Die Zeichnung ist die Sprache des

Architekten – die Visualisierung seiner BASICS

entwerferischen Gedanken und
beabsichtigten Konstruktionslösungen.
Basics Technisches Zeichnen vermittelt
CONSTRUCTION
Studenten gebündelt das Wissen für die
Entwicklung professioneller Dar stellungen CONCRETE
von Planungen in allen Projektphasen.
CONSTRUCTION

BETONBAU
Katrin Hanses

ENTWERFEN
DARSTELLUNGSGRUNDLAGEN
KONSTRUKTION
BERUFSPRAXIS KONSTRUKTION
BAUPHYSIK UND HAUSTECHNIK
BAUSTOFFKUNDE
LANDSCHAFTSARCHITEKTUR
STÄDTEBAU
THEORIE
BASICS

www.birkhauser.com
Katrin Hanses

Concrete
­Construction
Katrin Hanses - Sebastian El Khouli
Bert Bielefeld

Entwurfsidee
Concrete
­Construction

Birkhäuser
BIRKHÄUSER
Basel
BASEL
 Contents
Foreword _7

INTRODUCTION _8

BUILDING material _9
Constituent materials _9
Kinds of concrete _12
Reinforcement _14
Material properties _20
Deformations _22
Defects _23

Construction method _25

In-situ concrete _28
Formwork _28
Concreting process _36
Precast elements _39
Surfaces _41

Building parts _47

Footings/foundations _47
Wall _53
Column _54
Beam _55
Ceiling/floor slab _58
Roof and roof parapet _65
Thermal separation _65
Staircases _69

In conclusion _73

Appendix _74
Standards and guidelines _74
Literature _75
Picture credits _75
The author _75
 Foreword
As a monolithic, cast material with a high loadbearing capacity, con-
crete is used in many areas of building. When combined with reinforce-
ment steel in the form of reinforced concrete the material can bridge
large spans and is very durable. Surfaces that differ in terms of structure
and colour can be produced using different formwork elements and
­admixtures. A good knowledge of this material, its properties and the
­process by which it is made is indispensable for the architect’s creative
process.
Reinforced concrete has been tried and tested over a long period and
is widely used in both architecture and civil engineering. Generations
of architects have discovered ever new and creative ways of using the
­material. In recent years, thanks to innovative reinforcement elements
and processing methods, marked progress has been made in building
with concrete, so that the ­diversity of this material has increased sub-
stantially, and it has proved possible to develop new areas of use.
It is at this point that this new book Basics Concrete Construction
begins and gives the reader an understanding of the special qual­ities of
concrete and the constructional possibilities that it offers. From the
­development of knowledge about the material, to the special production
methods of concrete building parts, to the connections between these
parts, it gives the architecture student the means for reflecting on crea-
tive solutions and developing new ­approaches to the construction of
buildings.

Bert Bielefeld, Editor

7
Introduction
Concrete is one of the most important materials in architecture and
civil engineering. As a poured material it offers a variety of possibilities
for architectural design and in making loadbearing building parts. Con-
crete allows monolithic ways of building – i.e. buildings which are “poured
in one cast” and through the use of various additives and composite
­materials its abilities are extremely varied. The concrete mix has a great
influence on the later qualities of the material and can be adapted to meet
the individual demands made on the building element. In designing con-
crete a great deal is possible – from the small to the extremely large scale.
As a material it has a strength that allows it to be used in primary
and secondary constructions as prefabricated elements so that, with con-
sistent planning, economic, high-quality execution is possible. When de-
signing concrete buildings various building parts must be fitted together,
different means of production combined, and the relationship between
the details and the structure of the whole must be resolved. A wide range
of knowledge about the fabrication, construction and later treatment is
indispensable. To explore the potential and possibilities of the material
this basic knowledge about concrete is conveyed here, opening the way
for an intensive examination of the material.

8
 Building material
Constituent materials
Concrete is traditionally made of water, cement and aggregate. To
these can be added air and various additives and admixtures, which are
being continuously developed. Consequently, concrete’s capacity and
the range of areas in which it can be used are growing all the time.
The proportion of water to cement and the consistency of the ­cement
paste produced in this way have a major influence on the quality and
workability of the fresh concrete. Mixing causes the concrete to become
malleable. The duration of the mixing process is strictly laid down for
each kind of concrete mix. The cement paste must surround the aggre-
gate, holding the pieces together and filling any hollows.
In terms of amount, the aggregate plays the major role in concrete, Aggregate
and is most important for the quality of the concrete. A fine-grained
­aggregate should be chosen particularly for exposed concrete building
elements or those on which great demands are made.
The aggregate can consist of broken or unbroken pieces. Natural
mineral materials are traditionally used but waste products or byprod-
ucts from industry can often also be employed. They need to have a cer-
tain grain strength and it must be possible to combine them with the
paste so that the durability of the concrete is not impaired.
The aggregate is differentiated according to its origins, structure,
unit weight, grain form and grain size. There are also different demands
in terms of durability and the geometrical, chemical and physical prop-
erties of the grain, as well as with regard to frost resistance. In this re-
spect there are special grain groups, compositions or forms.
Depending on the nature of the particular material, the aggregate Grain size distribution
must be processed for use in making concrete. The grain size distribu- curve

tion curve (a diagram depicting the composition of grain mixes) is de­

cisive for the quality of the concrete produced. This distribution curve is
produced by sieving the aggregate through sieves of different mesh sizes.
Standard distribution curves for grain mixes are 8 mm, 16 mm, 32 mm
and 63 mm, the maximum grain size, which in certain circumstances must
be produced by fragmenting, sieving or washing.
Up to a grain size of 0.125 mm we are dealing with powder. This fine
material has a positive effect on the workability of fresh concrete and en-
sures a dense structure, which is particularly important for exposed or
watertight concrete. However, the higher amount of cement also makes
it more expensive to produce.
One of the further main ingredients of concrete is cement, which can Cement
be subdivided into five main kinds (CEM I–V). > Tab. 1 Cement is a hy­draulic
binder that holds the concrete together.

9
 Tab. 1: Kinds of cement

Kind of cement Definition

CEM I Portland cement: strength class 32.5R (high initial strength)
CEM II Portland composite cement: various main ingredients (slag sand and
limestone), strength class 42.5N
CEM III Blast furnace cement (Portland cement, clinker and slag sand), strength
class 32.5N
CEM IV Pozzolanic cement
CEM V Composite cement

Blast furnace cement (CEM III) is used for the production of ultra high
performance concrete (UHPC). Alongside its low porosity (which protects
against ingress of liquid) it has numerous other positive qualities. Less
primary energy is required to produce it, and it saves on natural ­resources.
Cracking due to thermal stress is rare and it is more resistant to chem­
icals and salts.
Water-cement value What is called the w/c value should be determined at the planning
stage in accordance with the appearance required and the particular
function. This describes the proportion of water to cement and influences
the properties of the concrete. The higher the w/c value, the lower the
strength. The proportion of water to cement can also have an effect on
the colour: a lower w/c value makes the surface appear darker, whereas
a higher value produces a lighter-coloured surface.
In order for concrete to cure (= hydration), it must have a w/c value
of at least 0.4 (which represents 40% water). If more water is added the
cement can no longer bind the water, and the liquid emerges (“bleeds”).
If the proportion of cement is too high there is a danger of too rapid dry-
ing and shrinking.
Admixtures Admixtures can be in liquid or powder form or can also be added as
granulate or a paste. They influence the quality of the fresh or solid concrete
by chemical or physical processes. For example, they can change workabil-
ity or air content. > Tab. 2 The admixtures have only a minor effect on the mass
● of the fresh concrete and their volume can therefore be ignored.
Additives Additives are different materials that are added to concrete to influ-
ence or achieve certain properties. A distinction is made between two
different groups:
Type I: Almost inactive concrete additives (stone dust, pigment)
Type II: Pozzolanic or latent hydraulic concrete additives (fly ash,
­silica dust)

10
Tab. 2: Standard concrete admixtures

Admixtures Function
Concrete plasticiser and Gives the concrete a more plastic consistency despite the low water content so that it
super plasticiser flows better. This makes it easier to distribute the fresh concrete in the formwork.
Air-entraining agent Leads to the formation of air bubbles by means of chemical foaming. A higher
proportion of air improves concrete’s thermal insulation properties.
Sealant Makes the solid concrete waterproof.
Retardant Delays the curing of the fresh concrete, important in large building parts that are to be
produced without construction joints.
Accelerator Accelerates the curing and hardening process, is particularly important in sprayed
concrete to ensure that it quickly reaches a basic stability and does not drip (for
example, when used in building work overhead).
Pressing aids Improves the flowability. Used primarily in prestressed concrete.
Stabiliser Prevents “bleeding” (emergence of water) and ensures better cohesion of the mix.

As with aggregate, the additives should be taken into account as part

of the volume, according to their properties and the amount added. ◼
For the consistency of concrete it is important that throughout the Concrete consistency
production process no separation of the constituent elements should
take place. Consistency is the yardstick for the strength of fresh con-
crete, which must be flowable enough to allow good workability. Good
flowability also stands for good fresh concrete quality; consistency should
be determined before the start of construction and should be monitored
during production.
The compacting technique should be chosen according to consis­
tency. Consistency is divided into flow spread and compaction classes.
>  Tabs. 3 and 4 These are arrived at by using flow table tests and compaction

tests.

● Example: A plasticiser based on PCE (polycarboxyl­ ◼ Tip: Additives can also be used for design purposes.
ate ether) is added to the concrete to improve its For instance, pigments can be used to colour concrete,
flowability when being poured. In addition, through the translucency can be achieved, or the surface can be
material itself, air is removed. Later compacting is given a structure. For coloured areas of concrete it
therefore unnecessary, even in the case of compact makes sense to test the effect of additives and the
geometries or high amounts of reinforcement. A amount to be used on sample areas.
smooth, almost pore-free surface and a very efficient
concrete is achieved.

