Fig. 3. Full-Scale mock-up at Building Research Station
Fig. 4. Contractor's battery for production of wall units
or textured papering, and the floors with a composite dry finish laid direct- ly onto the slabs, provided that the im- pact sound damping requirements are
met.
This method was tried out at the Building Research Station. The casting process was begun with a portable flat hed, of lightweight concrete. large enough to accommodate the largest unit required, with adjustable edge forms for the other units, and cap- able of producing accurate, plane surfaces. On this bed were first cast two units, with extra reinforcement to enable them to withstand the pres- sures arising after the concrete was poured.
The pair of units was then placed vertically with the true faces inwards, and between them another unit was poured. This would have a true face on each side: Fig. 1. shows a panel being cast between two similar initial panels.
It was visualized that, after curing, the three units would be respaced to pour two further units, followed by re-positioning to bring the total to nine, and so on. One problem in such a battery is to ensure easy separation of the panels when cast, but it was found that the normal mould oils made this possible.
Both wall and floor units cast ver- tically in this way at the Building Re- search Station were used in the con- struction of a full-scale mock-up (Figs. 2 and 3). This experimental building, representing two storeys of corner flats in a projected block, was used to develop the production and erection process, and in assessing the suitability of various finishes and fit- tings.
It was found that variations in thickness, and to a reasonable extent in length of the units could be accom- modated within the batteries, and that reinforcement and miscellaneous fix- ings could be located readily and ac- curately. Erection tolerances were of the order of % in.
Figures 4 and 5 show the first ap- plication of battery casting in the pro-
Far East Architect & Builder August, 1966
duction of wall units for multi-storey flats by a contractor. Units of good quality in all respects were produced and the contractor was well satisfied with the efficiency of the process.
Frameworks of soldiers and walings are fixed to each of the two end-units and move with them. The soldiers stand in sockets in the concrete deck and are restrained by tie-bars at their heads. Further restraint and location are provided by the edge form 'lat- ches and the two rows of lower and upper spacer plates, which are split to facilitate striking. The equipment is adaptable and easily moved from site to site.
In traditional building it has often been stated that designs should be evolved with the closest consideration of the construction process at each stage. This is still more important for the successful use of large units such as the panels described here.
This approach has been adopted in the design of an 18-storey block which has been carried out jointly with the
Architect's and Building Departments of Edmonton Borough Council, UK. and their consulting engineers. The block (Fig. 7.), was designed from the outset to take full advantage of the battery casting of all wall and floor units, and to conform to good plan- ning and space standards.
Three batteries were employed for wall units, and three for floors. Only four 'specials' were required on each storey, for stair-flights and landings, and in situ concreting was restricted to jointing.
In this particular application, the battery method was used for site cast- ing though, of course, the method could well be applied to off-site fac- tory production. The outline below shows the way in which the produc- tion from the batteries may be inte- grated within the building process.
An essential for this casting method is a flat concrete working area, within crane reach of the block to be built. For production of the internal wall and floor units, this area will be about
Fig. 5. Contractor's wall battery with stop-ends in position
45
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