Precast Concrete Walls & Floors

History
The company started in early 90s supplying sand/aggregate. Readymix commenced in 99 expanding into blocks with precast following in 05. Head office based in Trammon, Co Meath Precast, Stone quarry and concrete blocks. Plants for ready mix concrete at
Duleek Agher Ballycoolin.

DULEEK

BELLEWSTOWN

TRAMMON AGHER BALLYCOOLIN

Stone Quarry at Bellewstown. Approx. 5 years ago expanded to start production of precast concrete walls and floors. twin wall and filligree slab based at Trammon. Our state of the art twin wall and floor slab plant in Trammon now forms the basis for the remainder of the talk.

Twin wall
What is Twin wall ? 2No. Skins of precast concrete 65mm thick The skins are held apart by a lattice girder to give the correct overall thickness of wall. Any wall thickness 200-400mm can be formed. Temporary weight always the same.

KC wall
What is KC wall ? 2No. Skins of precast concrete 65mm thick and 85mm insulation The skins are held apart by extruded Nylon Fibre ties to give the correct overall thickness of wall. Any wall thickness 300-400mm can be formed. Temporary weight always the same.

Filigree Slab
What is a Filigree slab? Precast slab only 65mm thick. Slab widths maximum of 2500mm wide. Ceiling joints minimised Slabs pre-engineered to accommodate service risers, lights, and ducts as required. Slabs are cast on perfectly smooth, level steel beds. No extra work on site to prepare the main surface for decoration. Floor slabs then mass concrete. Excellent acoustic properties regarding airborne and impact sound. Any shape can be accommodated. Most services run in conduits within the insitu topping to hide them.

Twin wall and Filligree slab

Design Process: All designed to current codes of practice for loadings and reinforced concrete BS8110 Pts 1, 2 and 3 BS6399 Pts 1, 2 and 3 Elements designed and reinforced traditionally. Disproportionate collapse principles easily accommodated. All window, door and service openings drawn in at this stage. Any cast in items also added to appear in the final design. Building constructed in true 3D as drawing process occurs.

Twin wall

A true rendered and reinforced picture is built up in the computer system for the entire structure.

Twin wall
How is it erected ? A line of starter bars is cast into the slab below the wall. The wall is hooked on and craned into position over the line of starter bars and shimmed to the correct level. 2No. Push pull props are fixed to the face of the wall in preformed sockets. The wall is plumbed and lined. Move on to the next wall.

Twin wall
Applications: Party Walls Lift Shafts Dock Leveller surrounds Internal division walls for apartments Inner skin of external walls Retaining walls Underground tanks Swimming pool walls and tank bund walls. Weighbridge decks ESB substation to ESB spec. ref.13320 Beams and Columns based on Twin Wall

Twin wall
Manufacturing process (Side 1): Once the drawings have been signed off the data files transferred directly to the factory computer. Data split with one part going to the robot plotter. Steel edge shutters and cast in items placed at next station. Rebar drawn, cut, bent as required from coil and placed by robot. Concrete placed into moulds for the first leaf. Pallet now placed by computer into curing chamber.

Twin wall
Manufacturing process (Side 2): Once cured the first leaf is taken out. (Next day) A similar process happens as before for plotting and casting the second leaf. First leaf picked up and turned into wet second leaf. Completed wall put back into the curing chamber Completed wall taken out and racked for delivery. Pallet placed in cleaning station where shutters stripped, cleaned, and oiled automatically and pallet also cleaned and oiled automatically.

Filligree Slab
How is it erected? The slabs arrive on a lorry loaded in the reverse sequence required on site. Slabs craned into position. Temporary supports placed under slabs at 1500mm centres. All slabs placed and handrail erected to slab edge.

Site works to precast concrete

When all walls and floors are placed the units are checked for plumb and line. The base of the wall is sealed to prevent grout loss. All vertical joints are sealed. Any openings in the walls are shuttered. Mesh sheets are placed down every vertical joint.

Site works to precast concrete

Now all of the walls and floor slab units are placed, plumb and shuttered. The walls are filled full with self compacting concrete. Pump or skip used depending on quantity Walls filled at a rate no greater than 850mm/hr.

Twin wall and Filligree slab

Advantages: Speed
Panels arrive as large as possible. Crane usage maximised

Fire resistance
Concrete is class 0. Standard wall (200mm) has 1.5hr. Can be easily increased to 4hrs.

Accuracy
Computer draughting Computer plotting in factory

Sound Resistance
Excellent resistance to airborne and impact sounds

Increased Health & Safety

A single crew (4 men) erect an average 540m wall a day. Traditional construction would take 35men.

Environmentally Friendly
Overall build programme can be reduced by means of the precast shell. All of aggregate procured locally, transport and pollution minimised.

Recent Projects

8No. Apartment blocks for P. Elliott Construction Limited. Height varying from 5-6 floors. Wall thickness 200mm Floor thickness 275mm Penthouse walls all over 3m. Double handling of walls.

Recent Projects
96No. Bed hotel wing for Bowen Construction Ltd. Low rise construction to ease impact on environment. Wall thickness 200mm Floor thickness 275mm Recesses formed in slab for bath pods. Curved top of panels formed to fit to curved green roof. All balcony door panels formed as one piece for speed on site.

Recent Projects
Dock leveller surrounds and associated retaining walls. Any size dock leveller can be accommodated. Walls designed to suit. Any profile of external ground can be accommodated. Leveller frame will sit on precast biscuit slab and be cast in with main floor slab pour. Retaining walls below GFS in twin wall.

Our commitment is to provide a high quality product, on time, every time.