includingtheprecastelementsusedandtheusagerequirementsoftheoccupants.Thesampleparkingstructureincludedinthishandbooksuggestsafloor-to-floorheightof10’-8.”Thisheightprovidesforoptimaleconomyandallowsaminimum7’-0”verticalclearanceundertheinvertedteebeams.

Fire resistanceDependingonnumerousfactors,aparkingstructuremayberequiredtohaveeithera1-houror2-hourfirerating.MostparkingstructuresfallunderthecategorytypeIIB,asdefinedbytheInternationalBuildingCode,anddonotrequireanyparticularfireresistanceratingatall.However,whenrequiredbydesign,precastparkingstructurescaneasilybedesignedtoahigherleveloffireresistance.

Fireresistanceratingsofprecastcomponentsaremeasuredandspecifiedaccordingtothecommonstandard,ASTME119.Fireenduranceisdefinedastheperiodoftimeelapsedbeforeaprescribedconditionoffailureisreachedduringastandardfiretest.Designingprecastelementstosatisfyagivenfireresistanceratingwillincreasecoststosomedegree–primarilywhenadditionalreinforcingorlargermembersizesareneeded.

opennessAprimarybenefitofthe48’bayisthattherearefewerverticalelementstointerruptthenaturalsightlines.Theinherentopennessofa48’bayparkingstructurecontributestoincreasedsecurityofparkingstructurepatronsandprovidesnaturalventilation.

Joints and revealsJointsizesbetweenprecastandCIPelementsvary.Recommendednominaljointdimensionsarenotedinthishandbook.Thesejointshavebeenestablishedbasedontolerancerequirements(seesectionbelow),andtoensurealong-lastingjointinterface.

Whendiscussingthesejoints,itisimportanttounderstandthatthedimensionsgivenare


Reveal

1”

Cau lk with backer rod

Pan el

1”

Tra pezoidal Reveal

Color #1

Color #2

Joints and Reveals


“nominal”–meaningactualjointsizesareallowedtodeviatefromthesevaluestowithinindustryacceptedranges,asdescribedinPCIMNL135.Whenselectingaccentrevealsorrusticationlines,itisimportanttotiethemtothechosenjointsize.Avoidtriangularrevealswherepossiblebecausetheyaredifficulttoaffixtotheforms.Instead,atrapezoidalrevealwillprovideaflatnailingsurfacefortheformbuildersandhelpminimizepossiblenailholeirregularities.Whenchoosingarevealsize,considerlimitingthedepthto¾”.Deeperrevealsdecreasetheeffectivesectionofthepanel.Thisreducespanelstrengthandincreasesthechanceforpanelcracking,whichmayrequireanincreaseinthepanelthickness.Besuretoincluderevealsbetweenanyandallcolorbreaks--whentwoseparatefacemixesareusedwithinthesamepanel,it’sstronglyrecommendedthatdesignersincludearevealbetweenthetwomixestoprovidethecastingcrewadistinctstoppingpointandhelpreducecolorbleed.Thiswillhelpensureasmoothbreaklinebetweenthetwocolors,asillustratedinthefigurebelow.

corners and QuirksWhenconsideringdetailsatbuildingcorners,it’srecommendedthata¾”quirkbeintroducedatpanelreturns–especiallythoseexceeding1’-1”inlength.Toachieveasuperiorfinishalongthepanelface,panelsareoftenproducedintwophases,whichresultsinacastingorpourlinebetweenthetwopieces(seesketchbelow).Thequirkwillminimizethiseffectbyessentiallyhidingthelineintheapexofthenotch.

Corners and Quirks

Panel Corner Detail –(Monolithic Pour)

Panel Corner Detail –(Sequential Pour)

Maximum panelreturn length = + 1’1”

Square corner possiblebut not recommended –

use quirk if possible

Pane 1 returnsgreater than 1’ - 1”

quirk¾” quirk

First pour

Second pour

Sequentialpour line

Facial ProjectionsFacialprojectionscanaddauniqueaccenttoyourbuildingproject.Becausethesefeaturesarecasttothepanels“bottominform”,aminimumdraftdimensionisnecessaryinordertobeabletostripthepanelsoutoftheforms.Withoutproperdraft,suctionforcesgeneratedbetweentheconcreteandtheformmaycausethepanelstobindupduringstrippingandpossiblydamagethepaneland/orforms.Toensurethisdoesnotoccur,Shockeyrecommendsaminimumdraftof1:6onfacialprojections,asnotedinthesketchbelow.Alsokeepinmindthatfacialprojectionsincreaseproductioncosts,sinceformsneedtobebuiltuptoaccommodatethefeature.

TolerancesPrecastconnectionsandpaneldimensionsneedtoallowforindustrystandardtolerances.AnexcellentguidetoprecasttolerancesisavailablethroughPCI.TheToleranceManual,MNL135,describesindetailtheallowableproductionanderectiontolerancesforvariousprecastelements.Requestacopyatwww.shockeyprecast.com.

PenetrationsVerticalpenetrationsthroughthedoubleteeflangescanbelocatedanywhereexceptinthestem.Penetrationsthroughtheprecastthatmayberequiredforwallhydrants,pipepenetrationsandlightfixturescanbecastintothepanelsprovidedthecoordinationforlocationandsizeisdoneearlyenoughintheshopdrawingdevelopment.ThelocationandsizeofthesepenetrationsshouldbefurnishedtoShockeyduringtheshopdrawingprocess.Thisistoensurethattheinformationcanbeincorporatedintotheshopdrawingsandfabricationdrawingsinadequatetime.Foropeningslessthan10”square,itisrecommendedthatthepenetrationsbefieldcut.

connectionsDesignoftheconnectionsisalwaystheresponsibilityoftheprecaster.Shockeyutilizesavarietyof“user-friendly,”safeandefficientconnectionsthatallowprecastelementstobesetandsecuredinatimelyfashion.Includedinthishandbookareanumberoftypical


Facial Projections

Panel as-cast

Forms built up to createfacial projections

Loops for stripping

Panel in finalerected position

Facial projection

6

1

Minimum draft


connectionswhichprovidethedesignerwithasolidbasisforcosteffectiveandhighlyefficientdesigns.Dependingonvariousfactors,includinglifeexpectancyanddurabilityrequirements,embedmentfinisheswillvaryfromjobtojob.TheShockeyPrecastGrouptypicallyrecommendsthefollowingplatefinishes:

• Non-weldedplateconnectionsexposed Hot-dippedgalvanized totheelements or‘J’Finish

• Weldedplateconnectionsexposed ZincRichCold totheelements GalvanizingCoated

• RodsandBolts Electroplated

• Allothermaterial Plain

• Flange-to-flangeshearconnections Stainlesssteel

MaintenanceEnsuringlong-lastingdurabilityofaparkingstructurerequiresownerstakethenecessarystepstomaintainthestructureoncecompleted.Properlymaintainingaparkingstructurenecessitatesregularinspectionsandcleaningoftheprecastjoints,andarangeofotheritems.Theissueofsnowremovalshouldbeaddressedearlyinthedesignphasewithownerssoitdoesnotbecomeasourceofconcernoncethesnowplowsbegintheirwork.Forexample,theimpropermoundingorremovalofsnowcancauseadegradationofthejointsorteesurfaces.

cIP concreteCIPconcreteistypicallynotincludedintheprecastscopeofwork.However,sinceCIPinterfaceswiththeprecastelements,thecoordinationofprecasttoCIPinterfaceisextremelyimportant.CIPelevationsanddetailsshouldcloselymatchtheprecastdesigntoensuretheproperfit-upandexecutionofthepieceswhentheyarriveonsite.

Followingisanexplanationofeachdesignteammember’sresponsibilitiesregardingthecoordinationofCIP-to-precastinterface:

• Engineer of Record (EOR) –TheEORshouldspecifytopofCIPpier,wallandfootingelevationsandprovideadequatereinforcingdetailsoftheseelementswithinthecontractdocuments.Pierandfootingdesignsshouldaccountforthepossibilityofupliftandslidingforcesatshearwalllocations.Reinforcingdetailsshouldspecifyadequateconfinementsteelatthetopsofpiersandwalls,asrequiredbytheACIcode.Pierandwallsizesshouldtypicallybealargerdimensionthantheprecasttheysupportsothatanchorboltsandembeddedplatescanbeeasilyplacedwithintheconfinementsteel.DowelsoranchorboltsusedtoconnecttheprecasttotheCIParetypicallytheresponsibilityoftheprecaster.Inmanycases,TheShockeyPrecastGroupmaysuggestalternatetopofpierorfootingelevationsthateitherenhancethestructure’sperformanceorimprovecost-effectiveness.Inthiscase,theCIPsubcontractorisaskedtoexecutethedetailsaccordingtotheprecastdrawings,sincethisishowthepiecesarefabricated.

• General Contractor (GC)–CoordinatetopofCIPpierandwallelevationswiththestructuralandprecastdrawings.EnsurethattheCIPsubcontractorfollowsandproperlyexecutesthereinforcingdetailsthatareshownontheContractDrawings(seenotesabove).

• The Shockey Precast Group–DesignandprepareanchorboltlayoutdrawingsforusebytheGCandCIPsubcontractor.SupplyallloosehardwareandanchorboltsneededfortheattachmentoftheprecastelementstotheCIPconcrete.

• CIP Subcontractor–CarefullyexecutetheCIPreinforcinglayoutsperthestructuraldrawings,includingtheconfinementtieslocatednearthetopsofpiersandwalls.Incorporateloosehardwarefortheprecastconnectionsaccordingtothelocationsshownontheprecastlayoutdrawings.WhenadiscrepancyexistsbetweenthestructuraldrawingsandtheprecastdrawingsfortopofCIPelevations,theprecastdrawingsgovern.

ThefollowingsketchillustratestheCIP-to-precastinterface:

ItisgenerallyrecommendedthattheCIPsystembedesignedsuchthattheprecastelementsarenotrequiredtoretainearthloads.Instead,CIPretainingwallscanbeprovidedthatactindependentlyfromtheprecasttowithstandtheseforces.Ifnecessary,itispossibletodesigntheprecastteesorwallsbelowgradetoacttoresistearthloads,asshowninthefollowingsketch.Thiscouldinfluencethelocationofshearresistingelements,connections,andmaynecessitatetheuseofacast-in-placetoppingonthetees.


Reinforcing including ACI requiredconfinement ties to be designed and detailed by the EOR, furnished andinstalled by the GC or CIP subcontractor

Anchor bolts or embedded platessupplied by Shockey, installed byCIP subcontractor at locationsshown on precast anchor bolt layouts

Always maintain top of pier or wallelevations as shown on the precastdrawings. Notify GC of anydiscrepancies between the structuraland precast drawings

Ideally, the CIP section should bewider than the supported precast.For piers, this should be 2” on allsides. For walls, 1” is suggested

CIP Pier for Precast Column

Free-Standing Wall Fixed Wall

Free standing, CIP retaining wall.Backfill wall and allow foranticipated wall movement orrotation to occur prior to setting precast .

