The Total Solution for the Structural Engineer

TOTAL PRECAST CONCRETE STRUCTURES SERIES - ARTICLE 4

Structural engineers report no difficulty in learning to design with total precast concrete systems.  They also benefit from the material’s ease of use and efficiency.

Lateral design flexibility:  Combining architecture and structure provides efficiencies in many buildings’ lateral support systems.  External elements, typically cladding-on-steel or concrete-framing systems, can become laterally stiff and resist wind and earthquake forces.  Parallel efforts by the precast engineer can provide the structural engineer with specific input ahead of final construction document preparation, limiting shop-drawing review effort and redesign.

All-in-one components:  Total precast concrete systems allow the architectural panels to serve structural functions, limiting the need to incorporate multiple materials and trades.  For instance, spandrel panels support floor systems and windows while providing final exterior finishes.  Or sill panels are used as grade beams, retain soil, support windows and provide the architectural exterior finish, avoiding complex cladding systems.  Combining exterior spandrels into the structural system provides deeper elements, limiting deflections and the complexities of designing for relative movements between frame and cladding system.  Precast cores support floor systems while providing secure and fire rated enclosures for elevators and stair functions.

Comprehensive drawing:  A total precast concrete system ensures one-stop shopping for the core/shell design.  One source can design and supply the entire system, generating a better coordinated set of drawings that allows construction to proceed more efficiently.  It eliminates the added effort needed to coordinate various trades when using mixed systems controlled by different supplies.

Easy handling:  Site construction moves smoothly because no special equipment or techniques are required to transport or lift combined structural and architectural components.  These types of activities often can require additional structural review and exposure.

Concrete systems mean success.  The benefits offered by total precast concrete systems accrue to the owner, architect, general contractor and structural engineer’s bottom lines – and ultimately benefit the end user.  The system provides an efficient design, cost effectiveness and a strong, durable appearance that will maintain its image throughout a long service life.

Key Benefits:

• Speed to market

• Design flexibility

• Aesthetic versatility

• High quality

• Low maintenance

• Environmentally friendly

• Strong engineering support

• Single-source supplier

-  Information courtesy of PCI.

The Total Solution for the General Contractor

TOTAL PRECAST CONCRETE STRUCTURE SERIES - ARTICLE 3

General contractors find precast concrete components make their job easier at the site, ensuring a smooth process for the owner and designer in both the short and long terms.

Construction speed:  Time is money for the entire construction team.  Precast concrete’s speed through design, fabrication and erection help meet tight deadlines.  This particularly aids contractors when permitting processes slow down or unforeseen delays arise at the site due to soil conditions or other factors.  Precast structural systems are ready to be erected when the contractor is prepared.

All-weather construction:  Contractors can minimize the added “cushion” created in schedule to accommodate bad weather conditions, since precast components can be produced and erected all year round.  The roughened surface of precast components does not become slick or difficult to handle in harsh weather as other building materials can.

Foundation aid:  Total precast systems can minimize foundation work by having sills designed as grade beams and basement walls and core walls designed as precast panels.  The components can be fabricated in advance and laid into place as soon as the site is ready.

Fireproofing:  This messy, time-consuming job can be eliminated, along with the need to patch and rework after other trades finish at the project’s later stages.  Precast members are naturally fire protected, because they will not burn.

Smooth erection process:  Because precast concrete pieces are fabricated in controlled conditions using high-quality procedures, design more exactly meets specifications.  Field adjustments thereby are reduced, creating a smooth erection process with minimal surprises.

Concrete systems mean success.  The benefits offered by total precast concrete systems accrue to the owner, architect, general contractor and structural engineer’s bottom lines – and ultimately benefit the end user.  The system provides an efficient design, cost effectiveness and a strong, durable appearance that will maintain its image throughout a long service life.

Key Benefits:

• Speed to market

• Design flexibility

• Aesthetic versatility

• High quality

• Low maintenance

• Environmentally friendly

• Strong engineering support

• Single-source supplier

-  Information courtesy of PCI.

Forklift and Crane Operator Training

Mid-States own Jeremy Ceballos and Jeff Morris recently became certified forklift and crane operator trainers.

The two went through training in December and January with Wisconsin Lift Truck and Konecranes to become certified.  On Jan. 21, the duo conducted training for the Mid-States team.  Fifteen people participated in forklift training and 11 took crane training, to meet the needs of the plant.  Once Ceballos or Morris certify someone, the certification is effective for three years.  Those that have been certified will need to undergo a recertification class to stay current.

At the Jan. 21 training, the team divided up the training and each taught separate sections.  Training included about five classroom hours and two practical hours.  Those that took the class had to pass a written exam and a practical exam to become certified.

Ceballos and Morris feel the weight of the responsibility of training.  Morris noted that there is definitely a pressure associated with training, as if a team member doesn’t understand something, it is on the trainers to do better.