11
Tab. 3: Classes according to flow table spread

Consistency Class Flow table Compacting technique

spread d
Stiff concrete F1 ≤ 34 cm Powerful vibrating or stamping, thin lift fill
Plastic concrete F2 35–41 cm Compacting by vibrating
Soft concrete F3 42–48 cm Light vibrating or rodding (for high-strength in-situ concrete
of at least class F3)
Very soft concrete F4 49–55 cm Rodding, is produced using plasticiser
Flowable concrete F5 56–62 cm Rodding, is produced using plasticiser
Very flowable concrete F6 ≥ 63 cm Only by gravity, plasticiser
Self-compacting concrete SVB Compacted only by gravity, air is removed, flows well between
reinforcement, particularly suitable for exposed concrete

Tab. 4: Classes according to compaction

Consistency Class Compaction c

Very stiff concrete C0 ≥ 1.46
Stiff concrete C1 1.45–1.26
Sculptural concrete C2 1.25–1.11
Soft concrete C3 1.10–1.04

Kinds of concrete
Distinctions are drawn between different kinds of concrete based on
the composition, additives, surfaces, production process, or the nature
of the reinforcement > Tabs. 5 and 6 This always affects the planning and de-
sign of a building made of (reinforced) concrete. For example, building
parts must be produced or maintained differently depending on the kind
of concrete used.
There are a wide variety of different types of concrete. They are dif-
ferentiated according to several criteria:

—— Unit weight
—— Compressive strength
—— Application
—— Special properties

The compressive strength of concrete is given in what are called

strength classes, which begin with C for “concrete” (lightweight concrete
= LC). This is followed by two numbers that are determined by test pro-
cesses (cylinder strength/cube crushing strength). The greater the
strength, the greater the difference between cylinder and cube. A low
strength class also means a low w/c value. > Chapter Building material, Constitu-
ent materials

12
Tab. 5: Kinds of concrete according to unit weight and strength

Kind of concrete Dry unit weight Strength classes

Lightweight concrete < 2000 kg/m3 LC 8/9 to LC 50/55
(theoretically possible from (LC 55/60 to LC 80/88 = high-strength lightweight
350 kg/m3) concrete)
Normal concrete 2000–2600 kg/m3 C8/10 to C50/60
C55/67 to C80/95 = high-strength concrete
(C90/105 and C100/115 in particular cases)
Heavy concrete 2600–5900 kg/m3 C8/10 to C50/60
C55/67 to C80/95 = high-strength concrete (C90/105
and C100/115 in particular cases)

Tab. 6: Kinds of concrete

Kind of concrete Described according to Definition

Normal concrete Reference point for all Generally used concrete
others
Lightweight concrete Concrete mix By adding coarse light aggregate (expanded clay
aggregate), better insulating properties are achieved.
Lower strength but also lower weight.
Aerated concrete Concrete mix A kind of lightweight concrete. Instead of aggregate,
aerated concrete contains air bubbles, which are produced
through a chemical process and further improve the
insulating qualities.
Heavy concrete Concrete mix/strength Particularly heavy aggregate (e.g. barite, iron ore, steel
class granulate etc.) with high dry unit weight, used above all for
protection against radiation or similar.
Ultra high performance Concrete mix/strength Uses furnace cement instead of Portland cement, very high
concrete (UHPC) class strength and good durability, allows slender design, saves
resources and can be used economically.
Water-impermeable Concrete mix/properties Concrete with a high resistance to the entry of water,
concrete used above all to seal building parts in the ground
(see Chapter Building parts, Footings/foundations)
Waterproof concrete Concrete mix/properties Similar to water-impermeable concrete, addition of barriers.
Self-compacting concrete Concrete mix/additives Addition of plasticiser, no additional compacting necessary,
finely pored surface and complex geometries possible.
Translucent concrete Concrete mix/additives Glass optical fibres are introduced into the fine concrete.
Depending on their density and arrangement they create
particular patterns and enable the concrete to become
translucent.
Refractory concrete Concrete mix/additives Withstands temperatures from 500 to 2000 °C
Recycled concrete Concrete mix/additives Aggregate produced from recycled materials
(e.g. building rubble)
Concrete screed Concrete mix Small aggregate size to allow thin layers to be made.
Especially for making floor layers.

13
Tab. 6: Kinds of concrete

Prestressed concrete Structural design/kind of Steel reinforcement is pre-spanned (pre-stretched),

reinforcement creating a high compressive stress. The properties of
concrete are better exploited, more efficient building parts
are produced. The stiffness prevents major deflection even
with large spans.
Textile concrete Kind of reinforcement Composite material with low thickness and high resistance
to compression and deflection. Flexible forms possible
through particular reinforcing materials.
Fibre concrete Kind of reinforcement Fibres can be made of plastic, glass fibre, carbon, natural
fibres or similar.
Self-cleaning concrete Surface characteristic The surface is treated with photocatalytically effective
metal oxides or sulphides. The self-cleansing, pollutant
disintegrating effect is achieved by light. In addition, the
surface must by super-hydrophobe (water repellent) or
super-hydrophile (water-attractive).
Exposed (fair-faced) Surface characteristic Smooth, fine-pored surface, generally produced as a
concrete prefabricated part.
Tamped or compressed Concreting process Unreinforced, historic method of use, produced layer by
concrete layer, compacted by tamping. High density, hardly any
shrinking, few cracks.
Spun concrete Concreting process For tubes, piles or masts, compacted by a rapidly rotating
steel formwork, low w/c value, very solid, dense concrete
(up to C100/115). Hollow cross sections are created that
can also be used to take service runs.
Sprayed concrete Concreting process Is particularly flowable and hardens quickly. Applied
through a spray nozzle using pressurised air. This method
allows concrete that is already compacted to be applied to
a wide area.
Vacuum concrete Concreting process Introduction of the fresh concrete by means of a vacuum.
At the same time superfluous water is suctioned off and a
dense surface with few cracks is created.

Reinforcement
Concrete is a freely formable building material and is used in combi-
nation with very different materials. Most often it is used as part of a
composite construction together with steel, and is known then as “rein-
forced concrete”. As with every composite construction, the materials
that make up reinforced concrete are used in accordance with their spe-
cific properties.
Concrete is characterised by a high compressive strength, while steel
can handle high tensile forces. Together they form a highly efficient
­material that can handle heavy loads and bridge considerable spans. At
the same time the combination of these two materials balances out their
poten­tial weaknesses. Steel tends to rust (corrode) but when completely
covered by concrete it is protected from this process.

14
Fig. 1: Reinforcement steel Fig. 2: Spacer made of plastic

However, the easy formability of concrete is restricted by the use of

steel reinforcement. This rigid material generally dictates an orthogonal
way of building, determined by financial and material budgets.
Steel is the main kind of concrete reinforcement in building above
and below ground level. However, more recently other kinds of reinforce-
ment, such as glass or carbon fibres, have become established. They are
pioneering trends and offer new design possibilities for both surfaces
and forms.
Steel reinforcement is measured and dimensioned on the basis of Steel reinforcement
the forces expected. Reinforced concrete building parts can also be made
under a certain mechanical prestressing, which enables them to be used
in an even more effective and efficient way.
The reinforcement in concrete allows homogeneous, solid connec-
tions to be made to other building parts and thus contributes to the mono­
lithic building method. Steel is particularly suitable as reinforcement
­because concrete and steel have similar thermal expansion behaviour
and thus during the changing climatic conditions over the course of a
year no internal tensions are produced in the building part.
Various methods have proved effective in introducing steel into con-
crete. Reinforcement baskets, mats and rods are used in orthogonal
building parts. They are fixed according to the reinforcement plan, which
is based on the structural engineer’s calculations and dimensioning.
The surface of the steel is usually ribbed or structured in some way
to create a better bind with the concrete. This allows a direct transfer of
forces to the concrete. > Fig. 1
To ensure that the reinforcement remains in position when the
­concrete is being poured it is fixed using spacers. > Fig. 2 These spacers
­primarily ensure the necessary concrete cover. They can be made of
­various materials, such as fibre concrete, cast concrete, plastic or
steel.

15
 stirrup

longitudinal
reinforcing
bar

c
concrete cover

Fig. 3: Concrete cover

Concrete cover Concrete cover means the distance between the outer surface of the
concrete and the outermost layer of reinforcement in the concrete. > Fig. 3
Concrete cover does not have a structural function; its purpose is to pre-
vent damage occurring to the building part. It ensures that the concrete
encases the steel on all sides so that it is not exposed to the external air.
If the cover is insufficient the concrete can flake off. The steel is then no
longer covered and may corrode. The building part is damaged funda-
mentally in the long term and this can lead to failure. Cover should not
be less than 15 mm, and is generally between 20 and 25 mm.
The concrete cover also ensures fire safety, as the concrete keeps
the heat away from the sensitive steel. As with the outside cover, a dis-
tance must be kept within the building part between the steel bars. This
distance must be at least 2 cm, and it should never be less than the dia­
meter of the largest bar. Depending on the aggregate size, even greater
distances may be necessary. If an internal vibrator is to be used to com-
pact the concrete, sufficiently large gaps must be provided.
Spalling If concrete carbonates in the course of time, moisture, CO2 and acid
solutions can be absorbed. The reinforcement begins to corrode, increas-
ing in volume in the process. The expansion causes the concrete cover
◯ to flake off (= spalling), exposing the reinforcement.
Corrosion Corrosion is the term used to describe the rusting of steel reinforce-
ment. The hardening (hydration) of cement produces calcium hydroxide,
which is responsible for the alkaline milieu in concrete. The alkalinity in
concrete protects the steel against corrosion. Both the pH of the con-
crete and the concrete cover are of fundamental importance in ensuring
◯ that a reinforced concrete building part functions properly.
Corrosion can be divided into two kinds depending on whether it is
caused by carbonation or by the entry of chlorides. > Tab. 7 The demands
made on a building part define its exposure class, which lays down the
minimum cement content, the highest permissible water-cement value,
and any post-treatment of the concrete.

16
Tab. 7: Exposure classes for reinforcement corrosion

Class Description of the Examples

surroundings
Corrosion of the XC1 Dry or constantly wet Building parts in interior spaces,
reinforcement due to normal air humidity; building parts
carbonation that are constantly under water
XC2 Wet, rarely dry Parts of water tanks; foundations
XC3 Moderately damp Open halls, interiors with high air
humidity, cattle sheds etc.
XC4 Alternately wet and dry External building parts directly
exposed to rain, buildings in areas
between high and low water levels
Reinforcement corrosion XD1 Moderate damp Buildings in areas sprayed from traffic
caused by chloride surfaces; individual garages
XD2 Wet, rarely dry Swimming pools; building parts that
are exposed to industrial water
containing chloride
XD3 Alternately wet and dry Building parts subject to water sprayed
from roads treated with de-icing salt;
parking decks driven on directly
Reinforcement corrosion XS1 Salty air, but no contact with External building parts near the coast
caused by chloride from seawater
seawater
XS2 Under water Parts of buildings in harbours that are
constantly under water
XS3 Areas subject to tides, sprayed Quay walls in harbours
water and mist

Prestressing offers a way to make even better use of the fundamen- Prestressed concrete
tal material properties of steel and concrete. In prestressed concrete the
steel reinforcement is prestretched according to precise calculations,
creating high compressive stress in the concrete building part. This func-
tions above all through the off-centre position of the reinforcement in the
cross section of the building part. When mounting the part, the prestress-
ing means that there are no tensile forces in the concrete. Highly effi-
cient building parts are made with high stiffness and low deflection that
can bridge considerable spans. > Fig. 4

◯ Note: Carbonation = through contact with CO2 the ◯ Note: Alkalinity describes the strength of an alkali.
alkaline milieu in the concrete is neutralised. The pH Milieus with a pH above 7 are regarded as alkaline.
sinks and the steel is no longer protected from corro- Cement stone has a pH of ≥ 12, a very high alkalinity.
sion.

