Structural Design
Precast Concrete Structure Design
For industrial facilities, warehouses, logistics and agricultural buildings, we calculate precast reinforced concrete elements, socket foundations and connection details, and prepare a structural design that fits the manufacturer's molds.
What we design in a precast concrete structure
In precast reinforced concrete structures, the columns, beams, purlins, roof girders and floor elements are cast in a factory, transported to site and lifted into place by crane. In structures with wide spans and repeating grid lines, construction time is shorter, and concrete quality is easier to control in the factory. The real difference from cast-in-place concrete is that the elements are connected to one another afterwards. Since these connections largely decide how the system behaves in an earthquake, the connection details are also the part of our calculation that takes the most time.
We prepare precast structural system designs for industrial facilities, warehouses, logistics centers, production halls and agricultural buildings. In Kocaeli our counterpart on this work is usually an employer building a new facility in an organized industrial zone or expanding an existing one. The 1999 Kocaeli earthquake showed that the connections were the weak point in many industrial buildings in the region, and we keep that experience in mind when deciding on details. Heavy racking and overhead cranes are common in these facilities, and adding solar panels to the roof later has become routine. We put these loads into the model from the start.
We start the design from the architectural design, the manufacturer's mold and element capabilities and the results of the ground assessment. There is no point drawing a section the factory has no mold for, or a beam too long to be transported to site. So we find out what the manufacturer can do before preliminary sizing.
Scope
Structural system layout
We set the grid spacing, column height and roof slope according to what will be done inside the facility. If a crane girder is needed, the column section and the bracket position change accordingly.
Element design
We calculate the section and reinforcement of columns, beams, purlins and roof girders, and of double-tee (TT) and hollow-core floor elements.
Socket (pocket) foundations
We calculate the dimensions and reinforcement of the socket foundation the column sits in, together with the conditions needed for the column to be fixed into the foundation.
Connection details
We detail pinned beam-to-column connections, dowels and elastomeric bearings. At this stage we also work out how the floor elements connect to each other and to the beams, and how the roof and floor act continuously as a diaphragm.
Erection-stage calculations
Until it has been placed and connected, an element does not work the way it will in the finished structure. We check lifting points, temporary supports and stability during erection separately.
Hybrid systems
In structures that work together with a steel roof, reinforced concrete shear walls or a cast-in-place section, we design the interface where the two systems meet.
Applicable regulations and standards
In the seismic analysis we apply the provisions of the Turkish Building Earthquake Code (TBDY 2018) for precast reinforced concrete buildings, and in element sizing TS 500 (the Turkish standard for the design of reinforced concrete structures). We take load values from TS 498 and the requirements for the concrete class from TS EN 206. On a plot in an organized industrial zone, the building permit and design approval are issued by the zone management (OSB); outside an OSB this authority lies with the relevant municipality. In both cases the building inspection firm supervises construction.
In precast structures, a large share of earthquake damage is seen in the connection zones and at the column-to-foundation connection. That is why we calculate each connection type separately and present the results in the calculation report in the same detail as the element calculations.
How we work
Requirements and data collection
We ask what will be produced or stored in the facility, the crane and racking loads and the zoning status, and we ask for the geotechnical investigation report prepared by an authorized firm.
Preliminary sizing
We compare the grid layout and element types with the manufacturer's mold capabilities. If a section is needed that there is no mold for, this is where we see it.
Analysis and design
We model the system in commonly used structural analysis software and size the elements and connections under seismic, wind, snow and operational loads.
Connection and erection checks
We check the column-to-foundation, beam-to-column and floor connections one by one. We make separate calculations for the cases where an element is lifted, transported and waiting on temporary supports.
Design and approval
We deliver the structural design and calculation report, and work in the corrections from the OSB management or the municipality and from the building inspection firm.
Production and erection coordination
We compare our element drawings with the manufacturer's drawings and close the differences. We answer technical questions that come up during erection.
Deliverables
- Structural and seismic calculation report
- Socket foundation and tie beam design
- Column, beam, purlin and floor element drawings with reinforcement schedules
- Connection and bearing detail sheets
- Erection-stage calculations and erection sequence notes
- Quantity take-off schedule
Frequently asked questions
Doesn't the manufacturer prepare the precast design?
Some manufacturers do. We can carry out an independent design on behalf of the employer, or prepare a structural design that matches the manufacturer's element drawings. We discuss which suits the job before we start.
Precast or steel?
There is no single right answer; span, fire requirements, operational loads and delivery time decide it. When a client is undecided, we carry out preliminary sizing for both systems and set the result side by side with the structural steel option.
Can future expansion of the facility be taken into account?
Yes, but the decision has to be made at the start of the project. On the grid lines in the direction of expansion, we arrange the foundation, column and connection details to take the extension.
Do you also design agricultural buildings?
Yes. We design precast systems for buildings such as barns, storage buildings and processing facilities. For grant-supported projects, see our Agricultural Buildings and IPARD / TKDK Grant Projects page.
What needs to be done if solar panels are going on the roof?
First, check whether the roof elements can carry the extra load. In new buildings we include the load of the panels and their support frame from the start. In an existing building we check the capacity of the roof girders and purlins and assess whether the addition is acceptable.
Request a quote for your project
Write to us with the type of building, its location and the documents you have. We will agree the scope and timeline with you and send a written quote.