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97.361 First published 1996 ISBN 0 7210 1498 4 Price Group C British Cement Association 1996

Published by the British Cement Association on behalf of the industry sponsors of the Reinforced Concrete Council. British Cement Association Century House, Telford Avenue Crowthorne, Berkshire RG45 6YS Telephone 01344 762676 Fax 01344761214

All advice or information from the British Cement Association is intended for those who will evaluate the significance and limitation of its contents and take responsibility for its use and application. No liability (including that for negligence) for any loss resulting from such advice or information is accepted. Readers should note that all BCA publications are subject to revision from time to time and should therefore ensure that they are in possession of the latest version.

B.T. O'Neill BA(Hons), DipAA, RIBA Eur Ing G. Shaw CEng, FICE, FlStruct F, MConsF M. Flynn BEng, MSc, DIC

FOREWORD
This publication was commissioned by the Reinforced Concrete Council, which was set up to promote better knowledge and understanding of reinforced concrete design and building technology Its members are Co-Steel Sheerness plc and Allied Steel & Wire, representing the major suppliers of reinforcing steel in the UK; and the British Cement Association, representing the major manufacturers of Portland cement in the UK. Brendan O'Neill is a director of Bennetts Associates and was the project architect for the PowerGen HQ building. Gerry Shaw is Technical Director of Curtins Consulting Engineers and was director in charge of the design and supervision of structural and civil engineering works for the project. Michael Flynn is a development engineer for the Reinforced Concrete Council.

TIMOTHY SOAR

CONTENTS

I I I

THE PROJECT THE BRIEF DESIGN Architecture Structure Services Substructure Superstructure Cladding and finishes Project details

2 3 4 5 6 7 8 8 10 11 12

I I
The RCC gratefully acknowledges the assistance of all those who helped with the production of this publication especially Hugh Davies of Buro Four Project Services, David Philips of Laing Midlands, John Caine of Curtins Consulting Engineers and Alan Jones of EDSL.

DESIGN/CONSTRUCTION INTERFACE CONSTRUCTION

I I

COOL CONCRETE APPENDIX

COVER PHOTOGRAPH PETER COOK

THE PROJECT
The recently completed headquarters of PowerGen is a naturally ventilated building which is setting the standard for a new generation of energy efficient offices. This purpose built administrative centre is located at Westwood Business Park in Coventry. The three storey building provides 140000 sq ft of office space and includes an undercroft car park. The long narrow floor plan consists of two parallel floor plates separated by a central atrium and lies on an east-west axis. The office layout is generally open plan. The building's orientation and layout provides good daylighting and air-flow patterns which are both important considerations in a naturally ventilated building. Even more significant in reducing energy costs is the choice of reinforced concrete for the structural fabric, as the thermal mass of the concrete frame helps to control the internal environment. Cooling of the exposed concrete soffit by night-time ventilation provides free, passive cooling during hot summer days. The coffered ceiling is perhaps the most obvious example of the fulfillment of functional, structural and aesthetic requirements in one feature, and it was achieved by the careful exploitation of the properties of in-situ concrete. Every aspect of the design contributed to the production of a spacious, integrated work environment. This was achieved by the team approach adopted by the client, designers and contractors for all aspects of the design and construction. The building performed magnificently during one of the hottest summers on record, receiving unanimous acclamation from users and observers alike. Furthermore, its actual performance closely matched predictions from thermal modelling.

Office areas are comfortable and well lit

The southern elevation from the main car park

PAUL HARMER

PETER COOK

THE BRIEF
PowerGen was keen to provide a modern, comfortable and efficient working environment in its new headquarters. Thus, design and planning focused on the workplace and the desire to create an environment which supported internal communications and teamworking. The original headquarters were spread out over two sites, and combining these in one purpose-built unit was essential. As a result, office accommodation was needed for 600 employees with a flexible working space to meet the needs of a variety of work activities. The additional requirement for an energy efficient building with low running costs led the design team to examine various natural ventilation strategies. Central to this requirement was the need to reduce heat loads and maximize passive cooling. The choice of structural material was clearly ofmajor importance, and the passive cooling provided by exposed concrete was considered vital to the success of the natural ventilation policy.
Open-balconied offices on either side of the atrium allow good internal communication

Typical floor section of in-situ concrete

Partitioned offices are available for meetings

A major consideration in setting comfort levels was the stipulation that employees should have local control of their environment, rather than rely on conventional control from the central plant room. This meant that mechanical ventilation equipment was to be kept to a minimum and that heating and ventilation controls should be easily accessible and simple to operate. Ultimately, PowerGen sought a building which would be energy efficient, environmentally friendly and able to yield savings in overall running and staffing costs. These savings would be achieved by moving away from fully air conditioned offices and by productivity gains from the improved, integrated working environment.