17
 beam
reinforcement

normal condition

stressed
reinforcement
high compression
stress

prestressing

beam
reinforcement

applying load high compression stress =

high stiffness

Fig. 4: The principle of stressed concrete

Other materials for Alongside steel reinforcement and its further developments, there
­reinforcement are also other reinforcing materials that help concrete play its loadbear-
ing role. These are at different stages of development and some of them
do not yet have official authorisation. Many can be used as fibre addi-
tives, in the form of textiles or mats. > Tab. 8
Fibre concrete Fibre reinforced concrete is evenly reinforced with fibres that are
generally made from steel, plastic or carbon. This kind of reinforcement
can be used for different purposes. It improves the tensile strength or
also the resistance to impact. In this case, additional steel can some-
times be dispensed with. In conjunction with standard steel reinforce-
ment, fibre reinforcement can be used to ensure less deformation or to
minimise the formation of cracks.
In selecting the fibres it is important that the material can be used
permanently in the alkaline milieu of the concrete and that it connects
with the concrete. Different production processes are used depending

18
Tab. 8: Reinforcement materials

Material Characteristic Use Innovation phase

Carbon Very light and tension resistant. Relatively high Fibre or textile Some already approved.
production costs, but great material savings Used principally in
as almost no concrete cover. Extremely thin improving existing
building parts are possible. buildings.
Natural fibre For example, hemp, flax or cellulose; high Fibre At the testing phase
elasticity, low weight. Cannot be easily
distributed in concrete and influence the w/c
value.
Glass fibre Can be used in much the same way as carbon, Fibre or textile Ready for the market
but less efficient.
Steel fibre As an alternative or together with normal steel Fibre Ready for the market
reinforcement
Plastic fibre Generally made of polypropylene, against Fibre Ready for the market
micro-cracking in fresh concrete. Used also in
high-performance concrete or for fire
protection.

upon the fibre type, and they can to some extent be adapted to the flow
of forces in the building.
Exactly as with concrete reinforced with steel, the tension forces in Textile concrete
textile reinforced concrete are taken up by the reinforcement. The tex-
tiles are produced from individual fibres (filaments), which, similarly to
fibre concrete, generally consist of glass or carbon. The filaments are wo-
ven into yarn and processed to form mats or meshes. The precision with
which the reinforcement can be positioned is also the great advantage
compared to fibre reinforced concrete: there is no danger of clumps or
concentrations forming or of the fibres being unevenly distributed. The
textiles can also adapt three-dimensionally to the flow of forces. The fili­
gree material is prefabricated precisely to meet the specific requirements
and consequently is utilised in an almost perfect way. The concrete that
is used for textile reinforced building parts must be flowable and fine-
grain (maximum grain size 1 mm), to ensure that it settles evenly around
the textile and in the mesh.
In contrast to steel reinforced concrete, textile concrete is not sub-
ject to threat from corrosion and therefore no minimum amounts of cover
are required. It is also characterised by its low weight, slender and pre-
cise building parts and an accordingly high efficiency. At present it is
used in maintenance work or in improving building parts. Production
costs are higher than those for steel reinforced concrete.

19
 Material PROPERTIES
Thermal insulation The nature of a building material determines its properties in terms
of building physics. The thermal capacities of concrete influence the val-
ues of, for instance, the material’s density, thermal conductivity and wa-
ter content. Concrete is the decisive material in the composite reinforced
concrete. It has a high density and therefore stores heat well. The solid
nature of concrete ensures that this heat is given off after a lapse of time,
allowing possible extremes of temperature to be evened out.
Thermal conductivity defines how easily heat is conducted through
layers of a building part. Concrete has a high thermal conductivity, which
is why the concrete parts of the thermal envelope must be given addi-
tional thermal insulation. > Tab. 9 The concrete mix and the additives can
also be altered in order to avoid high heat transmission losses. One
­example of this is aerated concrete, in which a high proportion of air voids
ensures a better thermal insulation effect. > Chapter Building material, Kinds of
concrete
Sound insulation Concrete also has good sound insulation properties on account of
its high bulk density. The denser and heavier a building material is, the
better the sound insulation. Airborne sound is well absorbed by concrete
building parts, while structure-borne sound can be reduced by ­decoupling
or separating building parts (for instance, by a floating screed). > Fig. 5
Fire protection One of concrete’s excellent properties is its resistance to fire. It is
essentially regarded as a non-flammable building material (Flammability
Class A1). Under heat, concrete retains its strength and does not con-
duct fire. It does not produce smoke or toxic gases either.
However, under great heat certain stresses arise in concrete that
can cause spalling. The reinforcing steel is then exposed, and can begin
to melt, which may result in the failure of the entire building part. A simi­
lar effect can occur when a fire is being extinguished; the water used to
put out the fire makes the building part cool down dramatically, and the
stress that ensues can cause concrete to flake off.
Without the need for any additional measures concrete can meet the
requirements for fire resistance classes from F30 to F180. Even at high
temperatures it is regarded as resistant to smouldering fires and it also
provides protection against the heat. Concrete is the most suitable build-
ing material for escape stairs (staircases, walls and ceilings). Concrete’s
resistance to fire can be even further improved through additives. What
is called “fire concrete” can withstand temperatures of 500–2000 °C.
Protection against Concrete is essentially permeable to water vapour. This means that
moisture it takes up water or moisture from the surroundings and releases it again
after a certain time. It can, however, be made almost water imperme­able
(waterproof concrete). The relationship to moisture depends upon the
concrete mix and proper compacting. A watertight construction made
from waterproof concrete is called a “white tank” (> Chapter Building parts, Foot-
ings/foundations). Waterproof concrete can also be produced in such a way

20
Tab. 9: Overview of typical building physics properties

Kind of concrete Thermal conductivity Fire resistance class Flammability class

Aerated concrete from 0.11 W/(m*K)
F30 to F180 without
Normal concrete 1.51 to 2.30 W/(m*K) A1 – not flammable
additional measures
Heavy concrete around 2.30 W/(m*K)

Airborne sound is contained by Impact sound transmission must be

the concrete. reduced by decoupling at the point of
transmission.

Fig. 5: Sound transmission principles

that it is resistant to frost and de-icing agents. There are four exposure
categories:

—— Moderate water saturation without de-icing agent: XF1

—— Moderate water saturation with de-icing agent: XF2
—— High water saturation without de-icing agent: XF3
—— High water saturation with de-icing agent: XF4

Concrete can also be made in such a way that it can resist chemical Resistance to
attacks for a certain period. To some degree it can be described as acid- chemicals

resistant. There are three degrees of attack strength:

—— XA1: weak attack

—— XA2: moderate attack
—— XA3: strong attack

Resistance to chemical attacks is required, for example, when hand­

ling process or waste water from industry, in the case of pollution by
fumes, or aggressive ground water and soil.

21
 Deformations
Deformation can occur in solid or liquid concrete as a result of vari-
ous physical properties and compositions. Changes in temperature, with-
drawal or absorption of water cause the material to change its form
­considerably. A number of such changes are listed below that can harm
concrete and hinder the building part in fulfilling its function.
These processes often cannot be stopped completely, but forward
planning can prevent serious losses of function. Alongside the planning,
the causes of harmful deformations are generally to be found in the con-
struction or execution, which should always be properly supervised. In
particular, care should be taken to ensure that the concrete mix is appro-
priate and that the concreting process is correctly carried out; the influ-
ence of water, air, salts or chemical pollutants must be monitored. The
concrete’s own movements must be calculated to ensure that the flow
of forces can take place unhindered.
Shrinking Shrinking means the shortening of concrete as it cures and hardens,
causing it to lose volume, when hair cracks can develop. The amount by
which the volume is reduced is known as shrinkage. Shrinking depends on
the moisture levels in the surroundings, the size of the building part, and
the concrete mix. With slow curing, shrinkage ranges from 0.2 to 0.5 mm/m.
Early or capillary In contrast to normal shrinking this process starts immediately ­after
shrinking water is added and is strongly dependent on the water-cement value.
Swelling Swelling is the opposite of shrinking. It describes the increase in the
volume of the concrete as the result of absorbing water.
Attacks An attack is a chemical reaction and takes place in solid concrete. It
results in an increase of volume (example: sulphate attack).
Creep and flow Creep and flow are deformations that take place under a sustained
load. They can be permanent or can diminish over the course of time.
They occur primarily with compressive loads, and are caused by the move-
ment of water in the cement stone.
Creep describes a reversible deformation, which diminishes over the
course of time and eventually stops. After the structural load is ­removed
the building part returns to its original state (creeping back). Flow is an
irreversible deformation that remains even when the load is removed.
The amount of creep is of particular importance for the structural
calculations of different building parts. With prestressed concrete, the
prestressing means that there is already great compressive load before
the element is inserted, the expansion of the stressing steel is reduced
and with it the pretension force of the building. In creep, the modulus of
elasticity (E) usually plays an important role. It gives the relationship of
tension to elastic deformation, which disappears once the load is re-
moved. The modulus of elasticity for normal concrete is between 22,000
and 39,000 E.

22
Fig. 6: Efflorescence

Defects
Defects can arise in both fresh and solid concrete during the produc-
tion and curing process, but can also be due to long-term external influ-
ences. Structural loads or temporary loads can also cause defects. These
effects generally weaken the entire building part if they exceed the cal-
culated movements in the material. They can arise as the result of mis-
takes in planning, construction or execution.
One example is lime efflorescence. During the curing process the Efflorescence
cement in the concrete separates out hydrated lime. This can dissolve in
water and be deposited on the surface. When the water evaporates it re-
mains on the surface and changes into limestone (calcium carbonate).
> Fig. 6 The limestone is visible as cloudy patches on the surface of the
concrete. Efflorescence occurs above all when water (e.g. rainwater)
­enters concrete from which the formwork has just been struck or runs
between the formwork and the surface of the concrete, when the weather
is damp and cold or when other effects cause a temperature difference
in the concrete. It can be avoided primarily by introducing measures to
protect the fresh concrete. Water should not be allowed to enter the form-
work and striking the formwork should only be done in dry weather.
Where subsequent treatment of the surface is necessary, foils should be
inserted between the concrete and the formwork and damp mats, or
appro­priate post-treatment agents used.
Cracks or cracking patterns are included in the calculations of the Cracks
building parts. >  Fig. 7 They result from internal stresses and external
forces, i.e. through deformation or the addition of loads. Particular crack
patterns are created depending on the consistency or composition of the
concrete . It is desirable to create as fine and even a crack pattern as pos-
sible, so as to weaken the building part as little as possible. A difference
is made between cracks that are close to the surface and separating

23
Fig. 7: Cracks Fig. 8: Rock pockets

cracks. The latter generally affect the entire cross section or large areas
of the building part, whereas surface cracks of 0.1 to 0.4 mm are accept-
able. Surface cracks generally only have to be visually removed and have
no serious structural implications. Cracks with a structural impact must
be avoided from the start by means of adequate reinforcement, incorpo-
ration of joints, and the correct concrete mix.
Rock pockets A rock pocket develops when separation of the aggregate occurs in
the fresh concrete. Coarse pieces of aggregate collect at one place. > Fig. 8
They should be avoided by suitable grading of the grain, allowing suffi-
cient mixing time, and by proper compaction.
Concrete bleeding Bleeding is the term used to describe the appearance of water on
the surface of the concrete during the concreting process. By this time
the concrete has generally separated. This can be avoided by minimising
the w/c value, choosing dense aggregate compositions, and compact-
ing intensively. In addition, the grain size distribution curve should be
­optimised and a finely ground cement used.