Precast double tee

Precast double tee

CIP or precast retaining wall.

Possible CIP topping

Connection


The 48’ Bay SystemToillustratethetypicalpaththatTheShockeyPrecastGroup’sdesign-assisteffortwouldtake,pleaseconsiderthefollowingexample:

TheShockeyPrecastGroupisapproachedbyapotentialcustomer,whobringstothetablethisinformationregardingaparkingstructure:

1. Thestructuremusthaveafloor-to-floorheightof11’8”gradetofirstelevated level,and10’8”onallotherlevels.

2. Rampslopeis6.1%atthefirstlevel,and5.6%attheupperlevels.

3. The256,000SFstructuremustbedesignedtoaccommodate790cars.

Usingthisinformation,TheShockeyPrecastGroupwillworkwiththedesignteamtoachieveanoptimallayoutusingthe12’doubleteesand48’baysystem.Onthefollowingpageisanexampleofowner-providedsketchestypicallyreceivedbyTheShockeyPrecastGroupatthebeginningofthedesign-assistprocess:


Usingtheowner-providedsketchesandbasicdeckrequirementsasaguide,TheShockeyPrecastGroupworkswiththeprojectdesignteamtodevelopacustomized48’baysolutionthatmeetstheowner’sneedsandsatisfiesthedesigner’svision.Specificsofthedeckarelistedbelow:

Deck Type12’wide,30”deeptees 48’widebays 10’-8”floortofloorheight 7’-0”minfreeverticalclearance 192’longrampwitha5.55%slope 177parkingspacespertypicallevel

ThefollowingpagesillustratethetypicalprecastcomponentsandconnectionsthatcompriseTheShockeyPrecastGroup’s48’baysystem.Thesedetailsareincludedtogivethedesignerabetterunderstandingofthe48’baymoduleasawhole,andtogiveinsightastonecessarydesignconsiderationsspecifictoprecastconcreteparkingstructures.


results: Floor Framing Plans and Parking Layout Plans


South Building Elevation (Highlightingproductdescription)

North Building Elevation (Highlightingproductdescription)


East Building Elevation (Highlightingproductdescription)

West Building Elevation (Highlightingproductdescription)


West Elevation at Stairwall (Highlightingstairwallcutaway)

Longitudinal Building Cross Section at Ramp walls


Building Cut-Away Section Illustrating Building Assembly


Pocketed Shear Wall Details


Horizontal Ramp Wall and Details


Vertical Ramp Wall Options


12’ Wide Double Tee Profile W/6’-0” Stem Spacing

12’ Wide Double Tee Profile W/5’-0” Stem Spacing



Inverted Tee Beam Profile Detail

Deck Drain Details



Stem Block-Out Details

Double Tee to Flange Chord Connections


Column to CIP Footing or Pier



Double Tee to Spandrel Connection Details

Double Tee to Spandrel Details Corbel Detail



Double Tee to Spandrel Connection Details Top Connection

Double Tee to Beam Connection Details



Non-Load Bearing Spandrel to Column Connection

Load-Bearing Spandrel to Column Connection



Outboard Column Option

TheShockeyPrecastGroup’s48’baymoduleoffersincomparableefficiencyandcost-effectivenessfortheowner.Thefollowingchapterhighlightstheflexibilityandfreedomavailabletothedesignerthroughthe48’baymodule.

PArkInG STrucTurE AESTHETIcSThedaysofplain,gray,box-likeparkingstructuresareover.Savvyownersanddesignersaretakingadvantageofthenearlylimitlessdesignfreedomofferedbyprecastconcrete.AtShockey,wehelpourcustomersrealizetheiruniqueprojectvisionswithindividualizedprecastsolutionsthataredurable,costeffectiveandbeautiful.Inthischapter,wewillexplorethevarietyoffinishoptionsavailablewithprecastconcretefromShockey.

color, Textures and Applied FinishesThroughavarietyofaggregates,choiceofmatrixcolors,varyingdepthsofexposure,andfinishingtechniques,precastcanmeetalmostanycolor,formortexturethatmaybespecifiedbythedesigner.Additionally,thebeautyofnaturalaggregatesisgreatlyaccentuatedwhentheaggregatesarefusedwiththecolorandtexturebenefitsofprecast.

colorTheShockeyPrecastGrouprecommendsthatcolorselectionsbemadeinthesameorsimilarlightingconditionsasthefinal,in-placeconditions.Inordertomaintainmatrixcoloruniformity,whitecementshouldalwaysbeusedalongwithcolorpigmentsconformingtoASTMC979.Evenwhenthedesiredmatrixcolorisgray,theuseofwhitecementandgraypigmentisstillhighlyrecommended.

The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM ParkIng Structure aeSthetIcS 51

52 ParkIng Structure aeSthetIcS The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM

Whenreviewingcostinselections,itisimportanttoconsiderthesourceofaggregateifdeepexposureisrequired(localsourcesarealmostalwaysmorecosteffective);andtorealizethatmatrixcolorssuchasblueandgreenarehighercostselections.

Variationsincolorcanbeachievedwithinareasofthestructureorwithineachindividualprecastunit.Useofmultiplecolorsrequiresclearlydefinedcolorbreaks,whichcanbeachievedwithreveals,jointsandprofilechangestoensurecrisptransitions.

Deepexposurefinishescanbeachievedeitherthroughtheuseofchemicalretardantsorthroughthesand-blastingprocess.Inbothcases,morethanjusttheextremesurfaceareaoftheaggregateisexposed,allowingthecoarsestoneaggregatetoprojectbeyondthecementmatrix.Theexposureshouldremainat40%ofthenarrowdiameterofthecoarseaggregateinordertopreventtheoccurrenceof“baldspots.”Bothtypesofsurfacetreatmentshighlightthenaturalbeautyofthestonewhileprovidingatexturethatcannotbeobtainedthroughtheuseoflighterfinishingtechniques.

TextureTextureexpressesthenaturalbeautyofthematerialcomponentsandcanbeusedtodefineoraccentuatespecificareasofthestructure’sfaçade.Texturetakesadvantageofitschangingrelationshiptolighttocreatearangeofsurfacedifferencesfromsubtletodramatic.Whenchangingtexturesorexposureswithinasingleprecastunit,clearandwell-definedbreakpointsareneededsimilartothoseforcolor.Texturedsurfacesalsohavetheaddedbenefitofhidingtheeffectsofweatheringandhigh-volumeuseareassincetheirregularitiesinthesurfacehelpdivertattentionfromlinestreakinganddiminishtrafficusemarks.

Texturecanbeachievedthroughavarietyofdifferenttechniques,andcanrangefromlightexposuretodeepexposure.

Applied FinishesTheseareavarietyofpost-appliedtechniquesusedtoachievethedesiredappearanceandcharacterofthefaçade.Thestructure’sfinalappearanceisobtainedthroughthecombinationofmixdesignselectionandthechoiceofappliedfinish.Althoughfinalfinishessuchasbrickveneersarecastinnaturalstoneorformliners,andmayreceiveapost-castingfinish,theyareaddressedseparatelysincethecriticalelementsofobtainingthedesiredappearanceareachievedduringthepre-pouroperation.

Thedepthoftheappliedfinishshouldtakeintoaccountthesize,function,articulationandconfigurationoftheunits.Finalselectionofthefinishgradationshouldbemadeduringthemock-upphaseandshouldincluderecommendationsfromTheShockeyPrecastGroup.Variationofappliedfinisheswithintheindividualunitscanbeusedtoenhancetheoverallappearanceofthestructure.Thiscanbeamorecost-effectivemeansofaccentuatingkeycomponentsorareasofthefaçadethantheuseofmultiplemixes.Whenmultipleappliedfinishesarepartofthedesign,thesamelogicregardingprofilechangesand/orrevealworktoensurecleanbreaksshouldbeappliedasthatofmultiplemixes.

Acid Etch FinishAcidetchingisaprocessthatdissolvesthesurfacecementmatrixtoexposethesandand,toalesserextent,thecoarseaggregate.Acidetchingistypicallyusedtoachievealight-to-medium-lightexposure.Theendresultissimilartothatofnaturalproductssuchas

sandstoneorlimestone.Theetchingprocessleavesasugar-cubeappearance,whichisenhancedbydirectsunlight.

Thedecisiontoincorporateanacid-etchfinishmustbemadepriortoorduringthemixdesignprocesssinceonlyacid-resistancesiliceousaggregates(granite,quartz,etc.)shouldbeused.Carbonateaggregatessuchasdolomiteandlimestone,suitableforsandblastingmixes,willdissolveordiscolorthroughtheacid-etchingprocessduetotheircalciumcontent.Complementaryaggregates(fineandcoarse)andcementpigmentsshouldalwaysbechosenwhenanacidetchfinishisselected.

Acidetchingisthecrucialsecond-stepprocesswhenthefaçadeofthestructurewillincludeclayproductssuchasthinbrickveneer.Thisprocessnotonlyhelpsremovesomeofthesurfacelaitanceonthebrickduringthemanufacturingprocess,butalsoexposesthesandbetweenthethinbrickjointstomimicthatofhand-laidbrickmortar.Itisusedasasafefinisharoundthebrickveneerforincorporatedprecastfeaturessuchaslintels,sills,bands,andprojectionsthathaveallbeenintegratedwithinthesameprecastunit.

Sand-Blasted FinishSandblastisthegenerictermusedfortheabrasiveblastingprocess.Varyinggradationsofblastmaterialareusedtochipawaytheprecastsurface.Selectionofaparticulargradationdependsonthedesireddepthoffinish.Sandblastingallowsthedesignerthefullrangeofdepthsobtainableinprecast(lighttoheavy).Onfinalexposedsurfaces,brushblastingshouldbeavoidedbecauseofitsinabilitytouniformlyremoveallthesurfacelaitance.Lightblastingprovidesasimilarappearancetothatfoundinnaturallimestonewithoutthe“sugarcube”appearancecreatedbyacidetching.

Incontrasttoacidetching,blastingtendstobebettersuitedtomutingorcamouflagingminorvariationsthatoccurinthemanufacturingprocess.Thisisespeciallytruewhenaddressingdeepprofilearticulations.Deeperblastshaveanincreasedabilitytoensureuniformity.However,onceblastingexceedsthelightleveloffinishandtexture,theendresultismoredependentonthenaturalelementsofthemix(aggregates).Complementaryaggregatesandmatricesshouldalwaysbeconsideredwhenspecifyingdeeperlevelsofexposure.Adeeperblastcanmimicothernaturalmaterialssuchasflamedgraniteandcancreateinterestingplaysoflightthroughitstexture.

Blastingcanalsobeamoreeconomicalmeansofachievingmultiplevariationswithinthesameunitthanincorporatingmultiplemixdesigns.Blastingcreatesmultiplevariationsbyexposingdifferinglevelsofthecoarseaggregateinpre-definedareasoneachpanel.Theoveralldesiredeffectoftextureisalsoinfluencedbythetypeandselectionofcoarseaggregateinrelationtothepsiofthematrix.Softeraggregateswillbecomeconcaveduringtheblastingprocess,whileharderaggregateswillbecomeconvex,dependinguponthedepthofexposure.