PETER COOK

PETER COOK

DESIGN
Architecture
Detailed analysis of PowerGen's overall design intent established that the office space requirements would be best met by a series of narrow floor plates. This would allow connection across the office space and encourage the personal communication between occupants which is vital to a thriving and productive office environment. The size of the floor plates also needed to accommodate a variety of departmental offices and allow for future flexibility. Within the 10.8 x 7.2 m structural grid are three coffers each 2.4 m wide which span from atrium to external window The coffers' elliptical cross section is designed to improve the acoustic performance of the office space by focusing unwanted noise onto the acoustically absorbent wings of the lighting rafts suspended beneath each coffer. The lighting rafts partially uplight the coffers to enhance their sculptural form. They also incorporate smoke and fire detectors, and the PA system, which would normally be hidden behind a suspended ceiling. In long section, the coffers taper towards their ends to increase the penetration of natural light into the office space from the external windows and the atrium. The exposed concrete soffit modifies the internal environment through its thermal mass, providing a heat sink during the winter and free cooling during the summer. The coffered profile contributes to these functions by providing a greater effective surface area than a flat slab and thus making the cooling concrete mass more accessible. As well as providing the circulation routes that link the floors, the stair towers contain much of the shared office equipment. This functional planning fulfils the dual purpose of bolstering the stair towers' role in promoting social contact and of removing heat-producing equipment from the office areas to hot spots where heat gains can be locally treated. The 113 m long central atrium was designed to further enhance natural ventilation and lighting. The open-balconied configuration of offices on either side of the atrium contributes to the open, communicative environment. The provision of facilities such as informal meeting areas in the atrium provides a focal area for staff social interactions. The facade consists of stack-bonded red brick panels and double glazed units. Glazed areas have three levels of opening window and on the southern elevation each floor features two rows of solar shades.

The sculptural form of the coffers is enhanced by the uplighting

Stair towers link the working areas and house the shared office equipment

PETER COOK

PETER COOK

Structure
In keeping with the integrated design approach, aesthetic and functional requirements had a major influence on the structural design solution. Curtins Consulting Engineers had to produce a structural design which fulfilled these diverse requirements. The excellent thermal mass qualities of concrete, and its low cost in comparison with other structural alternatives, focused the design effort on choosing between an in-situ, a precast and a hybrid concrete frame solution. The exposed structure required high quality finishes which initially led the team to consider a precast or hybrid concrete frame. However, both the precast and the hybrid options presented disadvantages of cost, buildability and procurement. Each precast unit would have spanned 10.8 m and weighed up to 20 tonnes. This would have created transporting and placing problems. The units would have cost some ten percent more than in-situ concrete and would have had to be ordered in advance of letting the main building contract. The balance between quality and economy was achieved by careful design. To enhance the quality of finish, specially designed GRP moulds were used to form the coffered ceiling profile. The decision to use prefabricated reinforcement considerably improved the speed and accuracy of its fixing. It was important that the speed of construction of the coffered solution should not differ significantly from traditional in-situ concrete floors, otherwise the economies of the in-situ solution would be lost. Curtins decided to use partial post-tensioning to minimize early thermal shrinkage effects and so ensure that there were no visible cracks in the exposed concrete coffers. The maximum designed crack width was 0.1 - 0.2 mm so that a standard emulsion paint could be applied to the soffit without the cracks showing through. The floorplates are supported by 400 mm diameter circular columns. Overall stability of the frame is achieved through bracing provided by the in-situ concrete stair walls. A reinforced concrete upstand was cast to the external edge of the floor slabs to support the ribbon windows and brick cladding panels. These slender brick panels were designed so that they could be assembled on site while the RC frame was being constructed. They were post-tensioned for safe handling and lifting into position. The atrium roof structure is supported by slender steel columns and was designed so that large parts could be assembled off site.

