40 CONCRETE WORK GROUND &
Information Modelling system, specifically configured for cellular wall construction. The 3D modelling generates mould and reinforcement details that are linked to the overall model, allowing alterations to automatically change these details. The integration of client’s M&E services using similar 3D systems, together with clash detection, reduces errors and costs.
Buchan builds a secure future
BUCHAN’S CROSSWALL SYSTEM OF CONSTRUCTING MULTI-UNIT ACCOMMODATION HAS BEEN USED EXTENSIVELY IN PRISON CONSTRUCTION OVER THE PAST 15 YEARS – FOR HOUSEBLOCKS, SEGREGATION UNITS AND ASSOCIATED PRISON BUILDINGS AT OVER 25 DIFFERENT PRISON SITES.
A
lready this year (2009), the company has completed a number of custodial projects – HMP Winchester, 116-cell houseblock; HMP Littlehay Segregation Unit, 12 cells; Harmondsworth Immigration Centre, 196 cells – and is currently building a 285-cell houseblock at HMP Shotts for Carillion and a 326-cell houseblock for HMP Parc Prison, Bridgend for Galliford Try. Another project recently completed is an extension for Skanska at HMP Dovegate, Staffordshire, privately operated by Serco, where the 260-cell two- storey four-winged K-shaped houseblock is an addition to the original 800-cell prison built for Skanska some seven years ago. Buchan’s contract was for the design, manufacture and erection of the new extension.
The design was carried out in-house using Tekla for precast concrete, a Building
Manufacture was undertaken at Buchan’s plant at Byley. The majority of walls are a minimum 150mm thick, reinforced with two layers of mesh. Internal walls are cast vertically in steel battery moulds and, following the minimal on-site finishing, are ready for decoration. External walls are cast flat, the top surface being that of the cavity face. Floor slabs are generally of solid, reinforced concrete or prestressed wet-cast construction with tight tolerances power floated and therefore do not require a screed.
All units were produced in high-strength, low water/cement ratio, low-permeability concrete. In addition, elevated temperature curing can be employed. Deliveries were to a scheduled “just-in-time” sequence to allow erection direct from delivery wagons.
Installation by Buchan’s own erection team took 19 weeks including the roof steel, during which time there was up to two crawler cranes and two mobile cranes in operation at any one time erecting some 1758 precast units and roof steel. The company input included erecting ground beams, roof steelwork and purlins.
The advantages of the system are many. Door frames, window grilles, electric conduits and boxes were all cast within the concrete wall and floor units including underfloor heating. All follow-on trades were able to start work almost simultaneously without one waiting for the other. Roof cladding, windows, brickwork, services, decoration and fit-out subcontractors all work together to drastically reduce the time required to complete the final construction. Finally, quality of product, robustness of structure, and the obvious security benefits together produce a maintenance-free structure with good fire resistance, acoustics and longevity.
Dovegate Prison Buchan Click here to request literature
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