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SPRING 2015 | VOLUME 8, ISSUE 1
SMC CORPORATION
NOBLESVILLE, INDIANA
KERKSTRA PRECAST
table of
contents
KP News | 4
Maximizing Your Design Build | 5
Project Spotlights | 6-9
New Team Members | 10
Hollowcore Fire Ratings | 11-13
2014 Project Map | 14-15
SMC CORPORATION
NOBLESVILLE, INDIANA
PAGE 3
kp news
Maximizing the Benefit with
Design Build/Design Assist
Written by Greg Kerkstra, President & CEO
We have been learning a lot over the years on how to participate in
design build and design assist project delivery. We have had many
successes over the years and we have had some learning experiences
as well. So much of it starts early and it starts with the expectations
and communications of the design team.
What does design assist mean anyway?
KP Volunteers
KP encourages our employees to get out in the community and get involved. Giving back is one of the core values of our company and we try
to give our employees opportunities to do the same. Each year employees are given one paid day to volunteer. Over the months of January
and February, 26 of our employees have used their volunteer day and donated a total of 224 hours of their time to Habitat for Humanity. They
completed a variety of tasks including putting up siding, framing, installing hand rails, installing wood flooring and finishing trim work.
Need More Space?
Find out how you can increase your home square footage without increasing your building footprint. Check us out at the upcoming
home show.
Cottage and Lakefront Living Show
March 27th-29th | DeVos Place
for more information visit https://devosplace.org/schedule/cottage-lakefront-living-show-grand-rapids
Can’t make it to the home show? No problem. You can find all of our details on our website at www.kerkstra.com/details or just give us a
call at 616-224-6176.
contact with the precast fabricator and their facility. Those past
experiences are expanded upon in the design assist delivery method
by leveraging the knowledge of the precast specialty engineer to
remove schedule impacts typically taken up in a DBB project. This
includes shop drawing review, bid processing, scheduling, and on
site coordination.
It is also critical that the project is driven and coordinated by a leader,
a good communicator and a decision maker. This may be an owner,
architect, contractor, and engineer or owners representative. We
can use the latest tools to collaborate on a project but without the
human element of leadership and communication the tool sits idle
and time and money is wasted.
Kerkstra recognizes our key role in this effort and we are continuing to
improve our expertise to bring the resources to the team so that you
can take full advantage of what precast can do. We have added four
engineers to our staff over the last two years. We will be leveraging
this experience to help during the design phase, fabrication and
installation to bring efficient precast structures to your team .
Our definition of design assist: being engaged early in a partnership,
while the design team is working in the schematic design phase or
earlier.
Kerkstra Precast is on the design team as the structural precast
partner of choice, or specialty engineer. We work to develop the
structural drawings in partnership with the structural engineer
of record and provide the structural sheets required as the design
process continues. The goal of these efforts is to utilize the precast
drawings, in conjunction with the other structural drawings, to
submit for a permit. During the permit review our internal team
works on the procurement of the materials, piece ticket drawings,
and may even start production of long lead items.
During the assist process we constantly communicate costs and So what are your expectations for a successful
work closely with the rest of the design team to provide value design assist precast project?
added solutions. We add input to help reduce costs in all areas while Well, ours would be a team that is led, that communicates and
looking and listening to find value to the client.
executes on time to support all its members’ needs of information in
order to deliver a project ahead of schedule and under budget.
What makes a design assist project go well?
The more successful experiences occur when members of the design
team or ownership team has experience with precast on past
projects. This typically is a DBB (Design Bid Build) delivery project
that engaged them via plant tours, CEU presentations, and direct
PAGE 5
project spotlights
Farbest Foods
This project is a 227,000sf turkey producing facility located in Vincennes, Indiana for one of the largest turkey producers in the nation. Farbest
supplies turkey products to other processors who then package and sell the turkey under their brand name.
The project consisted of 63,000sf of Insulated Wall Panels for the exterior along with 24,000sf of Insulated Wall Panels for the interior of the
building. Precast wall panels helped keep this project on schedule with quick installation. The food grade finish that can be achieved with precast
products helped eliminate extra interior finishes thus reducing cost and time needed for finishing.
“I was extremely satisfied with the product we received and the level of service on this project. I would recommend Kerkstra
Precast on future projects to my coworkers and will make sure they are given the opportunity to bid all jobs that I have a hand in.”