Exposed AggregateThisprocessisachievedbychemicallyretardingthematrix,whichprovidesanon-abrasivemethodofexposingthenaturalbeautyofthecoarseaggregates.Unlikethesandblastingprocess,thechemicalretarderdoesnotmuteordamagethecoarseaggregates.Thechemicalretarderisappliedtothemoldsurface,whichdelaysthecementpastefromsettingup.Afterstrippingthepanel,theretardedoutersurfacelayerofcementisremovedwitha



high-pressurewasher.Avarietyofdepths,fromshallowtodeep,canbeachieveddependingonthetypeofretarderused.Aswithotherfinishes,variationsofexposurewithinthesameunitcanbeachievedwithchemicalretarders;however,aclearrevealorprofilechangeisamustforthetransitionpointstopreventbleedingofexposure.Thechoiceofaggregatesizeisessentialwhenchoosingdepthtopreventexcessiveaggregateloss“baldspots.”Iftheownerordesigner’svisionistoenhancethebright,naturalcolorsoftheaggregates,chemicalretardersshouldbeused.Itisrecommendedthatcontrastingmatricesandaggregatesbeavoidedtopreventa“patchy”appearance.

Form LinersFormlinersofferthedesignerawidearrayofpossibilitiesinshapes,patterns,textures,anddesigns.Thelinermaterialuseddependsonthedesiredeffectandthenumberas-castrequired.Anycombinationofappliedfinishescanbeutilizedinconjunctionwithformliners.Formlinerfinishescanbeimplementedeitherasthemainaestheticfeatureorasahighlight,medallion,orlogo.Advancesinformlinertechnologieshavecreatedadesignpalettelimitedonlybytheimagination.Whenvastareasofprecastwilluseformliners,limitationsoflinersizesshouldbeincorporatedwithrevealworktopreventlinerbuttjoints.Formlinersprovidethehighestdegreeoftextureandwillenhancetheplayoflightandshadows,creatingachangingappearanceofthefaçadethroughouttheday.Keyplacementofnightilluminationcanalsocomplementtheeffectsoftheliner.

Formlinersareakeycomponentwhenimplementingathinbrickveneer.Thethreemaintypesofbrickliners(elastomeric,plasticgrids,andsnaps)eachhavetheirownpositiveattributes,dependingonprojectdesignandpanelconfiguration.TheselectionofalinershouldbemadewiththeguidanceofTheShockeyPrecastGroup.Whenadesignerchoosestouseaformliner,itisveryimportantthatthedesignerrecognizetheleadtimerequiredwithformliners.Leadtimewillvarybytypeoflinerandpatternselected.Linersrequiringuniqueartworkwillrequireadditionaltimefortheartisantocreatethemastermold.

Formlinerleadtimescanrangefrombetweenfourtoeightweeks.Whenelastomericlinersareusedinconjunctionwiththinbrick,asamplerunoftheactualbrickbeingusedisrequiredinordertoobtainthecorrect“fit.”Thefirst100bricksfromarunaremeasuredandtheformlinerisbasedontheaveragebricksize.Inadditiontotheleadtimefortheformliner,theleadtimerequiredonthebrickmustbeconsideredaswell.Brickmanufacturerswillusuallyfabricatethelightershadesinthebeginningofthemonthandthedarkershadesattheend(orviceversa).Dependingonthetimeofthemonthandthetypeandcolorofthebrickselected,itistypicallyfourweeksminimumuntilthefirstrunofbricksisdelivered.

case StudiesInthissection,wefeaturecurrentexamplesofprojectsthatbenefitedfromTheShockeyPrecastGroup’sdesign-buildcapabilities.Eachoftheseprojectsoffereditsownchallenges,includingaggressiveschedule,complexdesign,tightbudget,andlimitedsiteaccess.Theuseofprecastconcretecontributedsignificantlytotheoverallsuccessofeachoftheseprojects.

calvert Street Parking Structure, Annapolis, Md

TheCalvertStreetParkingGarageinhistoricdowntownAnnapolis,Marylandisa168,000SFparkingstructureownedbytheDepartmentofGeneralServicesoftheStateofMaryland.Designofthestructurecalledforfourbaysoffourlevelsofelevatedprecastframing,consistingoftworampedbaysandtwoflatbays,providing727parkingspaces.Exterioraestheticswereofparamountconcerntotheownerthroughoutthedurationoftheprojectgiventhecloseproximityofthenewstructuretoseveralhistoricalbrick-cladbuildingsoftheStateCapitolcomplex.TheShockeyPrecastGroupmetthisdesiredintentbyprovidingastructuralgrayprecastframesurroundedbyaseparatefaçadeofarchitecturalprecastusingamixofhighlyarticulatedthin-brickandarchitecturalprecastelements.Thearchitecturalfaçadewasessentiallyself-supportingwithregardtogravityload,withrequiredlateralsupportprovidedbytiebacktothestructuralframe.Inordertoensureasuccessfulproject,thedesignteamhadtobevigilantindetailingthenumerousinterface/offsetconditionsandconnectionschemessuchthatrequirementsforconstructabilityandaccesswereinconcurrencewithaestheticrequirements.

TheShockeyPrecastGroup’sWinchesterproductionfacilityprovided554piecesofstructuralprecastfortheproject,includingdoubletees,beams,columns,spandrels,verticalrampwalls,shearwalls,flatslabs,andstair/elevatorcorewalls.The223elementsofthearchitecturalfaçadewereprovidedbyTheShockeyPrecastGroup’sFredericksburgproductionfacilityandconsistedofanarrayofspandrels,wallpanels,cornices,coping,andcolumncovers.

ThedesignofthefaçadespecifiedtwocolorsofthinbricktobeusedineitherstandardrunningorFlemishbondcoursingatspecificlocationsalongtheexteriorelevations.Layoutanddetailingofthehorizontalandverticalcoursingofbrickpresentedaformidablechallengetoallmembersofthedesignandproductionteam,thusrequiringdiligentattentiontoassureproperalignmentofbrickbetweenprecastelements.Thepresenceofseveralhighlyarticulated,ornatecorniceandsilldetailsofarchitecturalprecastpresentedachallengetobothdesignandproductionteams.Inordertoaccenttheprecastfaçade,numerouspiecesofdecorativesteelcolumns,channels,beams,grilles,andglazingwerefield-installed.



Erectionofthestructurewasextremelydifficultduetolimitedaccesstotheinteriorfootprintofthestructure.Thearchitecturalfaçadehadtobeerectedinconjunctionwiththestructuralcomponentsoftheparkingstructure.Theaccessplanwaschangedtoeliminaterampconstruction,andthelastphaseofconstructionwasmovedtothetopofBladenStreetoutofthefootprint.Thischangesavedtimeandexpenseforthegeneralcontractor,andresultedinashorterandmorecontinuouserectionprocess.Erectionwascompletedonscheduleinapproximately12weeks.

Project Timeline:Design July2005–December2005Construction December2005–February2007ProductionWinchester January9,2006–May16,2006ProductionFredericksburg January3,2006–May17,2006PrecastErectionStart April3,2006ErectionComplete July21,2006OpentoPublic January10,2007

d.c. nationals Parking Structures, Washington, dc

Thisprojectincludedtwoparkingstructuresthatwouldprovide1,250parkingspacestoD.C.Nationals’patrons.Bothgarageswerescheduledtobebuiltduringconstructionofthenewbaseballstadium,NationalsPark.Theoriginalconceptspecifiedanundergroundparkinggarage;however,complicationsinthedesignprocessmadethisconceptimpractical.

Withonly12monthsremainingintheprojectschedule,theprojectwasredesignedasaprecastparkingstructureandTheShockeyPrecastGroupwasrecruitedasadesign-buildpartner.Shockeyassistedtheteamwithdevelopmentoftheoveralllayoutofthegaragessothattheowner’sconstructioncompletiondeadlineofApril2008couldbemet.On-timecompletionwasessential,asApril2008markedthestartofthe2008baseballseasonandopeningdayoftheNationals’newstadium.

Thesiteitselfpresentedsignificantchallenges.TheDCNationalsBallparkissetbelowgradeelevation,soitwasnecessarytoincludearetainingwallbetweentheballparkandthegaragesinthedesignoftheparkingstructures.InordertomeetLEEDrequirements,thedesignerhadtoallowforadditionalprogramfeatures,suchasbicycleparking,inthedesign.Parkingaccesscontrolswerealsoincludedtoaccommodatethefuturepossibilityofcommercialuseofthegaragesbytheowner.

TheShockeyPrecastGroupproducedatotalof308,000squarefeetofprecastdoubleteesfortheproject.Bothgaragesconsistofthreeframedlevelsandarethreebayswide.TheEastgaragefeatures170,000squarefeetofdoubleteesandtheWestgarageincludes138,000squarefeetofdoubletees.DesigndevelopmentwasanongoingprocessandtheShockeyteam’scoordinationeffortsincludeddevelopmentofthedrawingsandmatchingtheparkingstructures’precastfinishestothoseoftheballpark.TheShockeyPrecastGrouphadtoallowforretailandticketsalesonthefirstfloorofbothparkingstructures.Sincetheseretailareashadcast-in-placeconcretearoundthem,itwasnecessaryforTheShockeyPrecastGroup


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toincludecoordinationandinteractionwithCIPinitsplanninganddesign.Becauseofthesurroundingretailareas,thefirstfloorofthegarageswasunusuallytall,addingtothecoordinationconsiderationsincorporatedbythedesignteam.

Complexrevealsandtwodifferentsandblastpatternsincreasedtheoverallintensityoftheproject,buttheuseofarchitecturalprecastmadeitpossibleforthedesigner’svisiontoberealizedwellwithintheprojecttimelineandbudget.AnotheruniqueaspectoftheprojectforthedesignerandforTheShockeyPrecastGroupwasthattheprecastdesignhadtoaccommodatethehangingofartworkontheexteriorofthegarages.Theprecastshearwallswereincorporatedintotheexterior“windowdressing,”andatowereffectwasaddedtothefaçadetocreatevisualinterest.

ErectionoftheparkingstructuresbeganinJuly2007andwascompletedonNovember21,2007.ThefinishingofthestructureswascompletedonMarch1,2008.

Nationals Parking Structures Construction Timeline:June6,2007 ProductionstartJuly23,2007 ErectionstartNovember21,2007 ErectionCompleteMarch1,2008 FinishingCompleteApril15,2008 Walk-throughwitharchitect


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Gaylord national Harbor resort and convention center

ThePetersonNationalHarborCenterisa300-acresitelocatedona1¼milewaterfrontstretchofthePotomacRiverinPrinceGeorge,Maryland.NationalHarborishometo7,000,000squarefeetofrestaurants,shopping,officespace,residencesandhotels,includingtheGaylordNationalHarborResortandConventionCenter.TheGaylordNationalHarborResortisthelargestnon-gaminghotelandconventioncenterontheeastcoastandthelargesthotelinWashingtonD.C.

