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Construction
Introduction
Table 1: Benefits of hybrid concrete construction
Hybrid construction combines the most
Precast concrete Precast or in-situ In-situ concrete
appropriate materials and methods of construction. concrete
The search for greater economy, in terms of material
costs and reduced construction time, has resulted Economic for Inherent fire Economic for
repetitive elements resistance bespoke areas
in innovative approaches that seek to combine
construction materials and methods to optimum Long clear spans Durability Continuity
effect. Hybrid concrete construction (HCC) is one (structural efficiency)
such development that combines in-situ and
Speed of erection Sustainability Inherent robustness
precast concrete to maximise the benefits of both
forms of concrete construction. Buildability Acoustic Design flexibility
performance
Hybrid concrete construction embraces a number of different forms
High-quality finishes Thermal mass Services coordination
of structural frame, but in all cases precast concrete and cast in situ
and consistency of later in programme
concrete elements are used where they are most appropriate for the
colour
project. HCC produces simple, buildable and economic structures
which result in faster, safer construction and reduced costs. There are Accuracy Prestressing Locally sourced
many benefits of concrete which are shared by both precast and in- materials
situ concrete. Many of these are listed in Table 1 and described in the
Reduced propping Mouldability Short lead-in times
Benefits of Hybrid Concrete Construction section (page 3).
on site
Contents
Benefits of hybrid concrete construction 3
Hybrid options 8
References 15
The Ideas Store on Whitechapel Road, London is a hybrid precast and in-situ
concrete structure. The project, which was completed in 24 weeks, was a
combination of cast in situ beams and columns and precast ribbed soffits slabs
(as shown above). The designers deliberately exposed the concrete to provide a Cover images
high-quality visual interior finish, which also provides thermal mass efficiency. Main: Ideas Store, London, courtesy of Hanson
Courtesy of Adjaye Associates. Top inset: Homer Road courtesy of Foggo Associates
Bottom inset: West Quay Car Park, Southampton
This page: Ideas Store, courtesy of Adjaye Associates
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Hybrid Concrete Construction
Benefits of hybrid
concrete construction
Hybrid concrete construction produces simple, buildable and economic structures. It delivers increased
prefabrication, faster construction and consistent performance. HCC can achieve very significant cost savings
and can satisfy the requirements of the most demanding of clients.
Buildability Speed
The key advantage of HCC is its buildability. Because precast and cast in Speed of construction depends on designs which are easy to procure
situ concrete are used where most appropriate, construction becomes and construct. HCC takes a proportion of work away from the site
relatively simple and logical. The use of HCC encourages design and and into the factory, reducing the duration of operations critical to
construction decisions to be resolved at design stage. This means, for the building programme on site. The precast process takes place in a
example, that precast elements can be manufactured, stored at the controlled environment, unaffected by weather. Rigorous inspection
factory and delivered just-in-time to site. They can then be lifted from before installation removes causes of delay on site. Developments and
delivery truck to final position in a single crane movement, eliminating innovation in formwork systems and concrete technology mean that
the need for site storage and reducing crane hook time. in-situ elements of a HCC structure can also be completed within tight
programme constraints.
Traditional formwork typically accounts for 40 per cent of in-situ frame
costs and is dependent on weather and labour. The use of HCC means Some HCC techniques can reduce or eliminate following trades, e.g.
that a percentage of the frame is manufactured in a weather-proof installing ceilings and finishes. This enables even faster programme
factory, resulting in faster construction. times but requires greater co-ordination and care in detailing and
protection on site.
Cost
Although the structural frame of a building represents only 10 per Safety
cent of the total construction cost, the choice of material has dramatic A high proportion of hybrid concrete construction is carried out in the
consequences for subsequent processes. Hybrid construction can precast factory by experienced personnel. On site, the innovative use of
reduce frame costs by using precast concrete for the repetitive elements, HCC and the improved buildability helps ensure that each safety plan is
or to act as permanent formwork. In-situ concrete is more cost-effective prepared on the individual projects merits.
for large volumes (due to reduced transport costs) for tying the frame
together and for bespoke areas. Using the two together maximises the HCC can reduce the potential for accidents by providing successive work
cost efficiency. platforms and a tidier site. If precast spandrel beams are used they can
provide immediate edge protection.