Section through south elevation

Panels of Stackbonded red bricks and double glazed units form the faade

PETER COOK

Services
The choice of natural ventilation required the service engineers Ernest Griffiths & Son to consider all aspects of the building design. The arrangement of relatively narrow open plan office areas on either side of the three storey atrium provided the ideal layout for good natural ventilation. By minimizing solar gain effects and providing clear air paths, the exposed concrete soffit helps to control the internal environment. The building management system controls the top row of windows, which are opened at night to allow cool air to flow over the coffered concrete soffit. This cools the concrete which then acts as a cooling surface to absorb radiant heat the following day Computer simulations by environmental modelling specialist EDSL were used to model accurately the office environment and predict peak internal temperatures, taking into consideration external effects, internal heat loads and the passive cooling effects of the exposed concrete. The modelling helped develop the design strategy and establish the right mix of thermal mass and natural ventilation. It also showed that night-time ventilation was able to exploit the long term thermal dynamics of the floor. The latter were provided by the careful use of exposed concrete with sufficient thickness to absorb heat gains over many days. Internal heat gains are minimized by placing areas that require air-conditioning, such as the computer suite and kitchens, at the east and west ends of the building. The larger, heat generating office equipment, such as photocopiers, is grouped into segregated rooms, out of the open plan space. Staff have considerable control of their environment as the lower windows may be opened manually during the day. Underfloor ventilation ductwork has been installed to accommodate any potential future change of use or the addition of cellular offices. The electrically powered building uses a warmwater heat bus, which gathers heat from various sources including IT equipment, the atmosphere and a diesel generator. This heat is then distributed through underfloor pipes in the atrium, in antidowndraught radiators at atrium roof level and in air heater batteries which serve the underfloor ventilation system. A seven month appraisal of the building using the Building Research Establishment Environmental Assessment Method (BREEAM) earned the building a Very Good classification, including a maximum score for its ventilation system.

The sculptural form of the coffers is enhanced by the uplighting

Sunlight and airflow patterns in offices

Computer modelling used to predictn peak internal temperatures

PAUL HARMER

DESIGN/CONSTRUCTION INTERFACE
This building is a good example of the blending of architectural and engineering design solutions. This was achieved through a committed team effort which concentrated on providing an integrated design solution. This approach was complemented by PowerGen's desire to focus the design on the building's functional requirements. The design evolved through the development of a model floor plate in response to the space planning brief. In working on the coffered profile, it was vital to develop an integrated design where the boundaries between structure, services and architecture overlapped. Whilst the design was being developed, key aspects were tested by modelling and mock-ups. A 1:40 scale model of a typical cross section through the building was made to develop the atrium glazing, office glazing and concrete profiles for maximum lighting performance. A full-size mock-up of a 7.2 x 10.8 m structural bay was also built using glass reinforced plaster to form the coffers. This was invaluable for confirming and tuning the design of the coffer profile and light fittings, and for testing the acoustic performance and artificial lighting levels. When Laing Midlands were appointed as design and build contractors, they adopted the approved scheme and worked closely with the novated design team. The on-site mock-ups played an important role in incorporating key refinements such as the prefabrication of slab reinforcement into the final design solution. The benefits of a clear design intent, involvement of the contractor in the design process, and attention to detail in all aspects of design are demonstrated by the elegance, quality and economy of the exposed concrete framed structure.
POWERGEN

Prefabricated reinforcement ready for lifting into place

PETER COOK

The concrete soffits prior to painting

The full-size mock-up of a structural bay

BENNETTS ASSOCIATES

CONSTRUCTION
Substructure
The site had few problems in terms of ground conditions, and foundations were founded on weathered rock with a bearing capacity of 400-500 kN/m2. The building was cut into the site to provide low level undercroft car parking, and to make the best use of the site contours. The concrete columns are supported on mass concrete pad foundations. These pad foundations did not need to be tied together as lateral restraint was provided by the sandstone strata. The in-situ concrete shear walls to the stair areas are supported off reinforced concrete strip footings which were also founded on the sandstone strata. Two cast insitu retaining walls, one at either end of the building, extend from the undercroft car park to the end of the exterior car park. The car parks are finished in dark, block paving.