Anumberofdifferentparkingstructureconfigurationswereconsideredinordertomaximizetheoptimalnumberofparkingspaces.Theapproveddesignspecifieda247,700SF,six-levelstructuretoprovide1,933parkingspacesforstaffandvisitorstotheGaylordNationalHarborResortandConventionCenter.TheupperfivelevelsoftheparkingstructurewereconstructedofprecastcomponentsproducedbyShockeyatitsFredericksburgandWinchesterplants.Shockeymanufacturedanderected12’x30”doubleteeswitha4”flange,12’x30⅝”doubleteeswitha4⅝”flange,8”flatslabs,10”thickwalls,stairunits,columnswitharchitecturalfinish,L-beams,24”x36”inverted-teebeams,10”thickprestressedspandrelswithanarchitecturalfinishand10”thickprestressedverticalrampwallsfor6’stems.

Theparkingstructure’sarchitecturalprecastfeaturesincludehorizontalribsonspandrelsandexteriorelevatorwallpanels,columncoversandaplanteronthenorthendofthegarageroof.TheexterioroftheparkingstructurerequiredarchitecturalmixdesignandfinishesbeconsistentwiththoseoftheHotelandConventionCenter.

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TheuseofprecastratherthanCIPconcreteenabledthebuildingtobeconstructedwithinitsownfootprint.TheproposedschedulewasveryrestrictiveregardingShockey’sactivitiesandscheduleduringtheconstructionprocess.TheuseofprecastallowedthemajorityoftheworktobeperformedatShockey’smanufacturingfacility,whichenabledShockeytomeettheschedule’srestraints.


Products Used:12’x30”DTwith4”flange12’x30⅝”DTwith4⅝”flangeColumnCovers8”precastflatslabs10”thickwallsPrecastStairUnitsColumnswithArchitecturalFinishL–Beams24”x36”PrestressedInvertedTeeBeam10”thickprestressedspandrelswitharchitecturalfinish10”thickprestressedverticalrampwallfor6’stems


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Long&FosterParkingStructure,Chantilly,VA

THE ALTuSGrouPc-GrId® reinforced double Tees for Parking StructuresTheShockeyPrecastGroupisamemberofAltusGroup,anationalpartnershipofprecastconcretemanufacturersandsuppliers.Committedtoinnovation,AltusGroupdevelopsandmarketsCarbonCastproductsmadeusingC-GRID®carbonfibergridreinforcing–includingprecastwallpanels(architecturalcladdingpanelsandhighperformanceinsulatedwallpanels)pretoppeddoubletees,andresidentialwallpanelsandstemdecks.LEED-friendlyCarbonCastproductscanweighless,insulatebetterandlastlongerthancompetitivebuildingtechnologies.

In2008,ShockeyembarkedonitsfirstCarbonCastproject:the$7.68millionWinchesterParkingStructure.The140,000square-foot,five-storyWinchesterParkingStructureissituatedatacornerinWinchester’shistoricdistrict.Theparkingstructurefeaturesabrickfaçade,accentedwithprecastconcretefeaturesthatmimiclimestone.Anenclosed,elevatedpedestrianwalkwaywillconnecttheparkingstructurewiththeFrederickCountyOfficeComplex.TheWinchesterParkingStructurefeatures482precastcomponents,including204precastdoubleteesreinforcedwithCarbonCastC-GRID®carbonfiber.TheuseofC-GRID®reinforceddoubleteesprovidedacost-effectivesolutionthatenabledtheprojecttostaywithinbudget,whiletheuseofprecastconcreteenabledtheteamtomeettheowner’sveryaggressiveschedule.TheShockeyPrecastGroup’sotherC-GRID®projectsincludeparkingstructuresforTheUniversityofMarylandatShadyGroveandWalterReedMedicalCenter.

Shockey’smembershipintheAltusGroupenablesustobringknowledgeofandexperiencewiththeindustry’slatestinnovationsandtechnologytoeveryoneofourparkingstructureprojects.Notonlycanweoffereconomic,attractiveparkingstructuresolutions,wealsousematerialsandsystemsthatcanresultingreaterparkingstructurelongevity,durability,andoverallstrength.

The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM the altuSgrouP 63

TheShockeyPrecastGroup’sC-GRID®EmbedmentMachineplacesC-GRID®intoadoubleteefortheWinchesterParkingStructureproject.

64 the altuSgrouP The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM

The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM the altuSgrouP 65

These sections have been reprinted with permission from the Altus Group’s Carbon Cast Pretopped Precast Double Tees brochure.

66 the altuSgrouP The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM

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WashingtonDCNationalsParkingStructures,Washington,DC

SEcTIon 03 41 00PrEcAST STrucTurAL concrETE

GuIdE SPEcIFIcATIon

General1.1 SuMMArYA. Section includes: 1. Structuralprecastconcretefor: a. Columns b. Beams c. Spandrels d. FloorandRoofDoubleTees e. InvertedTeeBeam f. StairRiserSections g. WallPanels h. FlatSlabs i. ShearWalls 2. CaulkingandExpansionJoints 3. AccessoriesandSupportingDevices

B. Related Requirements: 1. Section034500-PrecastArchitecturalConcrete 2. Section079201–JointSealants

1.2 rEFErEncESA. American Concrete Institute: 1. ACI301-SpecificationsforStructuralConcrete 2. ACI318-BuildingCodeRequirementsforStructuralConcrete

B. ASTM International: 1. ASTMC33–StandardSpecificationforConcreteAggregates 2. ASTMA36/A36M-StandardSpecificationforCarbonStructuralSteel 3. ASTMC94–StandardSpecificationforReady-MixedConcrete 4. ASTME119-StandardTestMethodsforFireTestsofBuilding ConstructionandMaterials


The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM ParkIng Structure SPecIfIcatIonS 67

5. ASTMC150-StandardSpecificationforPortlandCement 6. ASTMA153/A153M-StandardSpecificationforZincCoating(Hot-Dip)on

IronandSteelHardware 7. ASTMA185-StandardSpecificationforSteelWeldedWireFabric,Plain,for

ConcreteReinforcement 8. ASTMC260–StandardSpecificationforAir-EntrainingAdmixturesforConcrete 9. ASTMA416/A416M-StandardSpecificationforSteelStrand,Uncoated

Seven-WireforPrestressedConcrete 10. ASTMC494–StandardSpecificationforChemicalAdmixturesforConcrete 11. ASTMA497-StandardSpecificationforSteelWeldedWireFabric,Deformed,

forConcreteReinforcement 12. ASTMA615–StandardSpecificationforDeformedandPlainBillet-SteelBars

forConcreteReinforcement 13. ASTMC618–StandardSpecificationforCoalFlyAshandRaworCalcined

NaturalPozzolanforUseasaMineralAdmixtureinPortlandCementConcrete 14. ASTMA666-StandardSpecificationforAusteniticStainlessSteelSheet,Strip,

Plate,andFlatBar 15. ASTMA706/A706M-StandardSpecificationforLow-AlloySteelDeformed

andPlainBarsforConcreteReinforcement 16. ASTMC979–StandardSpecificationforPigmentsforIntegrally

ColoredConcrete 17. ASTMC989–StandardSpecificationforGroundGranulatedBlast-FurnaceSlag

forUseinConcreteandMortars 18. ASTMF1554–Grade36AnchorBolts

C. American Welding Society: 1. AWSD1.1-StructuralWeldingCode-Steel 2. AWSD1.4-StructuralWeldingCode-ReinforcingSteel 3. AWSD1.6–StructuralWeldingCode–StainlessSteel

D. Precast/Prestressed Concrete Institute: 1. PCIMNL-116-ManualforQualityControlforPlantsandProductionof

StructuralPrecastConcreteProducts 2. PCIMNL-120-PCIDesignHandbook-PrecastandPrestressedConcrete 3. PCIMNL-123-DesignandTypicalDetailsofConnectionsforPrecastand

PrestressedConcrete 4. PCIMNL-127–PCICommitteeReport–Erectors’ManualStandardsand

GuidelinesfortheErectionofPrecastConcreteProducts 5. PCIMNL135–TolerancesforPrecastandPrestressedConcreteConstruction

68 ParkIng Structure SPecIfIcatIonS The Shockey PrecaST GrouP, WincheSTer, Va • WWW.ShockeyPrecaST.coM

1.3 dEFInITIonS

A. Fabrication Drawings: Documentsusedbytheproductionfacilityto manufacturetheprecastcomponents.Sometimesreferredtoas“Shop Drawings.”Informationincluded: 1. Requireddimensionalinformation 2. Descriptionandlocationonallinserts,bearingplates,anchorsand

reinforcementmaterialsrequiredtomanufacture,transport,anderecttheprecastcomponent

3. Finishrequirementsforeachcomponent 4. Handling,storageandshippinginstructions 5. Providedasaninformationalsubmittalonly

B. Erection Drawings:Documentsprovidingtheassemblyplacementofprecast componentsonthejobsite.ErectionDrawingsarereviewedandsealedbya ProfessionalEngineer.Informationincluded: 1. Plansandelevationslocatinganddimensioningallprecastcomponents.

Eachprecastcomponentisindividuallyidentified. 2. Sectionsanddetailsshowingconnections,openings,blockouts,andcast-initems

andtheirrelationshiptothestructure. 3. Descriptionofalllooseandcast-inhardwareformakingconnections.

C. Construction Plan: Amanagementplanforthesequenceofassemblyoftheprecast componentsoftheproject.Thisplanincludes: 1. Accessplanforcraneandtransportofprecastcomponents. 2. Erectionsequencebyloadsbeingshipped. 3. Erectionblockplanoutliningthesequenceoferectionactivity. 4. Specificerectioncriteriarequiredfortheparticularproject. 5. Project-specificconstructionstabilityplanthatoutlinesanyadditionalerection bracingthatmayberequired. 6. Technicaldatasheetongroutusedfortheproject. 7. Erectiontolerancesfortheproject.

D. Field-Use Erection Drawings: Theerectiondrawingswithanymodificationsmade duringtheapprovalprocessthataredistributedpriortoactualerectionoftheproject.

E. Control Number:Auniqueidentificationofeachprecastcomponentforaproject.

F. Piece Mark:Acomponentidentificationofaprecastelementonaproject.Similar piecescanhavethesamePieceMarkbuteachwillhaveauniqueControlNumber.

G. CIP: Cast-in-Place Concrete

H. Architectural Features: Wherefinalappearanceorformofprecastcomponents requiretheuseofcoloredaggregate,pigmentedconcretemixorsurfacetexturessuch assandblasting,waterwash,etchedfinishesorthinbrick.