Home Office Headquarters, London. The HCC frame was designed specifically for the project. This image shows the installation of the precast beams.
3
Hybrid Concrete Construction
and precast concrete resources under strict regulations ensuring the highest environmental
and social standards. Therefore the sector has been able to embrace
responsible sourcing and manufacturers have gained accreditation
at the highest level for their concrete products. This is recognised
in sustainability assessment methods, enabling designers to gain
Precast or in-situ concrete
maximum credits by choosing concrete.
Inherent fire resistance
Thermal mass
Durability
Buildings with concrete frames have embodied energy and CO2 of a
Sustainability similar order to equivalent buildings constructed from other materials.
For all buildings the operational energy consumption is far more
Acoustic performance significant than that during construction, but concrete buildings
utilising thermal mass can reduce this impact on the environment by
Thermal mass
moderating building temperatures, delaying the peak temperatures to
Prestressing later in the day and thus minimising the need for air-conditioning. Use
of thermal mass as part of passive solar designs can also reduce energy
Mouldability demands for heating during the winter, particularly in residential and
education sectors. Further information is available from the document
Low vibration characteristics
Utilisation of Thermal Mass in Non-Residential Buildings [3].
Fire resistance
Concrete has inherent fire resistance, which is present during all
Internal temperature Internal temperature External
construction phases, and is achieved without the application of with high thermal mass with low thermal mass temperature
additional treatments. The fire resistance is also maintenance free.
Concrete has the best European fire rating possible because it
Peak temperature Up to 6-8oC difference
does not burn and has low heat conductance. Further information delayed by up to between peak external
can be found in Concrete and Fire Safety [1] available from six hours and internal temperature
www.concretecentre.com/publications.
30oC
Durability
A well-detailed concrete frame is expected to have a long life and
require very little maintenance. It should easily be able to achieve a
60-year design life and, with careful attention to the specification of
the cover and concrete properties, should be able to achieve 100 years
even in aggressive environments. BS 8500 [2] is the British Standard for
durability and gives advice for various environments. 15oC
An award winning hybrid structure. Jubilee Library, Brighton. Courtesy of Bennetts Associates. For the full case study, see page 13.
4
Hybrid Concrete Construction
Acoustic performance
Concrete is a very good sound insulator, even when the source of
noise is an impact on the face of the concrete. For this reason concrete
floors and walls are often used in residential accommodation, including
flats, hotels and student residences, to prevent the passage of
sound between units.
Concrete can also be used to prevent the sound escaping into or out
of a building. A good example would be the use of concrete floors
beneath mechanical plant on the roof of a building to prevent the noise
penetrating to the habitable areas.
Prestressing
Prestressing concrete, using tensioned high-strength steel, reduces or
even eliminates tensile stresses and cracks. This gives rise to a range
of benefits that exceed those found in normally reinforced concrete
sections. Benefits include increased spans, stiffness and watertightness,
and reduced construction depths, self-weights and deflections.
Prestressing can be carried out before or after casting the concrete.
Tensioning the prestressing steel before casting (i.e. pre-tensioning)
tends to be carried out in factories e.g. in producing precast floor units.
Post-tensioning is more usually carried out on site using in-situ concrete.
Mouldability
Concrete can be formed into any shape and this can be achieved with
either precast or in-situ concrete. Concrete provides the opportunity to
create unusual shapes at a small cost premium. Repetition of elements
can make even complex shapes affordable for projects which are cost-
driven. This can be particularly beneficial if circular columns are required
for aesthetic reasons or where columns need to be contained in walls,
e.g. for apartments. Concrete can also be used for curved beams, unusual
plan shapes and shell structures. The layout of the vertical structure can
be arranged to suit the use of the building rather than having rigidly to
follow a structural grid.
V ibration control
For some types of buildings the control of vibrations induced by people
walking across the floor plate are important. This is particularly the case
for hospitals and laboratories containing sensitive equipment, but even
in offices long slender spans can vibrate excessively. The inherent mass
of concrete means that concrete floors generally meet vibration criteria
at no extra cost as they do not require additional stiffening. For more
stringent criteria, such as for laboratories or hospital operating theatres,
the additional cost to meet vibration criteria is small compared with
other structural materials.
