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PRESTRESSED AND PRECAST WALLS
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BESPOKE PRECAST CONCRETE SOLUTIONS
PRESTRESSED AND PRECAST
CONCRETE SOLUTIONS
FAQs
We are part of the Thomas Armstrong Group
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Heavy Duty Applications - Horizontal Prestressed Precast Concrete Wall Panels
ACP (Concrete) Ltd's Heavy Duty Horizontal Prestressed Precast Concrete Wall panels are designed to fit between vertical steel support columns (stub posts/kingposts) or to the building frame to produce a foundation free wall.
This cost-effective walling solution offers a fast installation whilst still providing a high quality, durable and robust prestressed wall ideal for a diverse range of heavy-duty applications across various industries including bulk storage walls for agriculture, waste recycling, food products, Biomass & renewables.
With a fire rating of up to 3 hours, depending on section size, they can also be used to construct fire separation walls. All our prestressed wall panels are designed and manufactured to Eurocode 2, BS8110 and BS5502 (Agriculture) industry standards and are all CE marked.
ACP (Concrete) Ltd's Wall Panels have a 'tongue & groove' joint system ensuring that the wall panels lock together allowing the load to be shared between connecting units and reducing the likelihood of damage from accidental impacts.
APPLICATIONS
- Internal Bulk Division Walls
- External Perimeter Walls
- Recycling and Renewables – provide structural walls for Waste, Bunkers, AD Silage, Biomass.
- Kingpost Retaining Walls – provide soil retaining in temporary or permanent applications including Bulk Stores, Bunkers, Push Walls, Car Parks, Goods Yards and Landscaping Projects.
- Firewalls - provide fire containment walls to warehouses offices workshops and retail buildings.
- Agriculture - provide structural walls to bulk grain stores, silage clamps and manure stores
KEY ADVANTAGES
- Eurocode 2, BS8110, BS5502 (Agriculture) CE Marked, manufactured using QA Concrete
- Durable
- High Impact Resistance – ability to flex under load
- Fast and Simple Installation
- Offsite production – known performance specification
- Wide range of sizes & performance capacities
- Modular - easily be dismantled and relocated
- Cost Effective
- Long Life Waterproof Joints when sealed with High Performance Polyurethane Mastic Sealant
- Foundation free
- Immediate use
DISCLAIMER
Please note that any information provided is to be used as a guide only. Any lifting/handling operations should be carried out by trained and competent personnel only. ACP (Concrete) Limited will not be held responsible for any damage or injuries in connection with handling or installation not carried out by ACP (Concrete) Limited.
H145
HD145
H180
HD180
H280
HD280
HX280
HDX280
High Quality Off-site Production
There are many advantages of using a prestressed precast concrete wall panels over traditional construction methods:
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To discover more about 'What is Prestressed Concrete?' visit our FAQs section
Manufactured off-site in controlled factory environment conditions from quality assured engineering grade concrete (60 N/mm²) and to recognised industry standards (EC2, BS8110, BS5502) providing known performance specifications.
Fast and Simple Installation
The prestressed precast concrete wall panels are delivered to site already ‘made to measure’ and ready for immediate use. Installation is quick and straightforward using the lifting points located in the top edge of the panels and lifters supplied to suit.
The panels are simply fixed using the zinc plated plates & bolts provided, one at each corner. Installation is largely independent of weather conditions and helps prevent unnecessary delays to your project.
Foundation Free
The panels sit on landing cleats bolted/welded to the columns or the concrete floor of the building/bunker eliminating the need for strip foundations. A compressible sealant strip can be supplied to accommodate small variations in the floor and to provide a watertight seal.
Design and Installation Service
We offer professional, comprehensive and reliable precast concrete design and installation service on all our products.
Available to all our clients and customers, these services give you the peace of mind of working closely with an experienced company you can trust to deliver every stage of your project.
Durable - Part 1
The term "prestressed concrete" (also known as pre-tensioned concrete) means that wet concrete is poured onto steel strands which have been tensioned.
After the concrete has reached the required strength the strands are de-tensioned. The cured concrete adheres and bonds to the strands and when the tension is released it is transferred to the concrete as compression by static friction. This gives the panels additional strength and enables them to flex under load without detriment.
By utilising the inherent strengths of the two materials, the performance of a prestressed precast panel can far exceed that of a precast section reinforced with a similar amounts of reinforcing bar or mesh.Continued...
Durable - Part 2
The durability is also enhanced. In a standard reinforced section, the reinforcement only really comes into play once the concrete is in tension or has hairline cracks. In prestressed precast units the reinforcement is “working” in all conditions.
The interlocking ‘tongue and groove’ joint system also enables shock loads to be transferred between units, reducing the likelihood of damage and providing excellent resistance to vehicular impact.
The smooth finish of our prestressed precast concrete wall panels makes out loading of any bulk storage structures quick and easy. The density and durability of the precast concrete wall panels give long maintenance free service.<< View Part 1
Modular System For Easy Relocation
Prestressed precast horizontal wall panels can be dismantled and relocated if required to accommodate alterations to create subdivisions, or extensions to the wall structure.
This modular nature also enables individual concrete wall panels to be replaced in the unlikely event of excessive impact damage. This saves cost, reduces down time and ensures the store or yard is back in service as soon as possible without lengthy on-site curing of repairs compared to traditional site cast walls.