I. BIF:“Bottominform”indicatesthesurfaceofprecastthatwillbeinthebottomofthe formduringcasting.

J. SIF:“Sideinform”indicatesthesurfaceoftheprecastthatwillbeinthesideofthe formduringcastingbybuilt-uprails.

K. TIF:“Topinform”indicatesthetopexposedsurfaceduringcasting.

1.4 AdMInISTrATIVE rEQuIrEMEnTS

A. Coordination 1. CoordinatetheWorkofframingcomponentsnotpre-tensionedbutassociatedwith

theWorkofthissection. 2. Coordinatecutting,drillingorcoringinprecastmemberswiththemanufacturer. 3. Coordinateallprecastopeningorpenetrationgreaterthan10inchesinany

dimensionwiththemanufacturerpriortosubmittalofErectionDrawings.

B. Pre-installation meetings 1. Conveneminimumoneweekpriortocommencingtheonsiteworkofthissection. 2. Coordinatethesequenceofinstallationwithfoundationandsupportingelements

inplacewithprecastitemstobedelivered.

C. Site Survey:Provideasitesurveytoverifyfielddimensionsandtolerancesaminimum of2weekspriortodeliveryofprecastunitsforinstallation.

1.5 SuBMITTALS

A. Action Submittals:Provideforreviewandapproval. 1. ErectionDrawings:Indicatelayout,unitlocations,unitidentificationmarks,

connectiondetails,dimensions,openings,andrelationshiptoadjacentmaterialsandconformancewiththerequirementsoftheContractDocumentsandsealedbyprofessionalengineer.Providecoordinationinformationforitemsrequiredtobeembeddedinadjacentmaterials.

2. DesignCalculations:Submitdesigndatareportsindicatingcalculationsforloadingsandstressesoffabricatedprecastcomponents,connections,andreinforcement.CalculationsshallbepreparedbyProfessionalEngineerexperiencedinprecastconcretedesign.

3. Samples:Submitthreesamples12x12inch(304.8x304.8mm)insizeillustratingsurfacefinishtreatmentofarchitecturalfeaturedcomponent.

4. Mockup:ProvideaccesstoamockuppanelattheprecastmanufacturingplantforapprovalbytheArchitectforcolorandtexture.Theapprovedmockupshallbethecontrolstandardforcolorandtexture.

B. Informational Submittals 1. MixDesign:Providetheconcretedesignmixwithcertificationregarding

compliancewithrequirementsoftheContractDocuments. 2. FieldUseErectionDrawings:Submitfielduseerectiondrawingsincorporating

commentsfromapprovedErectionDrawings.


3. ConstructionPlan:Submitpriortothepre-installationmeeting,aconstructionplan,includingcalculationsanddetailsforguying,stayingandshoringprecastelementstoassurestructuralstabilityduringtheerectionphase.Providefortheremoval,replacement,andrelocationofguying,bracingandshoringrequireduntilallpermanentstructuralconnectionsarecompleted.

C. Closeout Submittals 1. ProvideManufacturer’sWarrantyletter.

1.6 QuALITY ASSurAncE

A. Perform Work in accordance with requirements of PCI MNL-116, PCI MNL-123, PCI MNL-120, PCI MNL 135.

B. Fire Rated Construction: Rating as indicated by construction type on contract documents.

C. Source Quality Performance Testing: Provide for tests for all precast concrete workinconformancewithPCIPlantCertificationrequirements.Usecertifiedtest equipment,andunlessotherwisespecified,conformwith: 1. ManualForQualityControlForPlantsandProductionofPrecastand

PrestressedConcreteProducts,PCIMNL-116(latestedition) 2. PCIDesignHandbook,LatestEdition. 3. ACI318fortheBuildingCodeRequirementsforReinforcedConcrete

(latestedition)

D. Mockup Control Sample Unit:Provideamockuppanelattheplant,4feetby4feet insize,forqualitycomparisonoffinishedunittoanapprovedappearancesamplefor colorandtexture.

E. The plant quality control records and inspection procedures for this project shall be available for review, verification and in-plant inspection by an independent testing agent or the Architect/Engineer.

1.7 QuALIFIcATIonS

A. Fabricator:CompanycertifiedbythePrestressedConcreteInstitute(PCI)Plant CertificationProgramwithanin-houseengineeringdepartmentmanagedbya registeredprofessionalengineer.

B. Precast Engineer: Designprecastconcretemembersunderdirectsupervision ofProfessionalEngineerexperiencedinprecastdesignandlicensedinthestateof theproject.

C. Erector: Companywithexperienceintheerectionofprecastunitssimilartothose requiredforthisprojectandshallbeaQualifiedorCertifiedErectorunderthePCI FieldCertificationProgram.

D. Welder: QualifiedinaccordancewithAWSD1.1,AWSD1.4,andAWSD1.6


1.8 dELIVErY, STorAGE, And HAndLInG

A. Lift and support precast concrete members during manufacturing, yarding, transporting and erection operations only from identified support points with suitable lifting and handling devices.

B. Lifting inserts will have a minimum safety factor of 4. Reusable lifting hardware and rigging will have a minimum safety factor of 5.

C. Lifting or Handling Devices: Capable of supporting member in positions anticipated during manufacture, storage, transportation, and erection.

D. Storage: 1. Protectmemberstopreventstaining,chipping,orspallingofconcrete.Store membersoffthegroundondunnagematerialsasrecommendedbyfabricator. 2. Placeallunitssothatidentificationmarksarereadable. 3. Stacksothatliftingdevicesareaccessibleandundamaged.

E. Mark each member with date of production, job number, control number, and piece mark referenced from Erection Drawings.

1.9 WArrAnTY

A. Provide Manufacturer’s Warranty for a 1-year period.

ProducTS2.1 FABrIcATorS

A. Fabricators: 1. TheShockeyPrecastGroup,WinchesterVirginia,Tel:(540)667-7700,

www.shockeyprecast.com.

2.2 dESIGn rEQuIrEMEnTS

A. General: Theproject,asshownonthedrawings,includingcomponentdimensionsandconnectionconfigurations,providestherequirementsforthedevelopmentofthedesigndocuments.Designshallincludeconsiderationforcustomarystressesincurredinfactoryprecasting,transporting,anderecting.Thedesign,manufacturing,transportationanderectionprocessshallbecompatiblewiththerequirementsoftheContractDocuments.

B. Design Criteria: 1. Designallledges,haunches,bearingareas,andconnectionsasrecommendedin

PCIDesignHandbook.Haunches,dappedendbearingsandconnectionswithoutredundantmeansofloadtransferareconsideredcritical.

2. MinimumreinforcingforallprecastprestressedconcreteandprecastreinforcedconcreteshallbeinaccordancewithACI318.Analysisofprestressedcomponentswillincludeacheckoftheshearreinforcingrequirementsat.1L,.2L,.25Land.3L,whereListhecomponentlength.


C. Modifications:Submitallproposedmodificationstotheprojectdesignsrepresented onthedrawingswithcompletedesigncalculationsanddrawings,preparedandsigned byalicensedprofessionalengineerforreviewandapproval.

D. Maximum Allowable Deflection:PerACI318-9.5-ControlofDeflections

E. Seismic Design: Design and detail elements and connections to resist seismic force in accordance with code requirements and ACI 318 for the following:

1. As specified by contract documents.

F. Design members exposed to weather to allow movement of components without damage, failure of joint seals, undue stress on fasteners or other detrimental effects, when subject to seasonal or cyclic day/night temperature ranges.

G. Design system to accommodate construction tolerances, deflection of other building structural members and clearances of intended openings.

H. Calculate structural properties of framing members in accordance with ACI 318.

2.3 MATErIALS

A. Concrete Materials:AsappropriatetodesignrequirementsandPCIMNL-116. 1. Cement:GrayPortland,conformingtoASTMC150TypeIorIII. 2. Cement:WhitePortland,conformingtoASTMC150TypeI

(forarchitecturalmixes). 3. FlyAshAdmixture:ASTMC618ClassCorF--25%maximum. 4. GroundGranulatedBlast-FurnaceSlag:ASTMC989Grade100or

120–40%maximum. 5. Aggregates:ASTMC33exceptasmodifiedbyPCIMNL116. 6. Air-entrainingadmixtures:ASTMC260 7. Water-reducing,Retarding,AcceleratingAdmixtures:ASTMC494 8. Pigments:Non-fading,lime-resistantpigments:ASTMC979

B. Concrete Mix Design: ACI318,Chapter5,usingstandarddeviationcalculationsinaccordancewithsection5.3.1.1or5.3.1.2. 1. Theconcretemixdesignswillconformtothefollowingrequirements: Structuralconcrete:Columns,Walls,Stairs,SpandrelBeams StrengthofConcrete–5000psiminimum Water-cementitiousmaterialsratio–maximum0.42 AirContent–5.5%+/-1.5%

Structuralconcrete:DoubleTees,Beams StrengthofConcrete–6000psiminimum Water-cementitiousmaterialsratio–maximum0.40 Aircontent–5.5%+/-1.5%

Self-ConsolidatingConcrete(SCC) StrengthofConcrete–6000psiminimum Water-cementitiousmaterialsratio–maximum0.38 Aircontent–5.5%+/-1.5%


Architecturalconcrete: StrengthofConcrete–5000psiminimum Water-cementitiousmaterialsratio–maximum0.44 Aircontent–5.5%+/-1.5%

C. Batching concrete: 1. TheconcretebatchingplantwillbeinconformancewithASTMC94andwillbe

certifiedbytheNationalReadyMixedConcreteAssociation.Volumetricbatchingofconcretewillnotbepermitted.Allmeasurementsofthevariouscomponentswillbebyweightandwillbeaccurate(withinthemostrecenttolerancelimitsofASTMC94).

2. Theuseofcalciumchlorideoradmixturescontainingchlorideionsorothersaltsisnotmorethan0.15%chlorideionsorothersaltsbyweightofadmixture.

2.4 rEInForcInG And connEcTIon MATErIALS

A. General:Provideallreinforcement,accessoryandconnectionmaterialsrequiredforacompleteinstallationasindicatedontheapproveddrawings.Pourstripreinforcementtobesuppliedandinstalledbyothersunlessspecified.ProvideGroutingasrequiredfordesignbearing.

B. Reinforcing Bars:ASTMA615,Grade60.ReinforcingusedtofabricateembeddedpartsorconnectionsbyweldingwillbeASTMA706.

C. Welded anchor studs:AWSD1.1

D. Prestressing Strand:ASTMA416,270,000psiminimumultimatestrength,uncoated,7-wire,lowrelaxation.

E. Anchor Bolts:ASTMF1554Grade36

F. Welded Wire Fabric:ASTMA185(plainsteel)orASTMA497(deformedsteel);inflatsheets;unfinished

G. Carbon Fiber Reinforcement:C-GRID®asmanufacturedbyChomarat

H. Tensioning Steel Tendons:ASTMA416/A416MGrade270Kofsufficientstrengthcommensuratewithmemberdesign.

I. Rod Anchor bars: Dayton/Superior High Strength Coil Rod, or approved equal.

J. Supports for Reinforcement for Exposed-to-View Concrete: CRSI Class 1,

plastic protected legs

2.5 AccESSorIES

A. Connecting and Supporting Devices: 1. ASTMA36/A36Mcarbonsteel,Plates,angles,itemscastintoconcrete[or]

[itemsconnectedtosteelframingmembers,]insertsconformingtoPCIMNL-123;hot-dipgalvanizedinaccordancewithASTMA153/A153M.SurfacesrequiringfieldweldingshallbeZRCpainted.