24
 Construction method
As concrete is generally used in the form of reinforced concrete, the Constructional
concrete building parts are usually loadbearing and form the primary con- qualities

struction, even in large and complex buildings. But concrete can equally
be used as a non-loadbearing element that encloses space, and indeed
it is even used in furniture for indoors and outdoors. Vertical and hori-
zontal concrete parts can also span large distances. Depending on the
shape of the building part, reinforced concrete can be used to take loads
that are applied across an area, or point or linear loads. > Fig. 9
There are different ways of producing concrete building parts. Essen­ Production process
tially, the elements of the concrete must be mixed together and additives
added according to requirements. This mixed, liquid raw state is called
“fresh concrete”. The proportions of the various contents determine how
the concrete is to be worked, the feel of the finished concrete, and
whether it suits the requirements at its later location.

point load linear load

shell-shaped load surface load

Fig. 9: Reinforced concrete as a loadbearing structure

25
 Fig. 10: Compacting concrete

Compacting After mixing, the fresh concrete is poured into a formwork or shut-
tering in which the reinforcement has already been placed. > Chapter Build-
ing material, ­Reinforcement and Chapter Construction method, Formwork After the concrete
has been poured or pumped into the formwork it must be compacted in
order to avoid air pockets. There are a number of tried and tested meth-
ods of doing this. They include vibrating, tamping and rodding. For these
methods an ­additional compacting appliance is used (e.g. an internal
or  external ­vibrator, or a tamper). >  Fig. 10 Compacting prevents voids
­developing between the ­aggregate and shrinkage cavities between the
concrete and the shuttering. Current developments in self-compacting
­concrete > Chapter Building material, Kinds of concrete mean that tamping may some­
times no longer required. The special properties of this concrete allow
◯ an entirely new work process.
The concrete must be introduced in layers and constant care must
be taken that it does not separate during concreting or compacting. Tamp-
ing should not be carried out for too long but must still fulfil its function.
The concreting process should not be interrupted.
During the first few days the freshly introduced concrete must be
protected from the weather and environmental influences using films or
isolation layers. This not only provides protection against external influ-
ences but also contributes to the curing process. The water on the sur-
face must not be allowed to evaporate. Drying out must be prevented by
covering, or by introducing water from elsewhere.

◯ Note: Shrinkage cavities or shrink holes are cavities

in the material or indentations in the surface. These
can be merely aesthetic imperfections. But from a cer-
tain depth and size they are also structurally relevant,
as the cover is reduced.

26
 concrete cover

construction joint

connecting
reinforcement

Fig. 11: Construction joints

The surrounding temperature should be between +5 and +30 °C. Protection against

In the case of heat there is a danger of excessively rapid setting and evap- ­adverse influences

oration. This can be prevented by covering. In the case of frost the ­cement
lime no longer hardens sufficiently and the water in the concrete, which
has not yet set, can freeze and cause damage. Here, the use of warm con-
crete heated in the works or antifreeze agents can help. However, they
alter the colour of the concrete, which must be taken into consideration,
particularly with exposed concrete.
Wind can also contribute to accelerating the evaporation of the wa-
ter in fresh concrete. Accordingly, the concrete should not be exposed
to excessively strong winds. The same applies to protection against rain
to prevent the water content from changing too greatly in the part that
is curing.
Within the first 24 hours, concrete sets from a wet to a solid state.
It reaches its standard hardness under normal conditions within 28 days
and is then described as hardened concrete. During the curing process
the concrete is called young or green concrete.
Depending on the size of the building part, the concrete cannot all Construction and
be poured in a single process but the part must be broken up into differ- movement joints

ent concreting stages. This necessitates construction joints, which should

be included in the planning. However, construction joints should be
avoided wherever possible as they always represent a weak point. If they
are necessary to ensure better bonding they should be produced with a
roughened surface (e.g. expanded metal) and protected against damp or
the entry of water using sealing tapes or similar.
Movement joints may be needed to avoid tension cracks between
two building parts. They must be based on the structural situation and
included in the planning and are used above all to deal with expansion or
settlement movement. In movement joints the reinforcement is inter-
rupted in order to avoid stress, whereas in construction joints the rein-
forcement is continued. > Fig. 11

27
 Checking the The parameters for the composition of the concrete that were
­concrete ­ ecided upon in the planning must be monitored and checked during the
d
construction work. This can be done by checking the concrete supplier
and by taking samples on site.
The bulk density of fresh concrete (kg/dm3) allows a first assess-
ment of the concrete quality to be made immediately after it has been
put in place. It describes the mass of fresh, compacted concrete includ-
ing pores. It is calculated by weighing a sample piece. Low density means
lower strength. The greater the amount of water and pores in the con-
crete, the lower the bulk density.
The manufacturing process can vary according to the location and
the circumstances. Concrete building parts are either produced on site
at their final place of use or are precast in a prefabrication works under
standardised conditions and later transported to the building site.

In-situ concrete
Manufacture In-situ or cast-in-place concrete means what is called “building site
concrete”, which is mixed and processed on site. Due to the lack of pre-
cision, building site concrete is used only in small amounts and is not the
standard case. The term in-situ concrete is now used above all to de-
scribe transported concrete that is used most commonly in the building
sector. > Fig. 12 This is mixed precisely in the works and then delivered as
fresh concrete to the building site where it is poured into the formwork.
Special properties/ The advantages of a building part made of in-situ concrete are the
advantages and possibilities for strong monolithic connections and the economic use of
­disadvantages
the material. In-situ concrete is generally used for parts of the building
that are not visible or on which there are few demands for the surface
appearance. However, this method of construction also has disadvan-
tages. The entire curing process takes place on the building site, i.e. even
under unfavourable weather conditions, which can have a major impact
on the results of concreting and on the progress on the building site.
­Extreme temperatures or rainfall often lead to considerable delays and
require the construction process to be flexibly planned.

Formwork
The formwork or shuttering is the negative form of the concrete build-
ing part. The reinforcement steel is placed in it and the liquid concrete
then poured into it. It must therefore be dimensioned to withstand the
pressure resulting from the introduction of the concrete.
Formwork consists of different parts, generally a formwork system
and formwork sheeting. To ensure that the concrete can be released from
the formwork after hardening, the sheeting must initially be treated with a
release agent (oil, wax, varnish etc.). With standard orthogonal formwork
for a wall or a ceiling slab, prefabricated formwork panels are generally
used as the formwork sheeting. They are held together by formwork

28
Fig. 12: Concrete mixer and mixer vehicle Fig. 13: Exposed concrete with regular anchor holes

3 4 5
1 threaded rod
2 nut
6 plastic plugs
3 formwork
1
4 connecting cone
5 sliding sleeve
6 reinforced concrete
2

formwork tie with sliding sleeve

tie holes as cones

design element

example of elevation tie steel concreted in place

Fig. 14: Formwork anchors

a­ nchors that take the pressure off the concrete. When the formwork is
struck (removed from the building part) the holes remain where the an-
chors were. In building parts that will be visible, the position of these
holes should also be considered at the planning stage. > Figs. 13 and 14 They
can either be closed or adapted to suit the design concept, but remain
visible. The position of openings in and holes through the concrete must
also be considered before making the formwork and the necessary
­adaptations.

29
 1

5 1 formwork element
2 tie holes
4 3 spacer
4 formwork strut
5 second formwork element, back

6 formwork tie rod

7 reinforcement mat

7 8

or

8 reinforcing bars
concrete with reinforcement cage

9 Second element closes the system,

which is fixed and can now be filled
with concrete.

Fig. 15: Erecting the formwork

30
Fig. 16: Smooth surface with a large proportion of pores. Rough surface showing marks of
board shuttering

The sheeting can be made from a variety of materials that influence Formwork sheeting
the later appearance of the concrete surface. Wood can be used as the
formwork sheeting in several different ways. Depending on how it is
worked it can produced smooth or rough structures. > Fig. 16 Wood can be
used planed, flamed, rough-cut or brushed. The absorbency of the form-
work sheeting plays a decisive role. Wood tends to be essentially absorb­
ent: it takes water and air from the concrete while it is curing and thus
gives it a particular surface quality. This surface has fewer pores and a
more even appearance.
Formwork made of plastic, aluminium or steel is non-absorbent. In
contrast to wood, steel or aluminium formwork is expensive but can be
used several times. Plastic formwork is inexpensive and durable. Non-
absorbent formwork can produce particularly smooth concrete surfaces,
but also encourages the formation of pores. As a result, cloudy discol-
ouring or marbled surfaces can develop more quickly. There are also
many structured formworks that give designers the freedom to create a
structured surface for exposed or fair-faced concrete. > Fig. 17
The different formwork systems are named after the way they are Formwork systems
constructed. The most commonly used system is frame formwork. The
name is derived from the fact that the formwork panels consist of fixed
aluminium or steel frames to which the formwork sheathing (e.g. of wood
or plastic) is fixed. These modular elements are suitable for wall and ceil-
ing slab formwork. > Fig. 18 Frame formwork can be erected quickly thanks
to its modular system and allows rapid progress to be made with the con-
struction work. Generally speaking, curves or angles are possible only
with other systems.

31
Fig. 17: Design of different surfaces

A further widely used system is grid formwork, which can also be

used for walls and ceiling slabs. It offers a greater degree of flexibility but
is somewhat more complex to use, as the formwork system and the sheet-
ing must be mounted as single parts. The girder formwork consists of a
grid of girders on which the formwork sheeting is mounted. It can be
­adjusted precisely and when removed does not leave behind the grid-like
pattern of lines caused by frame formwork. This is due to the fact that
the sheeting can be inserted in different sizes and materials indepen-
dently of the formwork construction principle. The beam system is gen-
erally built from solid web or lattice girders made of aluminium. > Fig. 19 In
connection with the formwork systems, different terms have become part
of building site jargon. A girder formwork is also called a “flex formwork”,
and a premounted ceiling slab formwork is also called a “ceiling table”.
> Fig. 20
Special building parts require special formwork systems, for in-
stance, column and round formworks. Column formwork is relatively
­expensive as it must generally be made using a special cross section
based on the structural engineer’s calculations. The relatively small sur-
face area means that work must be carried out precisely, and a high level
of concrete pressure develops within the small formwork. All the columns

32
Fig. 18: Frame formwork

formwork sheeting

girder system

supports

Fig. 19: Girder formwork

within a building should therefore have the same cross section if pos­
sible. Even though this may mean that more concrete is used it saves on
labour costs and time. The individual formwork can be used several times
and the system does not have to be readjusted each time. Round ­columns
are even more difficult as matrices have to be inserted in the sheeting,

33
 Fig. 20: Supporting a ceiling slab formwork

which is generally orthogonal. However, there is an alternative system

using cardboard forms. Cardboard tubes that are coated internally allow
a round cross section with a smooth surface to be created easily. > Fig. 21
However, large round formwork using the classic system is generally more
expensive and must be planned very precisely. Special formwork systems
must also be used for building parts such as downstand beams.
Uniform formwork systems generally reach their limitations when
complicated, small-scale or individual building parts are involved. Form-
work for stairs, for example, is therefore generally produced individually,
or entire staircases are concreted in the works. In most cases the stand-
◯ ard systems are of limited use only.
Climbing or gliding To produce several floors one after the other, especially in high-rise
formwork buildings and tall vertical building parts, a climbing or gliding formwork
can prove most efficient.

◯ Note: A permanent or “lost” formwork is one that

cannot be removed after concreting. This can be due
to the geometry of the building part or to special
­circumstances, for instance, when the underside of a
floor slab in the ground is no longer accessible.

34
Fig. 21: Columns in cardboard formwork

concrete

formwork work concreting

platform stage

anchoring in the cones

of the previous stage

Fig. 22: Climbing formwork

The climbing framework can be used either “crane-assisted” or “self-

climbing”. Crane-assisted climbing formwork consists of large wall form-
work elements that are fixed to console platforms on travelling trolleys.
The platforms are anchored in notches in the previously concreted sec-
tion below and provide a working area for the next section to be con-
creted. The platform and the formwork are lifted in stages by the crane
and thus “climb” upwards. > Fig. 22

35
 hydraulic jack

beam holds formwork together

(concrete pressure)

work platform

formwork
(1.20 m)

moves in 5 cm steps
cradle

Fig. 23: Gliding formwork

Where it is not possible to use a crane, the formwork moves upwards

in stages with the aid of hydraulic lifting mechanisms and is therefore
“self-climbing”. The concreting stages generally consist of one floor. Both
kinds of climbing formwork offer a high level of quality and flexibility dur-
ing the construction process.
A gliding formwork is used above all for tall building parts with few
inserted elements where no great demands are made on the quality of
the surface. A continuous wall cross section makes this kind of formwork
even more efficient.
The formwork in this case glides in small steps along rods that are
centred up the wall and concreting is carried out in layers. > Fig. 23 The work
process is continuous and the formwork cannot be changed, cleaned or
repaired during it. This kind of formwork ensures that speedy progress of
the construction work along with low use of material but on account of its
lack of flexibility it demands precise planning from the very start.