The substructure nearing competion

Well planned construction ensured good progreess

POWERGEN

Superstructure
Laing Midlands were appointed as design and build contractors, and they decided to construct the concrete frame themselves. They produced a comprehensive method statement and worked closely with the design team to finalize detailed design considerations. A full size concrete mock-up of a typical structural bay helped in fine tuning various aspects of the design and methods of construction. Refinements were made to the concrete mix design and the fabrication details of the preformed reinforcement for the coffered slab. The methods for fixing, supporting, aligning and striking the shutters were also improved through the use of the mock-up. A rigid quality control procedure was set up for the supply of the ready-mixed concrete. Every load was to be slump tested before being accepted and the supplier had to guarantee the same sand source for all concrete delivered to site. Portland cement was used for all concrete pours and this helped to achieve early strength gains, which allowed early striking of the formwork. The custom-made GRP formwork gave a smooth, high quality finish to the coffered concrete ceiling. All the moulds had the same standard profile, as the shape of the coffers is uniform throughout the building. Although these moulds were more expensive than proprietary systems, savings from their reuse, together with the elimination of the need for suspended ceilings,

Rebates formed in the concrete soffit

PETER COOK

POWERGEN

helped to offset their cost. The consistent, high quality finish achieved using these forms was a major factor in attaining the striking appearance of the soffit. Perhaps the area of greatest importance to the visual qualitv of the concrete was the joints formed between the moulds. The joint former had to be simple and reusable, and had to prevent leakage which would have been detrimental to the finish of the concrete. Rather than trv to hide the joints, rebates were cast-in to form a feature between the coffers: these joints also provide a location for the office partitions. Aluminium strips were chosen to form the rib joints at the junctions of the moulds, and extruded rubber sections were used to form the rebates over the curved sections of the mould. The mock-up was used to improve the methods of fixing reinforcement in the coffered slab formwork. The contractor worked closely with the engineer and reinforcement supplier ROM to detail mesh reinforcement for the slabs, which was prefabricated off site. Cage reinforcement for the edge beams was prefabricated on site and simply lifted into position by crane. The wide use of preformed reinforcement for both beams and slabs meant that all the reinforcement in the 520 m2 of a typical floor plate was fixed in just two days. Concrete was placed using both pump and skip. The rail mounted crane enabled concrete to be lifted by skip along the length of the building, while mobile concrete pumps were used for the larger slab pours. After careful compaction of the concrete the slabs were float finished. The partial post-tensioning of the slabs to minimize early thermal shrinkage cracking proved very successful, and no visible cracking occurred to any of the coffered sections. This allowed the soffit to be finished by simply applying two coats of emulsion paint. The post-tensioning operation required close monitoring of the concrete temperature, as the initial stress was applied as the heat of hydration began to dissipate. The final stressing was carried out when the concrete had achieved a strength of at least 25N/mm2. Plastic sheathing was used to protect the unbonded tendons. The coffer ribs were back-propped at three points along their length and the loads were transferred through to foundation level. Further props were required to support wheel loads from cranes and concrete pumps on the atrium floor slab. The close working relationship between contractor and the design team meant that

GRP Moulds were used to form the coffers

The repetitive nature of the coffers allowed prefabricated reinforcement to be used

The GRP moulds wer supported off aluminium falsework which was easily lowered after casting

LAING MIDLANDS

ROM TLD

LAING MIDLANDS

buildability requirements of complex shapes could be incorporated without adding critical time and expense. All parties are highly satisfied with the quality of the concrete, and the decision to use insitu rather than precast has been vindicated. Despite having to work through the winter against low temperatures and high winds, the coffered structure was constructed on time to the tight programme of 16 weeks and required very little making good.