2. ASTMA666Type201LN,302or304stainlesssteel,Tee-to-Teeflange connectionsconformingtoPCIMNL-123. 3. AnchorBolts:ASTMF1554Grade36

B. Grout:Non-shrink,non-staining,minimumyieldstrengthof5,000psiat28days.

C. Bearing Pads: 1. StandardBearingPad:Rubberpadcomposedofhomogeneousblendof

ozone-resistantrubberelastomerandhighstrengthrandomsyntheticfibercords;Surfacehardnessof75ShoreAdurometer+/-5percent;Compression,8000psi;MASTICORDasmanufacturedbyJVIInc.orapprovedequal.

2. LaminatedFabric-rubberPads:Preformed,unusedsyntheticfibersandnewunvulcanizedrubber.Surfacehardnessof80ShoreAdurometer+/-10%.(Capralonorapprovedequal).

3. ExpansionBearingPads:Assembliesconsistingofloweranduppercomponents.Dynalonorapprovedequal.

a. Theuppercomponent:Anassemblyofasheetofstainless(14gageminimum)withaminimum2Bmillfinish.Sizedlargerthanthelowerelementbyaminimumof1/2inchineachdirection.

b. Thelowerelement:AnassemblyofaStandardBearingpad,withastainlesssteelsupportplateandabondedcontactlayerofPTFE(Teflon).

D. Shims:Steel,ASTMA36;orengineeredmultipolymerplasticmaterial,compressive strengthof8000psi;Korolath,oranapprovedequal.

E. Mechanical Splice for Future Expansion Column and Wall Reinforcing

Anchorage: Erico Lenton or NMB Splice Sleeve.

F. Double Tee Flange-to-Flange Shear Connectors:JVIVectorConnector,or approvedequal,manufacturedfromASTMA666Type201LNor304Lstainless steel,or,wherestainlesssteelisnotrequired,ASTMA36steelwithJ-Finish corrosionprotection.

G. Bolts, Nuts and Washers:ASTMA307High-strengthsteeltyperecommendedfor structuralsteeljoints;Corrosionresistantchromium-nickeltype.

H. Prime Paint: (ZRC) Zinc rich alkyd type coating.

2.6 FABrIcATIon

A. Fabrication procedure to conform to PCI MNL-116 and ACI 318.

B. Maintain plant records and quality control program during production of precast members. Make records available upon request.

C. Ensure reinforcing steel, anchors, inserts, plates, angles, and other cast-in items are embedded and located as indicated on erection drawings. Clean surfaces of all embedded items of rust, scale, grease, and foreign matter.

D. Hardware supplied by other trades shall be furnished to the fabricator fully assembled and tagged for location a minimum of 30 days prior to scheduled production.


E. Fabricate required openings with dimension larger than 10 inches (250 mm) in diameter or larger for rectangular openings as shown and approved on erection drawings. Provide openings in Tee stems for running electrical conduit as coordinated with approved shop drawings; and embed accessories provided by other Sections, at indicated locations.

F. Tension reinforcement tendons as required to achieve design load criteria.

G. Ends at Stressing Tendons:Coattheexposedendsofprestressingstrandsinallprestressedmemberswithabitumasticcoating;SonnebornHydrocide700orapprovedequal.Recessexteriorexposedtoviewendsoftendonsandpatchtomatchsurroundingsurface.

H. Weld steel fabrications in accordance with AWS D1.1. Weld reinforcing steel in accordance with AWS D1.4. Welding processes shall not reduce the cross-sectional area of the concrete reinforcement. Do not tack weld reinforcing. Paint all field welds with ZRC.

I. Mark each piece of precast concrete for identification and record the date of casting. Marks will be placed so the final appearance of the product is not impaired.

J. Provide free access by the Architect/Engineer to all parts of the manufacturing facility.

K. Minor patching in plant is acceptable, providing structural adequacy and appearance of units is not impaired.

2.7 FInISHES

A. Finish exposed-to-view architectural finish surfaces of precast concrete members to be uniform in color and appearance.

B. Cure members under similar conditions to develop required concrete quality, and minimize appearance blemishes including non-uniformity, staining, or surface cracking.

C. Patching where required, shall be accomplished by skilled craftsmen in such a manner that the structural adequacy is maintained and the appearance and durability are not impaired.

D. Provide finishes as indicated on the finishes schedule listed below.

Double Tees 1. TeeareasofCIPconcretetopping:Topsurfaceshallbetransverserakedto0.25”

depthminimumtoinsurebondoftopping 2. TeeareaswithoutCIPconcretetopping:Topsurfaceshallreceiveroughhorizontal

broomorswirlbroomfinishthatshallnotexceedadepthof0.25” 3. SIF,BIFandedges:Standardformfinish 4. Depressorholes:Shallbefilledwithnon-shrink,non-staininggrouttomatch

surroundingsurfaces


Inverted T-Beams 1. TopsurfacestoreceiveCIPtopping:Topsurfaceshallbetransverserakedto

0.25”depthminimumtoinsurebondoftopping 2. TopsurfacesnotreceivingCIPtopping:Topsurfaceshallreceiveroughbroom

finishthatshallnotexceedadepthof0.25”andthatshallbeperpendiculartothelengthofthebeam

3. SIF,BIFandedges:Standardformfinish

Columns 1. Fornon-architecturallyfinishedcolumns:SIFandBIFshallbestandardform

finish.TIFfinishshallbesteeltrowel 2. Forarchitecturallyfinishedcolumns:SIFandBIFsurfacesshallreceivefinishas

prescribedbyapprovedarchitecturalsample.TIFfinishshallbesteeltrowel

Spandrels 1. TIFsurface:Shallreceivealightbroomfinishthatshallnotexceedadepthof

0.125”andthatshallrunperpendiculartothelengthofthespandrel 2. SIFandBIFsurfaces:Standardformfinish 3. Forspandrelsthatrequirearchitecturalfinish:SIFandBIFwillreceivefinishas

prescribedbyapprovedarchitecturalsample

Walls 1. TIFsurface:Shallreceivealightbroomfinishnottoexceedadepthof0.125”ora

steeltrowelfinish 2. SIFandBIFsurfaces:Standardformfinish 3. Forwallsthatrequirearchitecturalfinish:SIF(whererequired)andBIFwill

receivefinishasprescribedbyapprovedarchitecturalsample

Stairs 1. Topsurfaceinfinalconstruction:Roughbroomfinishnottoexceedadepthof

0.25”orsandblastfinishtoprovidenon-slipsurface 2. SIFandBIFsurfaces:Standardformfinish

Flat Slabs 1. FlatslabareasofCIPconcretetopping:Topsurfaceshallbetransverserakedto

0.25”depthminimumtoinsurebondoftopping 2. FlatslabareaswithoutCIPconcretetopping:Topsurfaceshallreceiverough

broomfinishthatshallnotexceedadepthof0.25” 3. SIFandBIFsurfaces:Standardformfinish

2.8 FABrIcATIon ToLErAncES

A. Conform to PCI MNL-135 1. Exception:Doubleteelengths+1/4inches/-3/4inches

2.9 SourcE QuALITY conTroL And TESTS

A. Test and analyze concrete in accordance with PCI MNL-116.


EXEcuTIon3.1 EXAMInATIon

A. A minimum of 2 weeks prior to scheduled delivery of precast materials, verify supporting work and site conditions are ready to receive work and field measurements are as indicated on field use erection drawings.

B. General Contractor shall provide to fabricator verification that supporting structure has met or exceeded the design requirements of the precast system design as required by PCI guidelines and Contract Documents. Support requirements shall include but not be limited to:

1. FieldPlacedBearingWallsorFootings:Providetruelevelbearingsurfaceswithelevationsof+/-1/2inchunlessshownotherwiseontheDrawings.

2. Accurateplacementandalignmentofanchorbolts,plates,ordowelsinCIPcolumnfootings,beams,wallfootings,andotherfieldplacedsupportingelements.

3. CIPConcretesupportingstructurehasmetdesignstrengthrequirementsasspecified.

3.2 PrEPArATIonA. Preparesupportequipmentforerectionprocedure.

3.3 ErEcTIon

A. Install and secure precast units as shown on the Contract Documents and as indicated by the field erection drawings in conformance with PCI – MNL 127.

B. Erect members without damage to structural capacity, shape, or finish. Replace or repair damaged members.

C. Align and maintain uniform horizontal and vertical joints, as erection progresses.

D. Maintain temporary bracing in place until final support is provided.

E. Provide temporary lateral support to prevent bowing, twisting, or warping of members.

F. Adjust differential camber between precast members to tolerance before final attachment.

G. Secure units in place. Perform welding in accordance with AWS D1.1, and AWS D1.6 for stainless.

3.4 ErEcTIon ToLErAncES

A. Erect members level and plumb within allowable tolerances.

B. Conform to PCI MNL-135 and PCI MNL 127 – Tolerances for Precast and Prestressed Concrete Construction.

C. When members cannot be adjusted to conform to design or tolerance criteria, consult with Architect/Engineer. Execute modifications as directed by Architect/Engineer.


3.5 FIELd QuALITY conTroL

A. Welding: Inspect welds in accordance with AWS D1.1, AWS D1.4, and AWS D1.6 as appropriate.

3.6 ProTEcTIon oF InSTALLEd conSTrucTIon

A. Protect members from damage caused by field welding or erection operations.

B. Use non-combustible shields during welding operations to protect adjacent Work.

3.7 cLEAnInG

A. Clean weld marks, dirt, or blemishes from surface of exposed members.

B. Remove all debris and surplus materials associated with this scope of work from the premises.


GLoSSArYA

Abrasivenosing-anon-skidmetalunitwhichiscastintothenoseofaprecaststairpanel.

Addendum-asupplementtospecificationsorcontractdrawingsissuedpriortotheexecutionoftheconstructioncontract.

Admixture-amaterialotherthanwater,aggregates,andcementusedasaningredientofconcreteorgrouttoimpartspecialcharacteristics.

Admixture,airentraining–amaterialaddedtotheconcreteforthepurposeofentrainingminutebubblesofairintheconcreteduringmixingandthusimprovingthedurabilityofconcreteexposedtocyclicalfreezingandthawinginthepresenceofmoisture.

Aframe–anA-Shapedframeusedtosupportpanelsonflatbedtrucksduringshipping.

Aggregate–naturaloccurring,processedormanufacturedinorganicparticleswhicharemixedwithPortlandcementandwatertoproduceconcrete;normallycomprises60to80percentofthetotalvolumeofconcrete.