Concreting process
Pouring The actual concreting process is one of the many factors that have
a lasting impact, not only on the appearance of the concrete but also on
its performance. The standard kind of in-situ concrete is pumped into
the formwork on site. Care must be taken in pouring that the drop into
the formwork is not too great. In favourable situations concrete can be
transported to the place where it is to be used either directly from the

36
Fig. 24: Pouring concrete

transport vehicle or by means of concrete pumps and crane-assisted con-

crete buckets. > Fig. 24
Shotcrete is a further method of concreting. A special mix makes it Shotcrete
especially flowable and it hardens rapidly, generally due to the addition
of an accelerator. Shotcrete allows flat areas of compacted concreted to
be made. This method is suitable in particular for improving existing build-
ing parts.
A distinction is drawn between the wet and the dry process. In the
former, standard mixed concrete with a small aggregate size is used and
applied using the appropriate pressure. In the dry spray process the ­water
is first added to the concrete mix in the spray nozzle; this process is par-
ticularly suitable for repair work to damaged building parts.
If shotcrete is used to repair damaged building parts it should be
noted that the increased amount of concrete increases the weight of
the building part. It must be assessed whether the structural ­capacity
­remains unimpaired after the improvement work. The use of the shot-
crete process frequently makes particular sense for retaining or ­restoring
concrete’s fire protection qualities.
In the production, care must be taken to ensure that the old and new
concrete areas can bond well. If the concreting stage is interrupted it
must be possible to ensure a connection. What is known as “rebound” is
the loose material that accumulates on the surface of the shotcrete. It
must be carefully brushed off before concreting can recommence.

37
 Fig. 25: Principles of strengthening a ceiling slab with shotcrete

existing slab

reinforcement
sprayed concrete

existing slab

textile insert (several layers)

sprayed concrete

Fig. 26: Soffit of a ceiling slab to which shotcrete has been added

Shotcrete work can be carried out vertically or overhead and conse-

quently it is often used to strengthen areas of ceiling slabs. > Figs. 25 and 26
This work is generally carried out from below. If reinforcement must be
used as well, this generally takes the form of lamellae or textile inlays
consisting mostly of carbon. Both processes ensure that the carbon struc-
tures increase the tensile strength of the building part.
Shotcrete can sometimes be applied to wet surfaces and it is also
used in securing building excavation pits.
Tamped concrete Tamped concrete is named after the concreting process or when
tamping is the kind of compaction used. This traditional method is one

38
of the oldest ways of concreting, and is carried out by introducing con-
crete layer by layer into the formwork and also compacting it layer by
layer. The height of the individual layers should not be greater than 15 cm.
After the formwork is stripped, the lines of the tamped layers are visible,
creating the characteristic visual effect. We can also see ­certain irregu-
larities, such as denser and less dense areas or collections of aggregate.
Tamped concrete can be used only without reinforcement and there-
fore the building parts can only handle compression loads or can be used
in non-loadbearing situations. Nevertheless, its special aesthetic means
tamped concrete is still often used outdoors. Today it is generally not
produced in the traditional way but instead a low-mortar concrete is used,
which leads to porous areas that create the visual effect required. The
aggregate is no longer completely enclosed and is visible externally. This
surface can be created by tamping but equally well by compacting in
­layers.
Spun concrete is produced by compacting the concrete in a hollow Spun concrete
mould. The procedure is the same as with pouring concrete, in that the
reinforcement is fixed in the formwork and the concrete then added. The
rapid rotation of the mould around its own axis presses the concrete
against the outer walls. The centrifugal force drives the heavier elements
outwards and lets the water flow off inwards. This produces a low water-
cement value. Through the compacting process, the concrete acquires a
void at the centre of the cross section and an external surface free of
bubbles.
This method of production is particularly suitable for masts, piles,
piers or columns. Steel tubes can also be coated with concrete in this
way and protected against corrosion. The internal void created is always
round, even if the external shape is orthogonal or of a different form. The
void is also suitable for taking service runs.

Precast elements
Precast concrete elements are produced in the factory and delivered Special properties/
to the building site ready to be fitted into position. The advantage of this advantages and
disadvantages
production method is the precise, clean nature of the process and the
quick assembly it allows. Setting times and the weather conditions on
the building site need hardly be taken into account at all during the build-
ing process. A disadvantage, however, is that the dimensional tolerances
are far lower than with in-situ concrete. Precise planning and coordina-
tion are required. On the other hand, the precast building method makes
it considerably easier to produce fair-faced concrete surfaces. The
­qualities of the surface can be far more precisely planned and a uni-
form appearance created, as in the factory the precast concrete parts
can be produced under constant conditions without exposure to the
weather.

39
 Fig. 27: Hall-type building made from precast elements

In order to exploit the advantages of both methods, precast and

i­n-site concrete parts are often combined. For example, complex stair-
case ­geometries are produced in the factory and combined with an ­in-situ
­concrete floor slab, which can incorporate any tolerances that emerge.
However, entire building elements can also be produced in the factory.
>  Fig. 27 In general, though, the size of the elements should take into
­account the economic aspects of the precast construction method. While
building parts of almost any size can be made on site, the question of
their transport effectively limits the size of precast elements.
Element construction The element construction system is a particularly efficient use of
method precast elements. Precise production in the works and the repeated use
of the same elements can allow work that is very cost and time efficient.
The production of the individual elements depends on the size of the mod-
ules: for example, on the concreting stages, formwork panel sizes or
­similar. The joints and anchor holes – which are primarily necessary for
transport and which, for visible building parts, must be considered in the
planning – are also made in the works. Equally, however, entire prefabri-
cated building cells can be mounted on site.
Filigree elements Filigree elements are so-called semi-finished parts. This means that
filigree prefabricated parts are produced in the factory and then filled on
site with fresh concrete. In the case of a wall, for example, the concrete
is poured between the two externally visible surfaces. > Figs. 28 and 29
In producing a filigree ceiling slab, the tension reinforcement is fixed
in the prefabricated part in the factory. Lattice girders ensure the later
bonding with the in-situ concrete. The filigree ceiling slab is placed in
pos­ition on the building site, providing the lower formwork, and concrete
can then be poured on top of it. Bonding means the construction later
functions as a bracing panel. A filigree ceiling slab can, however, also be
produced as a prestressed building part and can thus allow large spans.

40
Fig. 28: Filigree elements

precast part with reinforcement

outer shell, precast part

with reinforcement

in-situ concrete
lattice girder

in-situ concrete with upper reinforcement

lattice girder

filigree slab precast part with lower reinforcement

Fig. 29: Filigree floor/ceiling slab

Surfaces
A distinction is drawn between concrete that is used purely for struc- Fair-faced concrete
tural reasons and is later covered with other layers such as plaster, and
what is called fair-faced or exposed concrete.
As already mentioned in > Chapter Construction method, Formwork, achieving
a smooth exposed concrete surface requires special planning and exe-
cution. The composition of the concrete also influences the effect made
by the surface. The choice of aggregate tends towards increasingly fine
kinds. Different classes are explained in > Chapter Building material, Constituent
materials. ◼
The quality of fair-faced concrete is also divided into classes; the
rele­vant class should be stated in the specifications. > Tab. 10 The ­individual

41
 criteria for the execution and the surface quality are defined by giving
the planned fair-faced concrete class. This is the only way to ensure the
quality of the result. The individual criteria also help to achieve the ­desired
overall impression and, where necessary, to introduce changes during
the execution phase.
Texture The texture and formation of the element joints are divided into the
criteria T1 to T3. The closed quality of the concrete surface and visibly
defective areas along loose joints in the formwork sheeting, which later
turn dark, are classified.
Porosity The porosity of the surface is difficult to check. Classes P1 to P4 limit
the maximum amount of porous areas on a test area of the building part.
As porosity can differ considerably according to the formwork sheeting
used, a distinction is made between absorbent and non-absorbent form-
work.
Evenness of shade Differences in shade are referred to, independently of their cause,
by FT1 to FT3. These are only textual formulations that cannot be fixed
by precise parameters. Here, too, a distinction is drawn between absorb­
ent and non-absorbent formwork.
Evenness Evenness classified E1 to E3 relates to general dimensional toler-
ances in building construction and, where necessary, is adapted to the
relevant national standards.
Construction and The designations AF1 to AF4 primarily limit the surface offsets be-
formwork sheeting tween two formwork elements that are acceptable.
joints
The formwork sheeting is divided into the classes SHK1 to SHK3.
Test surface and They describe the condition of the sheeting and are relatively clearly dis-
formwork sheeting tinct from each other. The relevant construction firm is responsible for
class
maintaining the sheeting class. To enable architects to define their con-
cept for the finished surface as precisely as possible, the sheeting class
can be determined individually and further criteria added.
Additives The nature of the surface and the visual appearance of the building
part can be manipulated by the use of additives. In general these do not
have any major effects on the basic properties of the concrete but have
a considerable impact on the design. For instance, pigments can be used

◼ Tip: For a smooth surface quality the w/c value

should not be greater than 0.5, the cement content
should be above 350 kg/m3, and the proportion of
aggregate grain to cement should not be greater
than 6:1.

42
Tab. 10: Fair-faced concrete classes and their relationship to demands

Evenness of
Porosity

shade

Construction and formwork

Building parts (examples)
Fair-faced concrete class

Formwork sheeting class

Demand profile

Non-absorbent

Non-absorbent
Absorbent

Absorbent

Evenness

Test area
Texture

Costs
SB 1 Low Basement walls, T1 P1 FT1 FT1 E1 AF1 Optional SHK1
demands walls of rooms with

Low
commercial use
SB 2 Normal Staircase walls, T2 P2 P1 FT2 FT2 E1 AF2 Recommended SHK2

Medium
demands retaining walls

SB 3 High design Facades in building T2 P3 P2 FT2 FT2 E2 AF3 Strongly SHK2

demands construction (most recommended

High
commonly used class)
SB 4 Especially Representative T3 P4 P3 FT3 FT2 E3 AF4 Required SHK3
high design building parts in
demands building construction,
for representative
prominent buildings
(built on the basis

Very high
of SB 3 with somewhat
more stringent
requirements)

to give concrete a colour. The colour created is homogeneous and in prin-

ciple there are no boundaries to the shade that can used. By means of
coloured aggregates or granulates, small-scale accents can be introduced
which, depending on the grain size, influence the appearance of the sur-
face as a whole.
In addition to design with colour, translucency can be produced or
highlights introduced using other materials. For example, optical glass
fibres worked into concrete can conduct light through the solid building
material. The concrete becomes translucent. Depending on the arrange-
ment and density of the fibres, different appearances and intensities can
be produced. Translucent concrete can be used both indoors and out-
doors. > Fig. 30