Cladding and finishes

While concrete was being poured, the team was also active on another part of the site, prefabricating stack-bonded brick panels for use as the external cladding to the two main elevations of the building. These panels are 3.6 m long, 1.6 m high and 0.102 m thick, and were post-tensioned so that they could be lifted into position by crane. The supporting stainless steel angles on the top and bottom of the brick panels were simply connected to fixing plates bolted to the concrete structure. The glazed areas have three levels of opening windows. The double glazed, low emissivity units have a motorized top pane controlled by the building management system and two lower panes can be opened by staff during the day. On the south side, adjustable solar shading panels are supported by stainless steel rods which are suspended from aluminium support brackets. Slender steel columns on either side of the atrium support the elegant roof structure from the 400 mm thick flat slab which spans the undercroft car park. Large elements of the roof structure were assembled at the factory; delivered to site for further assembly and finally lifted into place in large sections. The striking building structure is enhanced by high quality finishes. Stair core walls are clad in American cherrywood panelling to blend in with the timber staircases. The work-station finish is beech with a matt lacquer to reduce glare. To ensure that clear air paths and good daylighting are maintained, the heights of the partitions between work-stations have been kept to a minimum. A wetlands feature compliments the building's surroundings. A system of three interlinked ponds was created, and a series of wooden walkways added to allow access to the ponds. The double-height reception area is enclosed by a glazed cube and commands views over the surrounding wetlands and woods beyond.

The Structure nears completion

Brick cladding and glazing enclose the frame

American cherrywood is used for stairs and wall panels

10

POWERGEN

POWERGEN

POWERGEN

COOL CONCRETE
Energy efficiency has become a central theme in modern office design as owners and clients seek to cut operating costs and increase productivity through the creation of a healthy, integrated work environment. Thus the trend towards naturally ventilated offices looks set to continue with PowerGen HQ as the exemplar structure. The passive cooling effects of the exposed concrete soffit are fundamental to the success of this type of structure. The inherent thermal mass of concrete reduces temperature swings, particularly on hot summer days, and thus ensures that natural ventilation maintains a comfortable working environment. This is the case of PowerGen, where during the 1995 summer heatwave, the building's internal temperatures were maintained some 3C below those outside. The structural frame satisfies both functional and structural requirements. This achievement is the result of a committed team effort on the part of all involved in the design and construction process. The exposed concrete structure was carefully moulded to enhance the building's acoustic, lighting and thermal performance. This illustrates the way in which the traditional boundaries between design disciplines were overcome by focusing on an integrated design solution. Furthermore the design team produced an elegant architectural feature in the exposed coffered ceiling. The cost of this office building is remarkably low considering the quality of the structure produced. Primary cost-saving items include the use of a reinforced concrete frame, prefabricated brick cladding panels and the omission of suspended ceilings and air conditioning in the offices. Add to these capital savings those achieved from reduced running costs, and the economies of this type of structure become very significant indeed. The ultimate test of the benefits or otherwise of an energy efficient building is how it performs in use. PowerGen moved into their new offices in January 4995 and since then the performance of the building has been extensively monitored. Throughout one of the hottest summers on record this building has performed magnificently with employees indicating high levels of satisfaction with their working environment. The experience of PowerGen HQ demonstrates the economy and quality of in-situ concrete frames and the vital role their thermal mass will play in energy efficient offices of the future.

Concretes thermal mass reduces the temperature swings and helps to maintain a comfortable internal environment

Monitored thermal performance during the summer of 1995

Environmentally friendly, economic to operate and a comfortable workplace

PETER COOK

11

EDSL/KINROSS CONTROLS

PETER COOK

A P P E N D I X

THE PROJECT TEAM

Client Architect Structural engineer Services engineer Quantity surveyor Project manager Design and build contractor Fit-out architect Landscape architect Services QS Environmental modelling PowerGen Plc Bennetts Associates Curtins Consulting Engineers Ernest Griffiths & Son E.C. Harris Buro Four Project Services Laing Midlands Fletcher Priest Mark Westcott Matt Green & Wall Environmental Design Solutions Ltd

THE PROGRAMME

AREAS
Gross floor area Nett lettable area Car park spaces 12 700m2 10 600m2 550

CONSTRUCTION TIME
Start Finish Duration
POWERGEN

May 1993 September 1994 17 months

12

CONSTRUCTION COSTS
Substructure Frame Roof Cladding Internal walls & doors Finishes Services Fittings & furniture Preliminaries Total /m2 19.53 135.56 70.33 124.91 53.08 74.38 348.69 10.35 63.72 900.55 % 2.17 15.04 7.81 13.87 5.90 8.26 38.73 1.15 7.07 100.00

Level three plan

Section

Reflected ceiling plan

13

PETER COOK

PROJECT PROFILE: POWERGEN HEADQUARTERS B.T O'Neill, G. Shaw; M. Flynn BRITISH CEMENT ASSOCIATION PUBLICATION 97.361