Aircraftcable–multi-strandsteelcable,inloopform,castinprecastpanelsforhandlingpurposes;cableismoreflexiblethanprestressingstrand.

Airentrainment–anincreaseintheamountofairinaconcretemixthroughtheuseofanair-entrainingadmixture(seeadmixture,airentraining);airentrainedconcretedisplaysincreasedworkabilityandcohesiveness.

Airpocket–pits(entrappedairorwaterbubbles)intheformfacesofapanelcausedbyimproperconsolidationorinadequatedraft.

Alignmentface–faceofawallpanelwhichistobesetinalignmentwiththefaceofadjacentpanels.

Anchor–(1)headedstuds,deformedstuds,straps,rebar,etc.weldedtosteelangelsorplatesandembeddedinconcreteforuseaspartofaconnection(2)anyitemcastintoorpre-affixedtothestructureforthepurposeofreceivingaconnection

Approval–acceptanceofthePrecaster’sdrawingsbytheArchitect,EngineerofRecord,andGeneralContractorindicatingthatallbuildingconditionsanddimensionsshownarecorrectandfinal.

Architecturalprecastconcrete–anyprecastconcreteunitofspecialoroccasionallystandardshapethatthroughapplicationorfinish,shape,color,ortexturecontributestothearchitecturalformandfinishedeffectofthestructure;unitsmaybestructuralordecorative,andmaybeconventionallyreinforcedorprestressed.

Assembly–asetofpartsarrangedintooneunit.

B

Backupmaterial–materialusedtolimitthedepthofthesealantinpaneljoints.

Backupmix–theconcretecastintothemoldasafillerbehindathinlayerofthemoreexpensivefacemix

Bagtie–thingagewireties(generallyNo.

16,15,or14gage)usedtofastenreinforcing

barstogetheratintersections.

Barchair–anon-corrosive,rigiddeviceusedtosupportand/orholdreinforcingbarsatagivendistancefromtheformfacebeforeandduringconcreting.

Baseplate–asteelplateanchoredtothebottomofaprecastunitforthepurposeoffastingittothefoundation.

Batch–theamountofconcreteproducedinonemixingoperation.

Beampocket–openinginaverticalmemberinwhichabeamistorest.

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Bearingarea-thesurfaceinsquareincheswhichcomesintocontactwithaverticalloadtransferringmember.

Bearingpad–apad,usuallyneoprene,

whichisplacedbetweenamemberanditssupport.

Bearingplate–asteel-orTeflon-coated

plateplacedbetweenamemberanditssupport.

Billofmaterials–materiallistforindividualproject

Bleedhole–aholdinaplateoranglewhichisprovidedsolelytoreleaseentrappedairorwaterduringconcreteplacingoperation.

Bleeding–aformofsegregationinwhichsomeofthewaterinamixrisestothesurfaceoffreshlyplacedconcrete;alsoknowaswatergain.

Blocking–theshimsrequiredtoleveland/orplumbaunitinitsproperposition.

Blockout–toformahole,orreducetheheightorwidthofapanelbyaffixingmaterialtotheform(spacewithinaforminwhichconcreteisnottobeplaced).

Bondbreaker–asubstanceplacedonamaterialtopercentitfrombondingtotheconcrete,orbetweenafacematerialsuchasnaturalstoneandconcretebackup.

Bowing–thedeflectionofaverticalpanelinasingleplane.

Bulkhead–averticalpartitionintheformblockingfreshconcretefromasectionoftheform;dividesacontinuouscastingbedintogivenunitlengths.

Bundling–placingseveralparallelelementsofreinforcementincontractwitheachother.

c

Camber–(1)theupwarddeflectionwhichoccursinprestressedconcreteelementsdue

tothenetbendingresultingfromstressingforcesandself-weight.Itspecificallydoesnotincludedimensionalinaccuraciesduetoerrorsinmanufacture,improperbearings,orotherdeficienciesinconstruction;(2)abuilt-inupwardcurvatureinsomeformsforprecastconcrete,otherthanprestressed,toavoiddeflectionunderloadtobelowadefinedlineoffinishedproduct.

Cast–toplaceconcrete(inplasticstate)intoaform.

Cast-in–catintegrallywithaconcreteunit;notstabbedinaftercasting.

Cast-in-place–concretewhichisplacedinthefield.

Caststone–precastconcretewhosefinishresemblesthatofcutorpolishedstone.

Caulking–anelastomericsealantusedtofillpaneljointsthussealingabuildingfromtheelements.

Chamfer–abeveledcorneroredgewhichisformedinconcreteworkbyplacingathree-corneredpieceofwood(cantstriporskewback)intheformcorner.

Chamferstrip–triangularorcuredinsertplacedinsidecornerofformtoproduceroundedorbeveledcorner;alsocalledfillet,cantstrip,skewback.

Clearance–thedistancebetweentwosurfaced.

Clearspan–thedistancebetweentheinsideedgesofthebearingsurfacesoftwosupportingmembers.

ColdJoint–ajointnecessitatedbyseveralcastingstagesbutdesignedandexecutedtoallowtheseparatecomponentstoappearandperformasonehomogeneousunit;termonlyapplieswhenthefirstcastingisallowedtohardenpriortoplacingthesecond.

Column–anelementusedprimarilytosupportaxialcompressiveloadsandwitha

heightatleastthreetimesitssmallestlateraldimension.

Columncover–aprecastpanelwhichcoversoneormoresidesofacolumnwhichwouldotherwisebeexposed.

Compositeconstruction–atypeofconstructionwhereinthefloorslabisfastenedtothebeamsinsuchamannerthattheyacttogetherasamoreefficientmemberincarryingliveloads.

Concrete–amixtureofportlandcement,fineaggregate,coarseaggregate,andwater.

Concrete,structurallightweight–concretethathasa28-daycompressivestrengthinexcessof2,500PSIandanair-dryunitweightoflessthan115PCF,;alightweightconcretewithoutnaturalsandistermedall-lightweightconcreteandlightweightconcreteinwhichallfineaggregateconsistsofnormalweightsandistermedsand-lightweightconcrete.

Concretecover–thecleardistancefromthefaceoftheconcretetothereinforcingsteel.

Consolidation–theuseofhandtools,vibrators,orfinishingmachinesduringthecastingprocesstoeliminatevoids,otherthanentrainedair,andtoprovideadenseconcrete,goodbondwithreinforcement,andasmoothsurface.

Coping–apanelwhichformsthetopofawallandsealsitformtheelements.

Corbel–steelorreinforcedconcretebracketwhichprotrudesfromacolumnorwallpaneltoprovidesupportforanothermemberortakesupportfromanadjacentpartofstructure.

Cornice–panelwhichfitsunderaceilingorprojectingroof.

Curtainwall–precastwallpanelswhichwheninplacemayformwindowframesandinterior/exteriorwallconstruction,butsupportnoloadsfrombuilding.

d

Deflection–thedistanceastructuralmembermovesfromitsnormalpositionwhensubjectedtoaload.

Draft–theslopeofconcretesurfaceinrelationtothedirectioninwhichtheprecastelementiswithdrawnfromthemold;itisprovidedtofacilitatestrippingwithaminimumofmoldbreakdown.

Drip–aprojectingfinorgrooveattheouteredgeofasill,projectinghorizontalwallelementorsoffit,designedtointerrupttheflowofrainwaterdownwardoverthewallorinwardacrossthesoffit;dripsarenormallyusedonlyonunitshavingsmoothorlightlyexposedfinish.

E

Elongation–inprestressedwork,thedifferencebetweenastrand’sinitiallengthanditslengthafterstressing.

Engineerofrecord-engineerwhocreatesoriginalbuildingdesignandisresponsibleforthedesign.

Erection–theplacingofprecastunitsintotheirrespectivepositionsinthestructure.

Expansionboltoranchor–anexpandabledevicemadeofmetalinsertedintoadrilledholeinhardenedconcretethatgripsconcretebywedgingactionwhenthenutorheadisrotated.

F

Fabrication–actualworkonreinforcingbarsorhardwaresuchascutting,bending,andassembly.

Face–thesurfaceofapanel.

Facemix–theconcreteattheexposedfaceofaconcreteunit;usedforspecificappearancereasons.

Falsejoint–scoringonthefaceofaprecastunit;usedforaestheticorweatheringpurposesandnormallymadetostimulateanactualjoint.



Fascia–theoutsidehorizontalpanelontheedgeofarooforoverhang.

Fenestration–thedesignandplacingofwindowsinabuilding.

Finish-treatmentortexturegiventoconcretesurfaces.

Form–atemporaryreceptaclewhichreceivesconcreteanddictatesaunit’sshape.Itcanbemadeofwoodorsteel,butrequiresnotpatternorpositive.

Formliner–moldedsheetwhichwhenaffixedtoaformgivesthepanelaspecialfinishtreatment;linersaremadeofrubber,plastic,wood,etc.

Formreleaseagent–asubstanceappliedtotheformsforthepurposeofpreventingbondbetweentheformandtheconcretecastinit.

G

Galvanize-tocoatwithrustresistantzincbyspraying,dipping,orelectrolyticdisposition.

Gradation–thesizingofgranularmaterials.Forconcretematerials,usuallyexpressedintermsofcumulativepercentageslargerorsmallerthaneachofaseriesofsieveopeningsorthepercentagesbetweencertainrangesofsieveopenings.

Grout–amortartypemixturewhichishandpackedorappliedunderpressureinsuchaconsistencyastoensurecompletefillingofallvoids.Theusualproportionsofagroutmixareone(1)partofcementtothree(3)partsofwell-gradedsandbyweightwithwatercontentadjustedsothatamassofgroutsqueezedinthehandremainsitsshape.

H

Hardware–acollectivetermappliedtoitemsusedinconnectingprecastunitsorattachingoraccommodatingadjacentmaterialsorequipment.Hardwareisnormallydividedintothreecategories:

Contractor’sHardware–itemstobeplacedonorinthestructureinordertoreceivetheprecastconcreteunits:e.g.,anchorbolts,angels,orplateswithsuitableanchors.

PlantHardware–itemstobeembeddedintheconcreteunitsthemselves,eitherforconnectionsandprecasterector’swork,orforothertrades,suchasmechanical,plumbing,glazing,miscellaneousiron,masonry,orroofingtrades.

ErectionHardware–allloosehardwarenecessaryfortheinstallationoftheprecastconcreteunits.

Honeycomb–acoarsestonyconcretesurfacewithvoidslackinginfines;someprobablecausesarecongestedreinforcement,narrowsection,insufficientfines,lossofmortar,andinadequateconsolidation.

I

Insert–aconnectingorhandlingdevicecastintoprecastunits.Insertsaremachineorcoil-threadedtoreceiveaboltorslottedtoreceiveabolthead.

J

Joint–Thespacebetweentwoadjacenterectedpanels.

k

Key–acontinuousorsemi-continuousslotinconcretetoreceivegrout,levelingblocks,ordowels.

L

Liftingdevice–anassemblyusedinhandlingorerectionofprecastpanels.