43
 Fig. 30: Translucent concrete Fig. 31: Examples of surface patterns and
structures

The addition of marble or glass, for example, can also place special
features. Shimmering effects or special kinds of surfaces can be achieved,
depending on the grain size of the additive and the mix proportions.
Formwork The formwork sheeting plays an important role in the design of the
concrete surface. Depending on the material chosen it can, through its
absorbent or non-absorbent quality, produce a smooth or a structured
surface. Non-absorbent sheeting generally produces a smooth surface,
which, however, tends towards a certain degree of porosity. Clients and
architects often require the concrete to have a particularly even appear-
ance.
Absorbent formwork sheeting ensures that the structure of the ma-
terial used for the sheeting is transferred to the surface of the concrete.
For example, the grain of wooden formwork can be shown on the con-
crete or other materials imitated.
A further way of creating a surface structure is to insert matrices
into the formwork. Generally made of plastic, these elements can pro-
duce almost any kind of motif or pattern. There are almost no restrictions
to a designer’s imagination. Other objects from the everyday world or na-
ture can also be inserted into the formwork for design purposes. > Fig. 31
Later surface Even after production the appearance of the surface of a concrete
­treatment building part can be manipulated. Such treatment methods can be
roughly subdivided into chemical, manual, technical and mechanical pro-
cesses. > Tab. 11
Chemical treatment methods include acid washing or the commonly
used exposed aggregate process. In acid washing a diluted acid is used
to remove the outer cement skin. Exposed aggregate concrete, in con-
trast, is ground with retarders allowing the different aggregates to ap-
pear. > Fig. 32 Photo concrete can depict precise graphic designs. Using a

44
Fig. 32: Exposed aggregate concrete facade

Tab. 11: Surface treatment methods

Chemical Acid washing with Exposed aggregate Photo concrete

treatment diluted acid concrete
Manual treatment Bush hammering: Chiselling: using Droving: using drove Bush hammering:
using bush hammer point chisel and chisel or machine using compressed air
or chisel ­hammer chisel
Technical treatment Sand or flame blasting
Mechanical Polishing Grinding
­treatment

silk-screen process, light and dark colour gradients can be produced on

the surface.
Skilled manual treatment processes are based on the principle of re-
moving the outermost concrete layer with the help of various tools. Bush
hammers or chisels, pointed chisels and hammers can be used. They pro-
duce a rough surface that is lighter in colour. In bush-hammering sur-
faces and edges can be worked up to a depth of 6 mm, whereas with
pointed chisels a depth of 10 mm can be achieved. Droving is carried out
with a machine or a drove chisel and creates a regularly structured sur-
face. In bush-hammering a compressed air chisel can be used, which cre-
ates a somewhat coarser surface. > Fig. 33
Technical treatments include the use of sand or flame blasting which
again changes the outermost layer of the concrete. In contrast, mechan-
ical treatment is carried out by polishing or grinding the concrete and
subsequently varnishing or waxing it. This creates a smooth, fine surface.

45
 Fig. 33: Droved (left) and bush-hammered (right) surface

Ageing and soiling When planning a building part that is to be constructed thought
should also be given to its ageing process. Soiling through environmen-
tal effects, fumes, rainwater or similar can cause massive changes to the
appearance after just a short time. In planning, the orientation and wind
directions should be taken into account as well as the flow pattern of
rainwater in order to avoid smears. The same applies to the inclination
of the building part and the nature of its surfaces. In addition to their de-
sign effects these can also be manipulated in terms of their capacities.
For instance, a watertight surface can be created by using silicone
resins that impregnate the pores close to the surface. This process is
called hydrophobing. The building part still remains permeable but the
water simply runs off.
There are certain treatments that can be used to provide protection
against graffiti, which cannot generally be covered over by a simple coat
of paint. What is called a “sacrificial coating” involves the treatment of
the concrete surface with waxes. It is easy to clean but this layer is “sac-
rificed” to the cleaning process. After cleaning has been carried out the
wax layer must be reapplied to the entire surface. An alternative is a per-
manent coating. It lasts for longer than a sacrificial coating but reduces
the diffusivity of the wall.

46
 Building parts
As with other building materials, many requirements for concrete are
regulated by standards and guidelines. The building parts must be
planned, checked and approved, before they are finally constructed. The
individual building parts are considered below and their ­nature explained.
Placing building parts together always involves connecting different
layers such as seals or protective films and ensuring that they function
perfectly. With regard to concrete, there are a number of special aspects.
The constructional connection of two building parts made of reinforced
concrete is generally done by means of connecting or projecting rein-
forcement. This varies according to the production method. Precast
­elements and in-situ concrete can be easily connected with each other,
as can two in-situ concrete parts. To connect two precast ­elements, spe-
cial bearing parts must be formed.

Footings / foundations
The function of the foundation is to transfer the load of a building to
the ground. Here it is necessary to investigate the bearing capacity of
the soil or the loadbearing layer. Together with the structural system of
the building, a suitable foundation for transferring the building loads to
the ground is then planned.
Every foundation must be made frost free. In central Europe a depth
of 80 cm from the surface of the ground must be guaranteed. If a foun-
dation does not itself reach this depth, either a frost skirt must be added
or the foundation must be made deeper. > Fig. 34

ground level or

ground level
≥ 80 cm

≥ 80 cm frost skirt
added

Fig. 34: Frost-free foundation

47
Tab. 12: Possible kinds of water in the ground

Non-pressing water
Soil moisture Moisture that is bound into the soil. Arises, e.g. by infiltration of rainfall into water permeable
ground.
Seepage water Water that gravity causes to move in the direction of the groundwater.
Non-accumulating Flows off almost unobstructed (gravel or sandy soils).
seepage water
Standing seepage Water accumulates at times above less permeable layers of ground.
water
Pressing water
Back water Water that accumulates in less permeable ground layers and, unlike seepage water, does not soon
flow off, but exerts pressure on the building part.
Layer water If in soil with generally poor permeability there are layers with better water permeability, the water
flows in such a layer towards the building and exerts pressure on it.
Ground water Water table in the ground, exerts pressure on the building where it extends down into the ground
water area.

Tab. 13: The demands made on a white tank

Demand class 1 Pressing and non-pressing water and at times standing seepage water
Demand class 2 Wet ground and non-accumulating seepage water
Use class A No ingress of water
Use class B Damp areas at joints or cracks are accepted

Sealing/­ The parts of the building in contact with the ground must be pro-
waterproofing tected against moisture. In general a distinction is made between non-
pressing and pressing water. > Tab. 12
In the case of non-pressing water a normal seal against ground mois-
ture, for example, a bitumen coating, can be used. Where there is press-
ing water the foundation must be protected against the entry of water.
This can be done by means of a bituminous sealant (black tank) or
­watertight reinforced concrete parts (white tank).
A black tank is produced by constructing the building parts in con-
tact with the ground in several layers. In addition, (black) sealing mem-
branes must be applied – giving the black tank its name. > Fig. 35
A white tank is made from waterproof concrete and essentially needs
no further sealing layer. Diffusion or capillary effects can, however, influ-
ence the watertightness of the white tank. It is not absolutely watertight
and, depending on the demands made on it, must be augmented by spe-
cial additives and very precisely made joints. There are different ways of
making watertight joints. Thermoplastic or elastomeric joint tapes can
be used or metal waterstops can be inserted; on the other hand, joints
are often sealed after they have been made.

48
 additional wall layer

seal
ground level ≥ 30 cm
external wall

base plate

protective concrete layer

granular subbase

Fig. 35: Building a black tank

joint tape on the outside waterstop expanding waterstop

Fig. 36: Sealing joints

Joint tapes protect against the entry of water into building joints with-
out continuous reinforcement, whereas waterstops (coated or uncoated)
are generally used for building parts with continuous reinforcement,
where they are concreted into the adjoining building parts. > Fig. 36
A white tank must meet particular requirements. The base slab and
the sides must be at least 25 cm thick and, depending on the function
and the soil condition, the criteria for particular demand and use classes
must be met. > Tab. 13 ◯

◯ Note: Joint tapes or metal waterstops bridge the

joints between different concreted sections, which
would otherwise allow the entry of water despite homo-
geneous watertight concrete. These generally include
the transition from the foundation slab to the basement
walls but also the different concreting stages in the
walls themselves or even sump pits or other penetra-
tions.

49
 column

in-situ concrete
column
sleeve
connecting foundation
reinforcement

footing

Fig. 37: Connecting reinforcement for a Fig. 38: Sleeve foundation

­column

Alternatives that require product-related approval include injection

hoses and expanding waterstops. These waterstops can be inserted, for
example, between the reinforcement rods. They swell when they come
into contact with water and seal the joint. In all cases the arrangement
◼ of the reinforcement must be suited to the joint sealing method used.
Pad foundation Pad foundations transfer point loads from the building such as the
loads of a column. They can be cast on site or made as prefabricated
­elements. For rigidly fixed columns the connection is made by means of
connecting reinforcement. > Fig. 37
A variation of the point foundation is the sleeve foundation > Figs. 38
and 39, which is also used for precast columns. The column is concreted
into the sleeve, forming a rigid connection.
Strip foundations The function of a strip foundation is similar to that of a pad founda-
tion: transferring linear loads from the building. Strip foundations are
therefore generally made under loadbearing walls. > Fig. 40 According to
the dimensions and the load, strip foundations can be made with or with-
out reinforcement. In very simple load situations, foundations without

◼ Tip: If rooms located in the ground are intended for

a high-quality use so that the entrance of damp must
be prevented at all costs, the combination of two pro-
cesses (e.g. white tank with black external sealing layer
or joint sheets and waterstops) can make sense.
Sealing poorly constructed tanks after they have been
built is difficult.

50
Fig. 39: Sleeve foundations

Fig. 40: Laying out strip foundations

reinforcement can be made using suitably dimensioned excavations that

are simply filled with concrete, without the need for formwork. When
foundations have to be reinforced and made in formwork, this should be
taken into account in calculating the total amount of excavation work,
which should also include a sufficient surrounding area for working.
Generally speaking, a raft footing can be made as a slab foundation. Raft footing
A suitably dimensioned ground slab transfers the loads to the ground. It
can be used where the soil bearing capacity is poor, as well as on ground
where the bearing capacity is good. The even distribution of the load can
prevent settlement and cracks. The raft foundation must be laid on a
granular subbase and an anti-capillary layer. The granular subbase pro-
vides a smooth surface on which to pour the concrete and functions as
the lower formwork. It offers the only possibility of ensuring that the lower
reinforcement has sufficient concrete cover. > Fig. 41

51
 min. 25 cm
for “white tank”

external wall
(“white tank”)
ground level

base plate

granular subbase
(lean concrete)

min. 25 cm
for “white tank”

Fig. 41: Raft foundation with granular subbase

loadbearing
ground

drive by boring, ramming etc. insert reinforcement fill with concrete while
until a loadbearing layer is reached withdrawing the tube

Fig. 42: Making a piled footing

Pile footing In soils with poorer bearing capacity or where the bearing layer lies
deeper, pile footings are used. > Fig. 42 The piles can be precast, or made
in situ or as composite piles. With the in-situ method the concrete is
poured directly into the bored hole. Prefabricated piles are made in the
factory as a whole or as individual parts. In the composite system a bear-
ing member of steel or concrete is inserted into the bored hole and
grouted with cement mortar. The bearing members are inserted by means
of ramming, boring, flushing, pressing, vibrating or by using screws. The
depth of the piles can also be combined with the use of geothermal
­energy. Depending on the nature of the ground and of the building there
are various special forms of piled footings and they can be combined
­individually with other kinds of footings.