Homer Road speculative office development showing the tapered edge of the
precast concrete perimeter unit. Courtesy of Foggo Associates. For the full case
study, see page 15.
5
Hybrid Concrete Construction
Benefits of precast concrete Acceptability of finishes and consistency of tone can be confirmed
prior to leaving the factory. A wide choice of precast concrete cladding
finishes and facings is available, including:
Accuracy Accuracy
Reduced propping on site Precast elements are cast to close tolerances, and checked in the factory
before delivery to site.
Reduced skilled labour on site
Reduced propping on site
Depending on the type of element used, there may be no temporary
Economic for repetitive elements propping or minimal propping required. This increases productivity and
Using precast elements reduces requirements for falsework; this saves reduces the temporary works.
cost through reduced resources and by shortening the programme.
There is also less reliance on wet trades, which can be delayed by Reduced skilled labour on site
unfavourable weather conditions. However, to maximise economy The production of precast concrete takes place in a factory environment,
the mould created to cast the concrete should be re-used as much removing labour requirements from site. The factory work is carried out
as possible, thus precast concrete is most economic where repetition in an internal environment at safe working heights.
is maximised. Repetition does not mean the finished building will be
uninspiring; designers can produce aesthetically pleasing designs by
innovative use of repeat elements.
Speed of erection
Speed of erection and tight construction programmes are primary
considerations in many building projects. To maximise the speed of
construction with precast elements two critical factors should be taken
into consideration:
Buildability
Precast elements are designed by specialist precast concrete designers.
Within their design they consider the erection sequence and process so
that the elements are engineered to be constructed easily. This planning
makes the frame highly buildable.
6
Hybrid Concrete Construction
The average distance from a concrete plant to any building site in the UK is 8km, providing a sustainable solution to transportation.
7
Hybrid Concrete Construction
Hybrid options
The ideal combination of precast and in-situ concrete is influenced by project requirements. There is a wide
range of possible options, a selection of which is presented here as representative of current UK practice. It is
not intended to be an exhaustive list.
Ease of Minimises Suitability for Clear spans Deflection Minimise Hybrid Soffit
Final version
Maximises Temporary
services storey holes control materials can be off-site works
Owen Brooker
27.11.08
Type 1
Type 2
Type 3
Type 4
Type 5
Type 6
8
Hybrid Concrete Construction
Precast twin wall and Potential structural uses of the twin wall system include:
Cellular type structures for residential use
in-situ concrete
Retaining walls; this has significant implications for the design
Single sided formwork situations, where there is no access to
one side of the wall to erect formwork, for example wall
Hybrid concrete wall panels are increasingly being specified on projects construction on a party wall line against neighbouring buildings.
throughout the UK and are often known as twin wall. They comprise
two skins of precast concrete connected by steel lattices, which are filled The major advantage is that it is an in-situ structure, fully continuous
with in-situ concrete on site. and tied together, but without the need for shuttering on site. Twin wall
can also be cast with fully trimmed openings and with ducts for cables
The external skins of the twin wall system are factory made, typically and other services.
using steel moulds. This results in a high-quality finish. The panel surface
quality is suitable to receive a plaster finish or wallpaper. The panel Advantages:
surface is not normally appropriate for visual concrete. Joints either have
Quality finish for walls and soffits enabling use of thermal mass
to be expressed as a feature of the finish, or concealed. This type of HCC
No formwork for vertical structure and horizontal structure
offers advantages to the contractor in terms of speed of construction,
when lattice girder slabs are used
as well as reducing the number of skilled site staff required to construct
Structural connection between wall and slabs relies on in-situ
walls. Often the twin wall system is combined with the use of lattice
reinforced concrete detail and is inherently robust
girder precast soffit slabs, with or without spherical void formers (Type
Reduced propping
6, shown on page 8). These provide permanent shuttering for an in-
situ slab that can be relatively easily combined with the wall system.
Disadvantages:
Spans of up to 8m are common and spans up to 14m are possible. (The
manufacturer should be consulted early on to ensure the longer spans Propping of lattice girder slabs is required prior to sufficient
are viable.) strength gain of in-situ concrete
The smaller dimension of the precast units is typically a maximum
of 3.6m, so joints in walls and soffits must be dealt with (expressed
or concealed)
Reduced flexibility of layout as this option requires walls rather
than columns.
