Delta Corporation

• Located at 218 Campersic Rd Herne Hill

• Est. 1966 - 50 years of experience in Precast
• Manufacturer of Precast & Prestressed Concrete
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Products
• Expertise in Architectural & Structural Precast
Concrete
• Modern company, old fashioned values
• Focus on Safety, Performance & Quality

safety
performance
quality
 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Concrete

Concrete according to Google

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast Concrete

Precast Concrete according to Google

safety
performance
quality
 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
What is Precast Concrete?

AS3850 : Prefabricated Concrete Elements

1.4.38 Precast element – A prefabricated concrete element
1.4.39 Prefabricated concrete element – A concrete element manufactured
at a place different from its final place of installation.

C1:4.39 Prefabricated elements may be manufactured on or off site, and

essentially include all concrete elements that are not cast in situ.
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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
What is Precast Concrete?

Effectively, precast concrete gives engineers an alternative to traditional in situ

poured concrete which results in some kind of advantage whether it be cost,
quality, safety, practicality etc.
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 What is Precast Concrete?
• Not all precast is the same!
• Massive variance in terms of
shapes, finishes and especially
quality
DELTA CORPORATION

• Tilt up wall panels onsite is not

PRECAST CONCRETE SPECIALISTS

the same as precast off site

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quality
 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast concrete projects

Curtin University 216

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast concrete projects

Curtin University 216

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
What is Precast Concrete?

safety
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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast concrete projects

Hale School

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast concrete projects

UWA IOMRC

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast concrete projects

UWA IOMRC

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast concrete projects

CIT Building

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Precast concrete projects

CIT Building

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 The Precast Concrete Process
Concept
The Conceptual Stage
First involvement with the architect in early 2013
Initially concerned with finishes and colour options
Moved on to design – how can we do this?
DELTA CORPORATION

Tender early 2014

PRECAST CONCRETE SPECIALISTS

Contract negotiations and alternatives

Samples
Contract award August 2014
Program finish February 2015

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 The Precast Concrete Process
Precast requires significant pre planning if it is to be done
properly
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Parties Involved include:

End client
Builder
Architect
Engineer
Precaster
Shop drawings drafter
Lifting design engineer
Temporary works engineer
Erection design engineer
Transport company
The installer
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 The Concept

Irregular shaped “statement” building

DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Curves and cantilevers

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 The Concept
Curved sun louvre panels
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Cantilevering beams

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 The Concept

“Spotless white” concrete facade

DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Large open spaces

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 DELTA CORPORATION

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PRECAST CONCRETE SPECIALISTS

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The Plan
 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The Plan

Columns – both a structural and architectural element

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The Plan

Huge cantilevered beams – both a structural and architectural element

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The Plan

…and more beams!

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The Plan

The irregular façade

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The Plan

Multiple panel types

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
Complex element shapes

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 Complex element shapes
Going for the Alphabet – 24 Panel Shapes from A to X
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

High Quality mixed finishes

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Shop Drawings – 517 No. in total

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 The process
High quality architectural finish

Both an architectural and

structural element
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Complex shape

Orientation of pour critical to

achieve finishes

Stripping of units without

damage critical

Bespoke composite moulding

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Heavily congested
reinforcement

Concrete mix design critical

Difficult to anticipate potential

clashes and other issues

Heavily reinforced beam

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Congestion, criticality of placing

fittings in the right locations and
appropriate positioning of lifters
increase the degree of difficulty

Cast in items have to be fitted into position

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

The finished beam

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Columns – note the remote grout tube fillers

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Stage 1 : Pour honed louvre section on custom steel moulds

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Off form finish of honed louvre section

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Stage 2 : Honing of the louvre section

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 The process
Note the expressed joint

Class 1 off form finish

DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Storage and handling critical

The finished product – form face

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 The process
Shorter louvres orientated vertically

Lifting arrangements
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Extent of honed finish

Grout tubes and connection inserts

The finished product – honed face

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The process

Unit orientated for delivery

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The reality

Hammerhead and tapered columns installed

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 DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS
The reality

Cantilevered beam and wall panels installed

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 DELTA CORPORATION

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The reality
 DELTA CORPORATION

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The reality
 What makes Precast concrete different?
Quality Control
Quality Control systems
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Work Method statements

Everything is checked

Documented

Records provided to the client as evidence

Records retained

Ensures the product is made in accordance

with the specifications and the design details

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 What makes Precast concrete different?
The Concrete
The concrete used in QUALITY precast is different from what you get on-site
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Made in the factory with strictly controlled low water / cement ratios

High levels of cement to ensure early age strength development

Use of admixtures to make the concrete workable

Results in significant strength gains over “bog standard” N Class concrete

Tested prior to removal from the moulds

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 What makes Precast concrete different?
Specification – 50MPa

1 Day ( 16 hours) 45MPa

DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

7 Day 72MPa
28 Day 89 MPa

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 What makes Precast concrete different?

Safety
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

The production process is planned well in advance

Multiple checks carried out throughout the production process

Everything is tested – before it leaves the factory

Everything is handled, multiple times, prior to delivery to site

Full traceability

Legislation framework and best practice result in higher safety standards

Significantly removes/reduces on-site construction risks

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 What makes Precast concrete different?

The flexibility
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Ability to produce just about any shape

The availability of high quality finishes difficult to achieve with insitu

Architectural and Engineering design freedom – not unlimited but able to be

innovative

Not on the critical path and subject to onsite construction issues

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 What does it mean for engineers?
The buck does stop with engineers

A massive responsibility – when you put your name to something it means your
signing off on the design. It’s on you!
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

Work with reputable companies and people you can trust

Be demanding but be fair and reasonable

Question and be prepared to be questioned

Don’t work in isolation – don’t do all the hard work yourself - get help from the
industry.

Make sure your design works – it is a requirement!

Precast properly designed and executed can result in significant time and
therefore cost benefits. Quite often, precast is selected because you just can’t do
it going insitu
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 More info?
Google it!
DELTA CORPORATION
PRECAST CONCRETE SPECIALISTS

AS3850 Prefabricated concrete elements

National Precast Concrete Association of Australia

Precast Concrete Handbook

www.deltacorp.com.au

Concrete Institute of Australia

Cement, Concrete and Aggregates Australia

Engineers Australia

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