52
 min. min. min. min. min. min.
min. 10-12 cm
10-12 cm 8-15 cm 6 cm 8–15 cm 4 cm 6 cm

loadbearing layer
air layer
facing layer

single layer multiple layers multiple layers multiple layers

(sandwich) (with air layer)

Fig. 43: Principles of wall construction

Wall
In accordance with its shape, a wall takes up linear loads and can be
made in different ways. In additional to vertical loads the plate effect of
a wall enables it to provide bracing and to take horizontal loads. Concrete
walls can also be made as space enclosing, non-loadbearing elements,
or as front-hung facade elements.
Where they form the external skin, reinforced concrete walls require
insulation in order to meet thermal insulation standards. The minimum
thickness of a reinforced concrete wall made of in-situ concrete is 10 cm,
as long as it is under a continuous ceiling slab. Otherwise it must be at
least 12 cm thick. For reasons of sound insulation, concrete walls in hous-
ing are generally 18 cm thick.
Prefabricated wall elements can consist of one or more layers. A Prefabricated wall
common element is the sandwich element, which, when delivered from elements

the factory, meets all the structural, building physics and design de-
mands. It consists of a loadbearing layer, insulation and a facing layer;
an air layer can be added if required. Openings and conduits for services
can also be made in the factory. > Fig. 43
Reinforced concrete walls produced as precast elements must, if
­under a continuous ceiling slab, have a minimum thickness of 8 cm, and
if outside at least 10 cm.
If the precast element consists of a bearing layer, insulation and fac-
ing layer, the bearing layer must be between 8 cm and 15 cm thick,
­depending on the load. It is dimensioned according to structural require-
ments, and reinforced. The facing layer is generally around 6 cm thick. If
the surface is to be treated later > Chapter Construction method, Surfaces, the outer

53
 layer must be made somewhat thicker so that, despite the surface re-
moved, the necessary concrete cover is still provided.
The maximum dimensions of precast elements depend on the means
of production, transport and fitting. The usual dimensions are between
4 and 10 m. In fluctuating temperatures, the facing layer should not be
exposed to any stress. A panel should therefore not be any larger than
15 m², with a maximum width of 5 m. Under some circumstances there
can be more joints in the facing layer than in the bearing layer.

Column
Reinforced columns can transfer enormous point loads. However,
they are less suitable for taking horizontal forces and should be designed
primarily to take compressive stress. The production and concreting of
a column requires a certain planning basis and guidelines that are ex-
plained in the > Chapter Construction method, Formwork and Concreting process. Depend-
ing on the formwork chosen, the design and economic constraints, there
are a number of different cross sections that can be selected for col-
umns. > Fig. 44
Prefabricated Columns can also be made as precast elements. Where there is a
­columns connection to a beam or ceiling element that is also precast, the transi-
tion from column to beam or ceiling slab cannot be monolithic and bear-
ing areas must be formed instead. > Fig. 45
A further variation is the composite column, which in principle con-
sists of a steel beam section that is filled with concrete. In this version

square column rectangular L-shaped cross section U-shaped cross section

column

cross-shaped circular hexagonal octagonal

cross section cross section

Fig. 44: Typical column cross sections

54
Fig. 45: Prefabricated columns

no formwork is necessary and columns with very slender cross sections

can be made. Conversely, a steel beam can also be encased in concrete
to create a loadbearing core. The minimum dimension for in-situ columns
is 20 cm, and 15 cm for prefabricated columns, independent of the type
of cross section chosen.

Beam
Beams can be made in very different dimensions. They can be used
to span smaller openings (lintels) or as part of a frame construction.
Equally, a beam can serve as the bearing or substructure for a ceiling,
and can be made as an upstand or downstand beam. Where the beams
and ceiling slab are made monolithic we speak of a T-beam or slab-and-
beam system. > Chapter Building parts, Ceiling/floor slab This system is made of
­in-situ concrete and generally in a single work process. The effective
structural height of the T-beams is that of the actual beam plus the thick-
ness of the slab. > Fig. 46
The beams generally have solid cross sections. To simplify produc-
tion and the formwork, rectangular cross sections are generally used. In
the prefabricated system profiles such T- and I-beams can be used to re-
duce weight. Here, thought should be given to which method of produc-
tion and type of cross section is the most economic and efficient. > Fig. 47
Recent developments in high-performance concrete allow thinner
and thinner sections, and make hollow sections possible as well; this
­enables both concrete and weight to be saved.

55
 effective structural
height

Fig. 46: Structural system of the T-beam

rectangular L or T profile U profile or channel beam

cross section as support for slab

trapezoid cross section beam with T cross section beam with I cross section

Fig. 47: Typical beam cross sections

Beams that are adapted to the form of the moment curve can also
be made, which both match the ideal flow of forces and allow other roof
forms with slopes. > Fig. 48

56
 parallel chord girder

pitched roof girder

Fig. 48: Beam forms

I-girder

T-girder

support for prefabricated beam in roof plane support for downstand beams double-T elements supported on
downstand beam

Fig. 49: Bearing area and jointing of different prefabricated elements

To connect different prefabricated elements, bearing areas have to

be made. > Fig. 49

57
 skirting
edge insulation strip
floor covering
screed
separating layer
impact sound insulation
ceiling slab

Fig. 50: Example of a floor construction

Ceiling / floor slab
In concrete construction a ceiling slab can be made using different
systems. The standard method is the in-situ ceiling slab. The formwork
is made using a ceiling “table”, the reinforcement put in place, and the
concrete then poured over it. However, precast or filigree elements can
equally well be used. > Chapter Construction method, Precast elements Various lay-
ers can be used for acoustic decoupling and to make the finished floor.
> Fig. 50 A ceiling slab is a horizontal plate and therefore as well as trans-
ferring forces in a vertical direction it also always has a bracing effect in
the horizontal plane. It can be made with or without prestressing. Ceil-
ing slabs in normal multi-storey building (housing) are generally made
with a thickness of 18 cm and more. Bearing points and the formation of
monolithic connections ­differ according to the nature of the wall mate-
rial. > Figs. 51 and 52
Reinforced concrete can be used most efficiently in creating differ-
ent structural systems. Every form of beam, beamed ceiling slab, ­coffered
ceiling slab or T-beam and slab can be made. By using slender downstand
beams at close centres > Chapter Building parts, Beam, monolithic ribbed slabs
can be made. > Fig. 53 The ribs, which are spaced 30–70 cm apart, run in
the main loadbearing direction and are more slender than ­standard down-
stand beams. In precast construction, what are known as double ­T-beams
are often used. These consist of two ribs and the projecting ceiling slab.
The joints are either filled with in-situ concrete on the building site or a
top concrete layer is poured over them. > Fig. 54
If the ribs run in both directions they form a coffered ceiling. > Fig. 55
The coffered ceiling slab can span in two directions. Here, too, the mono­
lithic connection with the ceiling ensures that the system has a highly

58
 internal plaster
skirting
edge insulation strip
floor covering
screed
separating layer
impact sound insulation
ceiling slab

separating layer or movable bearing

masonry wall
insulation plane
render

Fig. 51: Ceiling slab resting on masonry wall

in-situ concrete precast elements

concreting stage sealing mortar

Fig. 52: Ceiling slab resting on reinforced concrete wall

59
 30–70 cm

Fig. 53: Ribbed slab

joint sealant

concrete
top layer

Fig. 54: Double T-beam slab

60
Fig. 55: Coffered ceiling slab Fig. 56: Beam grillage

e­ fficient loadbearing capacity. However, production is elaborate, particu-

larly making the formwork. The ribs can theoretically be adapted to the
flow of forces in the building part, but this may further complicate pro-
duction.
Where the ribs are made without a ceiling slab, for instance, in order
to make transparent floors and roofs, the system resembles that of a
beam grillage. > Fig. 56 As in steel construction, this enables the loadbear-
ing effect of a flat surface to be achieved using linear building elements.
Flat ceiling slabs that rest only on columns and require no downstand
beams are also possible. They must be made somewhat thicker and, gen-
erally, are used for spans between 7 and 8 m, as for larger spans their
massiveness makes them no longer economically viable. Flat ceiling slabs
are particularly useful for free floor plans, as they create soffits without
any interruptions and are therefore very flexible.
To handle the enormous forces that develop at the columns when a
flat slab is used, punching shear reinforcement is often required. A higher
amount of reinforcement is laid around the column, which means that
columns for flat ceilings cannot generally be positioned directly at the
edge of the slab or at the facade. > Fig. 57 One version that offers a way of
dealing with bearing loads is the mushroom slab. > Fig. 58 The slab rests
on columns that have a specially shaped (“mushroom”) column head that
distributes the loads better. It allows structurally optimised use of the
slab but the formwork for the columns is considerably more elaborate.
In order to reduce mass and weight, hollow elements can be laid in Hollow core planks
the cross-sectional area that is not structurally required (hollow core
floor), depending on the particular structural demands.
Hollow core ceiling/floor slabs can be prestressed or made with
slack reinforcement. They have continuous voids in the longitudinal
­direction and can therefore be spanned uniaxially. The slabs are firmly
fixed to each other by interlocking, cross and longitudinal reinforcement,
and by filling the joints. In addition to using joint filler there are also kinds

61
 section plan

column strip of dowels

strip of dowels

column

Fig. 57: Punching shear reinforcement

Fig. 58: Mushroom head columns

in which a top layer of concrete is added that either has a load distribut-
ing function or also helps to carry the load. Depending on how it is made
the slab can function as a plate and can also take horizontal forces.
Prestressed hollow core floors allow wide spans with a low slab thick-
ness. They are reinforced in the longitudinal direction with steel strands
alone; the necessary tension reinforcement is positioned near the under-
side of the slab in the continuous solid webs. The elements are usually
80–120 cm wide and 16–40 cm thick.
Thanks to the prefabrication of the elements and the ease of moving
them by means of a mobile or building crane directly from the transport
vehicle, hollow core slabs ensure a speedy and economic construction
process. They can be placed in position without propping. They can be
connected with steel, reinforced concrete or masonry walls. The continu­
ous ring beam, made of concrete, is most important. > Figs. 59, 60 and 61

62
 masonry wall
insulation plane
back ventilation
facing wall

floor construction

ring beam, stressed hollow core planks

reinforced

Fig. 59: Connections of hollow core planks to masonry wall

end support on steel beam composite screed

for example in industrial building

angle as edge detail

ring beam

joint reinforcement
stressed hollow core planks

end support in steel beam plane composite screed

for example in industrial building

angle as edge detail

grouted anchor
ring beam
stressed hollow core planks
extension of flange/bearing e.g. with metal sheet

Fig. 60: Connections of hollow core planks to steel construction

63
 bearing on composite screed for example
downstand beam in industrial building, poss. strengthening
bearing strip reinforcement in transitions

stressed hollow joint reinforcement

concrete planks
downstand beam

end bearing in
reinforced concrete wall
composite screed for example in
industrial building, poss. strengthening
reinforcement in transitions grouting

ring beam

stressed hollow joint reinforcement

concrete planks

Fig. 61: Connections of hollow core planks to reinforced concrete wall and downstand
beam

The use of reinforced concrete allows optimal exploitation of mate-

rial and loadbearing capacity and also the integration of other building
functions. For instance, cross-sectional areas with no structural function
◯ can be combined with concrete core activation or other kinds of services.

◯ Note: Concrete core activation or building part

a­ ctivation is a system in which heating or cooling pipes
filled with water or air run through the concrete build-
ing parts. The system uses concrete’s high density and
storage capacity to regulate the temperature in the
building. Through the pipes laid in the concrete heat or
cold is given off later.