Liftpoint–predeterminedpointsfromwhichapanelistobelifted.

Loadbearing–supportingthedeadandliveloadofothermembers.

Load-bearingprecastunits–precastunitswhichformanintegralpartofthebuildingstructureandwhichareessentialtoitsstability.

M

MarkNumber–theindividualidentifyingmarkassignedtoeachprecastunitpredeterminingitspositioninthebuilding.

MasterMold–amoldwhichallowsamaximumnumberofcastsperproject;unitscastinsuchmoldsneednottobeidentical,providedthechangesintheunitscanbeaccomplishedsimplyaspre-engineeredmoldmodifications.

Matrix–theportionoftheconcretemixcontainingonlythecementandfineaggregates(sand).

Maximumsizeaggregate–aggregatewhoselargestparticlesizeispresentinsufficientquantitytoaffectthephysicalpropertiesonconcrete;generallydesignedbythesievesizeonwhichthemaximumamountpermittedtoberetainedis5or10percentbyweight.

Mitre–theedgeofapanelthathasbeenbeveledtoanangleotherthan90degrees.

Mockup–asectionofawallorotherassemblybuiltfullsize,ortoscale,forpurposesoftestingperformance,studyingconstructiondetails,orjudgingappearance.

Module–arepeatingorreoccurringdimensionordetail.

Mold–thecavityorsurfaceagainstwhichfreshconcreteiscasttogiveitadesiredshape;sometimesusedinterchangeablywithformbutmadeoffiberglassorconcrete;apatternorpositiveisbuiltfirstandthemoldisoverlayed.

Mortar–amixtureofcement,sand,andwater;whenusedinmasonryconstruction,themixturemaycontainmasonrycement,orportlandcementwithlimeorotheradmixtureswhichmayproducegreaterdegreesofplasticityand/ordurability.

Mullion–averticalprecastunitappearingbetweenwindowsand/ordoors.

Muntin–horizontalprecastappearingbetweenwindowsand/ordoors.

n

Nailer–abeveledwoodenstripcastintoaprecastpanelforthepurposeofnailingflashingorroofingtoit.Theuseofsuchmaterialinconcreteisnotrecommended.

Neoprene–asyntheticrubberbearingpad.

Normalweightconcrete–concreteforwhichdensityisnotacontrollingattributeandusuallyhavingunitweightsintherangeof135to160lbs.percubicfoot.

Nosing–aprojectionsuchasthatofthetreadofastairovertheriser.

o

Overhang–theprojectingareaofarooforupperstorybeyondthewallofthelowerpart.

P

Panel–anindividualprecastunit

Parapet–thatpartofthewallthatextendsabletheroofline.

Patch–torepairasuperficiallydamagedpanelbyfillingthedamagedareawithconcreteofmatchingcolorandtexture.

Pier–ashortcolumnusedasafoundationmemberinbuildingconstruction.

Pilaster–columnpartiallyorcompletelyembeddedinawall,oraportionofawallenlargedtoserveasacolumn.

Plate–asheetofmetalhavingathicknessof1/8inchorgreater.

Platewasher–aspecialwasherprefabricatedfromsteelplate.

Pouredinplace–(seecast-in-place)



Precastconcrete–aplainreinforcedorprestressedconcreteelementcastinotherthanitsfinalpositioninthestructure;precastconcretecanbearchitecturalorstructural.

Precastengineer–thestructuralengineerauthorizedbythemanufacturertoensuretheadequacyofthestructuralaspectsofthedrawings,manufacture,andinstallationforwhichthemanufacturerisresponsible.

Preliminary-notcompletelyfinalizedandreviewed.

Prestressedconcrete-concreteinwhichtherehavebeenintroducedinternalstressesofsuchmagnitudeanddistributionthatthestressesresultingfromloadsarecounteractedtoadesireddegree.

Prestressingbed-theplatformandabutmentsneededtosupporttheformsandmaintainthetendonsinastressedconditionduringplacingandcuringoftheconcrete.

Pretensioning–amethodofprestressingconcretewherebythetendonsareelongated,anchoredwhiletheconcreteinthememberiscast,andreleasedwhentheconcreteisstrongenoughtoreceivethestressesfromthetendonthroughbond.

Q

Quirkmitre–acornerformedbytwochamferedpanels.

r

Rebar–abbreviatedtermforreinforcingbar.

Reinforcedconcrete–concretecontainingreinforcement,includingprestressingsteel,anddesignedontheassumptionthatthetwomaterialsacttogetherinresistingforces.

Reinforcement–mesh,strand,orpost-tensioningcablesembeddedinconcreteandlocatedinsuchamannerthatthemetalandtheconcreteacttogetherinresistingloads.

Release–(1)thetimeatwhichtheprestressedstrandsareseveredpriorto

removingtheprestressedunitsfromtheforms;(2)submittalofdrawings;(3)strippingofprecastpanel

Releaseagent–(seeformreleaseagent)

Retarder–anadmixturewhichdelaysthesettingofcementpasteandthereforeofconcrete

Retarder,surface–amaterialusedtoretardorpreventthehardeningofthecementpasteonaconcretesurfacewithinatimeperiodandtoadepthtofacilitateremovalofthispasteaftertheconcreteelementisotherwisecured(amethodofproducingexposedaggregatefinish).

Return–aprojectionoflikecross-sectionwhichis90degreestoorsplayedfrommainfaceorplaneofview.

Reveal–(1)grooveinapanelfacegenerallyusedtocreateadesiredarchitecturaleffect;(2)theprojectionofthecoarseaggregatefromthematrixafterexposure.

Rib–(1)continuousverticalprojectiononawallpanelprojectingaminimumof6inchesfromthepanelface;(2)localthickeningprovidingstiffnessinconcretepanels.

Rustication–agrooveinapanelfaceforarchitecturalappearance;alsoreveal.

Rusticationstrip–astripofwoodorothermaterialattachedtoaformsurfacetoproduceagrooveorrusticationintheconcrete.

S

Sand-thatportionofanaggregatepassingtheNo.4(4.76mm)sieveandpredominantlyretainedontheNo.200(74micron)sieve.

Sandblast–asystemaabradingasurfacesuchasconcretebyastreamofsand,orotherabrasive,ejectedfromanozzleathighspeed,bywaterand/orcompressedair.

Sandwichwallpanel–panelconsistingoftwolayers(wythes)ofconcretefullyorpartlyseparatedbyalayerofinsulation;inemployingthisdetail,metalshearconnectorsareusuallyrequiredtotiethetwolayersofconcretetogether.

Sealants–agroupofmaterialsusedtosealjointsbetweenprecastconcreteunitsandbetweensuchunitsandadjacentmaterials.

Sealersorprotectivecoatings–materialsusedtocoastprecastconcreteunitsforthepurposeofimprovingresistancetowaterpenetrationorforimprovingweatheringqualities.

Section–cutawayviewthroughageneralplanorelevationviewtoexplaindetails.

Segregation–thetendencyforthecoarseparticlestoseparatefromthefinerparticlesinhandling;inconcrete,thecoarseaggregateanddriermaterialremainsbehindandthemortarandwettermaterialflowsahead;thisalsooccursinaverticaldirectionwhenwetconcreteisoverbibratedordroppedverticallyintotheforms,themortarandwettermaterialrisingtothetop;inaggregate,thecoarseparticlesrolltotheoutsideedgesofthestockpile.

Selfstressingforms–equipmentwhichinadditiontoservingasformsforconcretealsoaccommodatesthepre-tensionedstrands(orwires)andsustainsthetotalprestressingforcebysuitableendbulkheadsandsufficientcross-sectionalstrength.

Set-up–theprocessofpreparingmoldsorformsforcasting,includinglocatingmaterials(reinforcementandhardware)priortotheactualplacingofconcrete.

Slab–precastorprestressedfloororroofmembers.

Spandrel¬–thatpartofawallbetweentheheadofawindowandthesillofthewindowaboveit.(Anupturnedspandrelcontinuesabovetherooforfloorline.)

Spandrelbeam–beaminabuildingframe

whichextendsbetweenexteriorcolumnsatafloorlevel.

Specifications–thetypeorprinteddirectionsissuedbyarchitectstoestablishgeneralconditions.Standardsanddetailedinstructionswhichareusedwiththecontractdrawings;contractedterm,specs.

Stoneanchor–ananchorcommonlyusedtofastencutstoneunits;suchanchorsareseldomsuitableforuseinprecastconcreteattachment.

Stress–intensityofforceperunitarea.

Stripping–theprocessofremovingaprecastconcreteelementfromtheforminwhichitwascast.

Strongback–asteelorwoodenplatewhichisattachedtoapanelforthepurposeofaddingstiffnessduringhandling,shipping,and/orerection.

Structural–aunitwhichcarriesliveloadoranotherunit’sweight.

Submitted–presentedtothearchitect/engineerforreview.

Systemsbuilding–essentiallytheorderlycombinationof“parts”intoan“entity”suchassub-systemsortheentirebuilding;systemsbuildingmakesfulluseofindustrializedproduction,transportation,andassembly.

T

Temperaturereinforcement–reinforcementdistributedthroughouttheconcretetominimizecracksduetotemperaturechangesandconcreteshrinkage.

Tie–aclosedloopofsmallsizereinforcingbarsthatencirclelongitudinalbarsincolumnsandbeams.(seestirrup)

Tolerance–specifiedpermissiblevariationfromstatedrequirementssuchasdimensions,strength,andair-entrainment.

Topping–concretecastonerected



prestressedunitstoachievealevelfloorortoaidtheunitsinuniformlycarryingloads.

V

Vibration-energeticagitationofconcretetoassistinitsconsolidation,producedbymechanicaloscillatingdevicesatmoderatelyhighfrequencies;externalvibrationemploysadeviceattachedtotheformsandisparticularlyapplicabletothemanufactureofprecastitems;internalvibrationemploysanelementwhichcanbeinsertedintotheconcrete,andismoregenerallyusedforcast-in-placeconstruction.

W

Wallpanel–acomponentofaprefabricatedwallwhichderivesitsstrengthanddimensionalstabilityfromaprecastconcreteelement;thecomponentincludesanynonconcreteitemsincorporatedintheelementatthetimeofmanufacture.

Warping–thebowingofaprecastunitintwoplanes.

Weephole–aholeprovidedfordrainagethroughprecastpaneljoints

Weld–tojoinmetalsbyapplyingheatwithafillermetalwhichhasahighmeltingpoint.

Weldedwirefabric–areinforcingmaterialcomposedofcolddrawnsteelwiresfabricatedintoasheetconsistingoflongitudinalandtransversewiresarrangedatrightanglesandweldedtogetheratallpointsofintersection.

Weldplate–aplatewithattachedanchorscastintoconcreteforthepurposeofmakingaweldedconnection.

Workability–theeasewithwhichagivensetofmaterialscanbemixedintoconcreteandsubsequentlyhandled,transported,placed,andfinishedwithaminimumlossofhomogeneity.


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