As it was their first session, there were a couple learning experiences to be had.  For example, there was an individual who was struggling to pass the written test.  Upon talking to him, the trainers realized there was a language barrier. Once this individual was provided with a translator, he passed.  There was also one question on the exam that every person in the class missed.  The trainers looked at it and acknowledged it was a difficult question, but knew they needed to explain the concept in another way, to help people better understand it.

With the two certified as trainers, the goal is to put a schedule together for certification and re-certification, to help Mid-States stay ahead of expiration dates.  The two are responsible for the continuing certification of roughly 100 people and will provide both classroom and practical training for recertification.

Ceballos added it is beneficial to have the two of them teaching these classes, as they are also out on the floor, running cranes and forklifts as needed.  Plus, now that they have gone through training and have provided training, they are spotting things they didn’t before and can offer coaching right on the floor.

Our Safest Year Yet

Mid-States Concrete set a new record in 2016.

Last year was our safest year yet, with only seven recordable injuries.  And of those seven, Mike Wolff, Vice President of Safety and Plant Operations, said most were relatively minor.  Our previous safest year had 13 recordable injuries.  Generally, our yearly recordables have fallen somewhere in the teens.

In 2016, we had zero recordables in the Field and in Cage Tie.  Elematic had just three recordable injuries, Wetcast had two, the Yard had one and Maintenance had one.

Wolff said the decrease in injuries can be attributed to a few things.  Much of it has to do with the safety culture at Mid-States.  The company puts safety above all else.  Wolff credited the team for an incredible year though.  He said the team looks out for each other and everyone reported near misses, which help prevent future injuries.

“It truly shows our employee involvement in safety,” Wolff said.  “The team is engaged on a daily basis.”

Mid-States has a Field Safety Committee, as well as a Plant Safety Committee, and regularly conducts a night shift audit, to make sure proper safety protocol is being used.  In addition, all of our foremen are 30-hour OSHA certified.  Our entire field crew is also 30-hour OSHA certified.  The team is also regularly coached on the biggest reasons for injury:  complacency, fatigue, rushing and frustration.

“It’s about people caring for other people,” Wolff said.

With the dedication of the entire team, hopefully Mid-States can break its own record in 2017.

The Total Solution for the Architect

TOTAL PRECAST CONCRETE STRUCTURES SERIES – ARTICLE 2

In addition to helping meet all of the building owner’s goals, total precast concrete systems provide specific advantages to architects that make the design process smoother.

Interior design flexibility:  Precast concrete systems help building owners adapt to changing client needs through the years.  Double-tee spans of 45 to 50 feet match typical composite-steel framing and minimize the need for interior columns required with cast-in-place systems.  Precast spans can reach as much as 70 feet, providing flexibility for challenging interior requirements.  Precast also provides high floor-loading capability with little added cost.

Efficient design:  Working in parallel with the precaster can provide early and precise design aid that ensures the most efficient sizes and shapes for components, which minimizes the budget for casting, transporting and erecting pieces.  Component repetition reduces form costs and aids design speed while retaining design flexibility.  These cost efficiencies free up more of the budget for other critical design areas.

Aesthetic variety:  Innovative precasters continue to develop mixes, tints, insets, finishes and multi-color pours, providing an almost endless range of aesthetic options.  Virtually any desired appearance can be achieved.  The options include natural stone replication, inset brick, multi-color panels, multi-surface textures and special logo, emblem or signage embedments.

Strong finish-approval process:  Precasters can provide finish samples, range samples and large-scale mockups, ensuring that design concepts translate into reality.  Designers can inspect window interfaces, joint connections and other critical elements to ensure they are visually acceptable and will properly interface between trades.  Plant visits to discuss technical and aesthetic concerns provide control without required constant site supervision.

Green design:  Precast concrete offers a number of benefits that make it environmentally friendly, a growing need as the Leadership in Energy & Environmental Design (LEED) criteria become more popular.  Precast requires fewer chemicals to keep it clean over its long lifetime, and it offers a high thermal mass.  It can be produced locally and creates no job waste.  Cement reducers such as fly ash and other admixtures also aid its environmental friendliness.  And its high durability gives it a total service life that far outpaces designs using other building materials.

Tight floor-to-floor heights:  Precast concrete systems sometimes fit within alternative system depths but shouldn’t add more than approximately eight inches to each floor level, creating an approximate 5-percent increase in exterior wall material.  This slight addition is easily overcome by working with the precaster to make effective use of the overall floor-plan shape and using the benefits precast provides in repetition of component fabrication.

Concrete systems mean success.  The benefits offered by total precast concrete systems accrue to the owner, architect, general contractor and structural engineer’s bottom lines – and ultimately benefit the end user.  The system provides an efficient design, cost effectiveness and a strong, durable appearance that will maintain its image throughout a long service life.

Key Benefits:

• Speed to market

• Design flexibility

• Aesthetic versatility

• High quality

• Low maintenance

• Environmentally friendly

• Strong engineering support

• Single-source supplier

-  Information courtesy of PCI.