64
 Planning the openings is of equal importance in the design of both Openings
walls and ceiling slabs. They must be considered in drawing the form-
work and reinforcement plans and in the production. In positioning ceil-
ing openings in particular, the structural system must be carefully con-
sidered, as openings should not be in areas where the slab is subject to
the greatest stress. In optimised systems such as prestressed concrete
hollow core planks, the possibility of making additional openings later is
very restricted. During the planning stage careful thought must be given
to the direction in which the ceiling slab spans, how the downstand beam
and reinforcement systems run and where, if necessary, further strength-
ening has to be calculated.

ROOF AND ROOF parapet

In the form of a flat roof, a reinforced concrete slab can form the ­final
terminating part of a building and carry the necessary insulation and seal-
ing layers. In construction terms, concrete pitched roofs can also be
made, so that the standard change to timber construction for the roof
structure is often unnecessary.
With a flat roof in particular, proper sealing and a continuous insula-
tion layer must be ensured in order to avoid causing any damage in build-
ing physics terms. Like other roofs, a reinforced concrete roof is made
from a loadbearing layer, a moisture barrier, the insulation, and the final
sealing with a protective layer. A flat roof can use the loadbearing sys-
tems of the ceiling slabs. Particular attention must be given to drainage.
Proper falls of at least 2% must be ensured. The roof water drainage can
also run through the inside of the building. In this case it penetrates the
sealing layer in some places, which must be detailed and made with great
care. > Fig. 64 The fall is not generally made with the loadbearing element
but is produced later by an additional concrete layer laid to falls or by
sloping insulation. The roof parapet can be made in a number of differ-
ent ways. It can, for instance, be a monolithic upstand but it can also be
separated thermally. This alters the construction thicknesses through
­additional insulation measures. > Figs. 62 and 63

Thermal separation
One common joint is the connection of a projecting element, such
as a balcony slab. Here, the thermal separation of the ­element presents
a particular challenge as it penetrates the outer skin. A number of manu­
facturers have examined this problem and have developed elements that
can both insulate and provide the structural connection.
As with roof parapet walls there are essentially two ways in which
this connection can be made. Either what is known as an Isokorb is made
to ensure thermal separation > Fig. 65, or the balcony slab must be in­sulated
on both sides. > Fig. 66 Naturally, this latter solution requires additional
material and also has a visual effect on the final thickness of the slab.

65
 concrete cover

metal flashing

fall made with sloping insulation

Isokorb with
connecting
reinforcement sealant
(thermal separation) insulation
moisture barrier
insulation plane r.c. slab
render

Fig. 62: Roof parapet wall, thermally separated

metal flashing
wood-based panel
upstand
continuous insulation

fall made with sloping insulation

sealant
insulation
moisture barrier
r.c. slab

insulation plane
render

Fig. 64: Internal drainage

66
 sealant
insulation
gravel trap moisture barrier
and gully r.c. slab

fall made with sloping insulation

Fig. 63: Roof parapet as upstand wall

continuous insulation
plane

Fig. 65: Thermally separated cantilever

67
 outside inside

height difference

construction
thickness

Fig. 66: Insulation on both sides

paving slabs on supports

drainage/protective mat
insulation (treadable)
moisture barrier
(depending on
construction undercoat,
bituminous) outside wall
screed laid to falls window
r.c. slab base profile

floor covering
screed
separating layer
impact sound insulation
slab with step

Fig. 67: Transition to loggia with reinforced concrete slab folded downwards

68
 If the slab is not a cantilever but, for example, a loggia above a living
room, there are great differences in the construction layers between in-
side and outside. Here, the designer must react at an early stage. > Fig. 67
If, for design reasons, it is not possible to fold the reinforced concrete
slab downwards, then steps or suspended ceilings must be used.

Staircases
Its particular geometry and function makes the staircase a most com-
plex building element. Heights, regulations about the dimensions of the
steps, and the choice of material play important roles. Precise execution
of the soffits and surfaces is also important. Concrete offers good op-
portunities in terms of design, loadbearing capacity and production. It
meets all the requirements for an escape staircase with regard to fire
and heat resistance, acoustic decoupling, and geometry.
Staircases made of in-situ concrete can be adapted on site to any
floor plan. The different tolerances of building parts already produced
can be handled easily. In contrast, precast staircases allow no departures
from the design dimensions, but they can be produced quickly and
cleanly. It should be ensured that the stairwell is sufficiently large to al-
low a precast flight of steps to be hoisted into the building. Naturally, the
main focus of attention is on the basic regulations about the dimensions
of treads and risers, numbers of steps without an intermediate landing
etc. > Tab. 14

Tab. 14: Basic dimensions for staircases

Building kind Kind of stairs Minimum Rise r min.   Tread t Tread t

usable width [mm] max. [mm] min. [mm]
[cm]
Residential building with Stairs required by the 80 140 200 230
up to two dwellings building regulations
  Stairs not required by 50 140 210 210
the building regulations
(additional stairs)
Buildings in general Stairs required by the 100 140 190 260
building regulations
  Stairs not required by 50 140 210 210
the building regulations
(additional stairs)

69
 separating mat

also at lower connection

Fig. 68: Decoupled flight of steps

Acoustic decoupling Particular attention should be paid to the acoustic decoupling of

flights of steps and landings. Just as with the thermal separation of pro-
jecting building elements, an Isokorb can be used, or a simple footfall
sound decoupling.
There are several possibilities and combinations as regards acous-
tic decoupling. Both the flights of steps and the landings must be decou-
pled. The flights of steps can be separated from the staircase side wall
by a simple joint that interrupts the transmission of sound without need
for any further measures. This joint should not be wider than 6 cm. If the
flights of steps are to adjoin the side walls directly, sound decoupling
mats can be inserted between the flights and the wall. > Fig. 68
Apart from decoupling from the wall, the upper and lower connec-
tion of the flight of steps must also be decoupled. At the foot of the stairs
a mat can also be used. The upper connection to the landing can be made
by means of a shaped bearing or an Isokorb.
Precast staircases can be connected to a bearing point that has
­already been made on the landing. > Fig. 69 For in-situ concrete, suitable
products with integrated connecting reinforcement can be used. > Fig. 70
The staircase landing can also be decoupled in a number of differ-
ent ways. Essentially, decoupling by means of a standard floor construc-
tion with a floating screed is possible and sensible, as it allows the

70
 decoupled bearing

precast stairs

decoupled bearing

floor covering
screed
separating layer
impact sound insulation
r.c. slab

Fig. 69: Precast staircase at landings with floating screed

bracket with connecting

reinforcement

in-situ stairs
bracket with connecting
reinforcement

floor covering
screed
separating layer
impact sound
insulation
r.c. slab

visible joint
should be considered in design of soffit

Fig. 70: Upper and lower connection of an in-situ flight of steps

71
 console with connecting
reinforcement
landing

elastomer bearing

Fig. 71: Bracket with connecting reinforcement

Fig. 72: Isokorb with connecting reinforcement

c­ onstruction heights of the standard floors to be matched. Decoupling

by means of supporting brackets can be useful for half-landings. > Figs. 71
and 72 A different finish can then be used for the landing.

72
 In conclusion
On account of its enormous diversity and the constant improvements
that have been made in the course of past decades, concrete remains
one of the most important materials in the building industry. It consists
of a number of different elements, which can be used as factors in
­determining and defining its performance. Whether the different kinds
of reinforcement materials, the additives or concreting processes, the
range allows concrete to be used in many different areas, from large
bridge structures to furniture and property.
New mixes, reinforcement materials and techniques allow us to hope
for advances in making concrete economical, sustainable and conse-
quently forward-looking. Therefore, on both the design and construction
levels, new opportunities and ways of using it will present themselves
­repeatedly in the future.

73
Appendix
Standards and guidelines
DIN EN 197-1, Cement 
DIN EN 206, Concrete - Specification, performance, production and conformity
DIN EN 934-2, Admixtures for concrete, mortar and grout 
DIN EN 1008, Mixing water for concrete – Specification for sampling, testing and assessing the
suitability of water, including water recovered from processes in the concrete industry, as mixing
water for concrete
DIN EN 1504, Products and systems for the protection and repair of concrete structures –
Definition, requirements, quality monitoring and evaluation of conformity
DIN EN 1520, Prefabricated reinforced components of lightweight aggregate concrete with open
structure with structural or non-structural reinforcement
DIN EN 1990, Eurocode: Basis of structural design
DIN EN 1991, Eurocode 1: Impacts on structures
DIN EN 1992, Eurocode 2: Design of concrete structures
DIN EN 1994, Eurocode 4: Design of composite steel and concrete structures
DIN EN 1998, Eurocode 8:  Design of structures for earthquake resistance
DIN EN 10138, Prestressing steels
DIN EN 12350, Testing fresh concrete
DIN EN 12354, Building acoustics – Estimation of acoustic performance of buildings from the
performance of products
DIN EN 12390, Testing hardened concrete
DIN EN 12620, Aggregates for concrete
DIN EN 12812, Falsework – Performance requirements and general design
DIN EN 12878, Pigments for the colouring of building materials based on cement and/or lime –
Specifications and methods of testing
DIN EN 13055-1, Lightweight aggregates
DIN EN 13225, Precast concrete elements – Linear structural elements
DIN EN 13369, General rules for precast concrete product
DIN EN 13501, Fire classification of construction products and building elements
(the classifications according to DIN 4102 cannot be directly applied to the European 13501-1)
DIN EN 13670, Execution of concrete structures
DIN EN 14487, Sprayed concrete
DIN EN 14843, Precast concrete products – stairs
DIN EN 14889, Fibres for concrete
DIN EN 15037, Precast concrete products – Beam-and-block floor systems

ISO 21930, Sustainability in building construction – Environmental declaration of building

products
ISO 21931, Susainability in building construction – Framework for methods of assessment of
the environmental performance of construction works
ISO 15686, Buildings and constructed assets – Service life planning

74
Literature
Edward Allen: Fundamentals of Building Construction: Materials and
Methods, 6th edition, Hoboken, Wiley, New Jersey 2014
Andrea Deplazes (ed.): Constructing Architecture, Birkhäuser, Basel
2013
Kim S. Elliott: Precast Concrete Structures, Butterworth-Heinemann,
Oxford, Boston, MA 2002
Awad S. Hanna: Concrete Formwork Systems. Civil and Environmental
Engineering Series 2, Marcel Dekker, New York 1999
Manfred Hegger: Basics Materials, Birkhäuser, Basel 2007
Friedbert Kind-Barkauskas (ed.): Concrete Construction Manual,
Birkhäuser; Edition Detail, Basel 2002
Alfred Meistermann: Basics Loadbearing Systems, Birkhäuser, Basel
2007
Martin Peck (ed.): Modern Concrete Construction Manual: Structural
­Design, Material Properties, Sustainability, Edition Detail. Munich:
Institut für internationale Architektur-Dokumentation, Munich
2014
David Phillips and Megumi Yamashita: Detail in Contemporary ­Concrete
Architecture, Laurence King Publishing, London 2012

Picture Credits
Figures 11, 14, 15: from the lecture notes for the subject building
­construction and design at Siegen University
Figure 31: Works by first-semester students, building construction and
­design, Siegen University
Figures 1, 2, 8, 13, 17 (part), 18, 20, 21, 24, 26, 39, 45:
Prof. Dr.-Ing. Bert Bielefeld
All other figures: Katrin Hanses

The Author
Katrin Hanses, M.A. architect, is a research associate in the depart-
ment of building construction and design at Siegen University and runs
her own architecture practice in Cologne.

75
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