One Coleman Street, London. Inset: Off loading twin wall units. Courtesy of John Doyle Construction.
9
Hybrid Concrete Construction
Precast column and floor elements, which are tied together with an in-situ structural topping.
The column formwork can be designed as a temporary support for
units with in-situ beams the precast beams and slabs to reduce the requirement for propping
of the precast floor. The joint between the beam and columns and any
structural screed is concreted with the columns to form a monolithic,
This form of construction allows a high proportion of the structure to be robust structure.
manufactured in quality controlled factory conditions off site leading to
fast construction on site. This system requires particular attention to the connection details
between the precast beam and floor units. It should be ensured that
A variety of precast floor products could be used with this type adequate structural ties are provided to achieve a robust structure.
of construction, including hollowcore units, double tees, lattice
girder slabs (with or without spherical void formers) or bespoke Advantages:
coffered floor units. The latter have successfully been used in
Precast floor structure can be erected quickly
high quality buildings designed for energy efficiency, where the
Precast beams support precast floor units, minimising floor
lighting, architectural features and cooling systems have all been
propping
incorporated into the unit.
Precast quality finish for soffits (although this is not always
possible with hollowcore units)
Advantages:
Formwork for in-situ columns can be used to prop
Vertical structure can be erected quickly; no formwork required precast beams
Precast floor structure can be erected quickly; no Structural connection between precast elements is via
formwork required standard reinforced concrete
Quality finish for columns and soffits (although this is not always In-situ structural topping to beam permits beams to be
possible with hollowcore units) continuous over columns
Structural connection between precast elements is via standard
reinforced or post-tensioned concrete Disadvantages:
Downstand beams need to be coordinated with the services
Disadvantages: distribution
Precast flooring must be temporarily propped
Sealing between precast units is required
10
Hybrid Concrete Construction
A
Safety
produced soffits provides the opportunity to take advantage of the Level +2 Concreting (column & stitch)
Precast beam
3
thermal mass properties of the concrete slab by exposing them. Concreting (column & stitch) Reinforcement
A A A
3
Concreting Propping& stitch)
(column Safety Reinforcement
Level +2 3 Precast
4 beam
Safety Reinforcement
Advantages: Level +2 Steel Precast beam
Safety
Level +2 formwork Propping
Precast beam
Precast floor structure can be erected quickly; no formwork Level +1 4
Propping
Steel 4
required Propping
A
formwork
Steel 4
Structural connection between precast elements is via Level +1 formwork
Steel
Level +1 formwork
standard reinforced concrete
A A A
Level +1
Quality finish for soffits
More flexible for late changes Stage 2:
Cast in situ columns poured to the top of the precast beams:
Disadvantages: stitching together the beam/column joint.
PLACING HOLLOWCORE PLANKS
Precast flooring must be temporarily propped
PLACING HOLLOWCORE PLANKS
Lifting
PLACING HOLLOWCORE PLANKS Hollowcore
PLACING HOLLOWCORE PLANKS 5
Level +2 Lifting
Hollowcore
Lifting 5
4 Propping Hollowcore
Props Lifting 5
Level +2 Hollowcore
5
Level +2
Level +2 4 Propping
Props
Level +1 4 Propping
Props
4 Propping
Props
Level +1
Level +1
Level +1
Stage 3:
Hollowcore slabs placed between the beams.
POURING TOPPING
Concreting
POURING TOPPING Topping
Finishing
POURING TOPPING 7 Concreting 6 Slab Reinforcement
POURING TOPPING
Concreting
Level +2Finishing Topping
Concreting
7
Topping 6 Slab Reinforcement
Finishing
Finishing 7
Topping 6 Slab Reinforcement
Level +2 7
FREE AREA 6 Slab Reinforcement
Level +2
Level +2
Level +1 FREE AREA
FREE AREA
FREE AREA
Level +1
Level +1 Stage 4:
Level +1
Slabs topped with 50mm cast in situ concrete to achieve
a monolithic structural unit.
The Home Office headquarters hybrid concrete structure was constructed using
Spherical void formers the above four stage sequence.