Watertight
Joints are sealed using mastic sealant applied to the joints after the panels have been sealed (sufficient for one side is supplied with the panels as standard). This sealing together with the density of the concrete and the smooth panel face eliminates concerns about damp ingress.
Another Solution
Our Cantilever Vertical Prestressed Precast Concrete Walls may be more a suitable solution. Our Vertical concrete wall panels are available in heights up to 4m in single skin application (depending on anticipated loadings).
These may also be installed entirely below ground for us on solutions such as of water storage tanks and cellars. For more information please visit our Cantilever Vertical Wall Panels or contact us direct.
Product Sizes & Performance Specifications
Wide Range of Sizes & Performance Specifications
The prestressed precast wall panels are available in three standard thicknesses, to suit a variety of anticipated loadings, and in a range of heights, the most commonly used being 1m, 1.2m and 1.5m. Lengths are cast as required up to 8m.
Click to download and view pdf 'Heavy Duty Wall Product Datasheet'
The tables below gives the maximum wall height for each prestressed precast panel type for a variety of products based on the bulk density, the internal angle of shear resistance of the material, the anticipated storage profile (surcharge or level fill) and the span between the supporting columns.
Click to download and view pdf 'Heavy Duty Horizontal Maximum Wall Height Tables.'
or click on the relevant boxes below to view the maximum wall heights tables.
Brief Overview: How to install Horizontal Concrete Wall Panels
1. Unload vehicles. Take care to avoid impact on panel edge at all times.
2. Align stacking timbers as shown
3. Attach lifting clutches to cast in inserts
4. Pull back slightly to ensure panel does not slip off stack during pitching
5. Lift panel to vertical, pause before taking full weight to avoid swing
6. Lift panel to location and align to column centre lines, lower into position
7. Attach fixing plates with M12 bolts into cast sockets and tighten
8. A vertical gap of 0mm to 20mm should be anticipated on the column face
9. Apply joint sealant to horizontal and vertical joints
To view a more detailed Step by Step Guide of the Installation and Delivery of the Horizontal Wall Panels, please click here.
DISCLAIMER
Please note that any information provided is to be used as a guide only. Any lifting/handling operations should be carried out by trained and competent personnel only. ACP (Concrete) Limited will not be held responsible for any damage or injuries in connection with handling or installation not carried out by ACP (Concrete) Limited.
Specifications and Literature Downloads
For more information click on the relevant box.
3D Drawings
3D Drawings
Click on the relevant option to view pdf
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CAD Drawings
CAD Drawings
Click on the relevant option to view pdf
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Safety / COSHH
Safety / COSHH
Click on the relevant option to view pdf
Precast Concrete Heavy Duty Horizontal Panels Safety Guidance
Arbosil 1070 - Fire Resistant Silcone Sealant Datasheet (Firewalls only) (External Link)
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Our Prestressed and Precast Concrete Design and Installation Service
At ACP (Concrete) Ltd we offer professional, comprehensive and reliable prestressed and precast concrete design and installation service on all our products. Available to all our clients and customers, these services give you the peace of mind of working closely with an experienced company you can trust to deliver every stage of your project.
Supporting you at every part of the process: design, construction and installation, our dedicated team of structural engineers and precast installers have extensive experience of delivering a wide range of prestressed floors, precast wall and stairs projects nationwide.
Design Service
Our experienced in-house engineering department offer a complete design and calculations service providing you with full construction drawings to deliver high quality precast solutions. Our design services including cantilever wall foundation design, precast wall panel design or design of bespoke precast products where our standard products don’t meet your requirements.
Our dedicated team will work closely with you to ensure that the precast concrete design meets your specific requirements, whilst ensuring that your project is designed to the highest standard whilst still providing a fit for purpose cost effective solution.
Installation Service - Part 1
All our precast concrete products are delivered and installed by the same professional team ensuring your project runs efficiently with people who fully understand your requirements. The team’s knowledge and experience of the complete precast and prestressed installation process is second to none, ensuring our products are installed on-site correctly and your project remains on-time and to budget.
We employ dedicated specialist reliable subcontract fixing precast teams who have worked closely with ACP (Concrete) Ltd over many years. Our Contract Manager's will assume control and co-ordination of the works on the placement of your order. This will ensure the free flow of information and design approval being achieved within the timescales.
Installation Service - Part 2
Our precast concrete wall solutions offer quick and simple installation which is usually carried out using either a crane or telehandler. The final product and method of installation will generally be determined by any site restrictions, the proposed sequencing of work and which product will provide the desired solution most economically.
Alternatively, help and advice for the safe handling and installation of precast units can be supplied as documentation and if required a supervisory site visit can also be arranged.
Site Specific Risk Assessments
Site Specific risk assessments and method statements are available following a prestart visit to site, which will be logged with all relevant parties, prior to commencement of work on-site.
Our experienced team will work to the site-specific method statement in conjunction with the detail of the approved design layout drawing ensuring your project is delivered to the highest standards of safety.
Site Specific Requirements
Site specific requirements, such as hard standing areas, movement of materials to create space and overhead obstructions will be identified and discussed with the Site Manager prior to commencement of installation work and these requirements will form part of the method statement.
Please contact us to discuss any of your design and installation requirements.
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Registered Office:
ACP (Concrete) Ltd
Part of the Thomas Armstrong Group
Workington Road
Flimby
Maryport
Cumbria
CA15 8RY
T: 01900 68211
Registered No: England 2212402
VAT Number: 533724550