Case Study-Based Challenges of Quality Concrete Finishing for Architecturally Complex Structures

Abstract

This paper focuses on the procedure utilized in the construction of tilt-up irregular concrete panels that are constructed on-site using concrete slabs and wooden formwork. The case study required high-quality concrete finishing. The erection and installation procedure called for a maximum panel-to-panel joint tolerance of $1.27\mathrm{cm}$ $\left(0.5\mathrm{in.}\right)$ , often $90°$ joints between panels. To meet precision requirements, the casting slabs were leveled and flattened with laser screed technology and smoothed with chemical solutions. To ensure that the final result met expectations, a mock-up model was built using different types of materials and to simulate site constraints. The architectural design is a composition of precast concrete panels like “Lego” pieces assembled similarly to a jigsaw puzzle. The unique construction process required a state-of-the-art analysis to produce the set quality. Quality conditions as set by the owner included creating a smooth concrete surface on all panels while avoiding damages and reducing equipment and material costs. The proposed methodology is described through its implementation on the case study, which is also described in this paper.