11
Hybrid Concrete Construction
Inland Revenue, Nottingham, interior of building. The design fully exploited the potential of precast concrete and prefabrication of other major structural elements to achieve
real buildability. Image: Martine Hamilton-Knight/Built Vision.
12
Hybrid Concrete Construction
Construction
The building consists of four storeys, with reading rooms, meeting rooms
and staff accommodation situated either side of a central, double-height
atrium, itself built on two floors. The central space was constructed using
an in-situ concrete slab supported by a series of eight tree-like
in-situ concrete columns with fins. The thermal mass of the concrete
assists with moderating the temperature fluctuations within the building.
Project team:
Architect: Bennetts Associates with Lomax, Cassidy and Edwards Architects
Structural engineer: SKM Anthony Hunt
Contractor: Llewellyn
Concrete frame contractor: Gallaghers
13
Hybrid Concrete Construction
The use of precast lattice girder slabs gave a safe working platform for
What HCC brought to the project
fixing reinforcement and pouring the topping concrete. The lattice girder
slabs also reduced the falsework and propping requirements allowing the The use of HCC allowed the project to be completed on time and within
bathroom pods to be lifted into position before placing the floor above. budget, with a remarkable lack of interface problems. In particular the
advantages of precast concrete double-tee floor slabs were fully realised;
Overall, compared to other construction methods, the site was cleaner they proved to be a positive way to create large areas of floor very
and there was less construction noise. quickly, whilst maintaining a high quality finish.
Project team
Project team Architect: BDP
Architect: Jestico & Whites Structural engineer: Pell Frischmann
Structural engineer: Adams Kara Taylor D & B contractor: Sir Robert McAlpine
Cost consultant: EC Harris D & B engineer: Sir Robert McAlpine Design Group
Construction manager: Bovis Lend Lease Precast floors: Tarmac
Concrete frame contractor: John Doyle Construction Precast concrete cladding: The Marble Mosaic Company
14
Hybrid Concrete Construction
Construction
The hybrid concrete structure consists of 430mm diameter precast
columns and precast floor units connected together by means of cast
in situ concrete spine beams. Each floor unit takes the form of a double
tee-section with end plates to each trough. At each column connection
the end plates are cast with a curved cut-out to follow part of the
column profile.
Once the precast columns were fixed on site, the double tee-section
floor units were connected to them, positioned so that the curved edge
profiles trimmed the outer edge of the columns. The cast in situ concrete
spine beam was then cast between two rows of end plates, stitching
lower and upper columns and adjacent units together. Between the
longitudinal joints, loop connectors were cast into the units and a
continuous cast in situ beam joined the units together. The floor units
are self-finished and no screed or topping was required.
References
1. THE CONCRETE CENTRE. Concrete and Fire Safety. The Concrete Centre, 2008.
2. BRITISH STANDARDS INSTITUTION. BS 8500 Concrete Complementary British Standard to BS EN 206-1. BSI, 2006.
3. THE CONCRETE CENTRE, Utilisation of Thermal Mass in Non-Residential Buildings, TCC, 2007
4. ARUP. Hospital floor vibration study. Comparison of possible floor structures with respect to NHS vibration criteria . Research Report, Arup, 2004.
5. THE CONCRETE CENTRE. Precast Concrete in Buildings. The Concrete Centre, 2007.
6. BROOKER, O. How to Design Concrete Buildings to Satisfy Disproportionate Collapse Requirements. The Concrete Centre, 2009.
7. WHITTLE, R & TAYLOR, H. Design of Hybrid Concrete Buildings. The Concrete Centre, 2009.
8. GOODCHILD, C H, WEBSTER & R M, ELLIOTT, K S. Economic Concrete Frame Elements. The Concrete Centre, 2009.
9. BROOKER, O. Concrete Buildings Scheme Design Manual. The Concrete Centre, 2009.
10. GOODCHILD, C H & GLASS, J. Best Practice Guidance for Hybrid Concrete Construction, The Concrete Centre 2004.
15
The Concrete Centre,
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Station Approach, Blackwater,
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Ref. TCC/03/53
ISBN 978-1-904818-75-5
First published 2010
MPA - The Concrete Centre 2010
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www.concretecentre.com
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