– Eric Sidebottom, Gray Construction
Location: Vincennes, Indiana
Contractor: Gray Construction
Architect: MSKTD & Associates
PAGE 7
SMC Corporation
SMC Corporation added 600,000sf of production and warehousing space to their
Noblesville, Indiana headquarters. The company is a pneumatic technology
developer and manufacturer. The building’s shell was constructed with 135,000sf of
Precast Insulated Wall Panels.
The design of the building included several reveals and windows to help break
up the panels and make for a modern and clean building. All of the panels were
stained in various neutral colors giving the building a clean and inviting feel. This
building is proof that your warehouse doesn’t need to look like a gray box, even
without adding unnecessary cost.
Location: Noblesville, Indiana
Contractor: Victory Unlimited Construction
Architect: Structurepoint
PAGE 9
new Team members at Kp
KURT DEKOCK
Director of Plant & Field Operations
Kurt joined KP in late 2014 as our Director of Plant & Field
Operations. Kurt has a BS in Construction Management from MSU.
After completing his degree, Kurt began his career right here at KP
where he worked for 12 years in our field division and also spent a
short time in production management. After five years, Kurt is back
to head up our Plant & Field Operations once again.
When not at work, Kurt enjoys spending time with his wife and
three children as well as all sorts of projects around the house. Kurt
and his family also enjoy spending time volunteering. They have
volunteered in Guatemala with Paradise Bound Ministries.
PHIL HOLTROP
Chief Financial Officer
Phil joined KP in late 2014 as our Chief Financial Officer. He holds a
B.A. in Accounting from Calvin College & Davenport University. Phil
came to KP with over 25 years experience as a CPA in manufacturing,
distribution and public accounting.
Fire Ratings in Precast
Building Components
Written by Nathan Krause, Structural Engineer at Kerkstra Precast
Fire Rating Specifications are an important part of any building construction project and are often dealt with during the beginning of the design
process. They sometimes drive the materials selected for the structure, its compartments and exterior components for the need to protect
the new structure in a fire event in an adjacent structure. Depending on the area of the project, there are a few different methods that can be
utilized to determine the requirements. This is a brief overview of what is common in our area, however each project is unique and local codes
should be consulted to ensure that the method selected is allowed. There is also a difference between Fire Rating and Fire Separation. A fire
rating typically means the duration for which a passive fire protection system can withstand a standard fire resistance test. Fire Separation is a
floor or wall having a fire rating required by appropriate authorities that acts as a barrier against the spread of fire within a building. Another
factor in the rating of floors and roof members is the use of end conditions. Plank can be considered restrained by the Architect or Engineer of
Record based on if thermal expansion is resisted by adjacent construction. Restrained bearing conditions offer longer fire endurances due to the
restriction of the ends of the plank to move during an event.
RESTRAINED
RESTRAINED
UNRESTRAINED
Phil has been married to Sandy for 30 years, they have three married
children and four grandkids who he loves to spend time with! In his
spare time, Phil enjoys traveling to all sorts of places near the water,
boating and home improvement projects
SUE ROLLINS
Director of Safety, Quality & Lean on Continuous Improvement
Sue leads our Quality, Safety & Lean departments here at KP. She
comes to us with a plethora of experience in the field from her career
in manufacturing and coatings. She attended MSU, GRCC, UofM and
MCC where she has taken a wide range of classes to enhance her
safety & quality background. This experience and education make her
an asset to our team.
When not at work, Sue enjoys spending time with her three adult
children. Sue and her kids love to spend time together skiing, golfing,
camping, hiking or just sitting around watching movies.
Typical Methods to Determine Fire Endurance in Plank:
1. 2012 International Building Code (IBC) / 2012 Michigan Building Code (MBC)
2. Rational Design Method as defined by PCI MNL-124, “Design for Fire Resistance of Precast Concrete”
*Industry Preferred method of design.
3. Underwriters Laboratories (UL) Fire Resistive Ratings
Continued on page 12.
PAGE 11
International Building Code (IBC) / (MBC):
The IBC and the MBC are very easy to use for achieving a fire resistance. Since 2000, hollowcore plank utilized as a roof or floor member is
required to have a fire rating. There are two requirements that have to be met in the code to achieve the desired fire endurance. They are the
minimum total slab thickness and strand clear cover. Below is a step by step process on how Kerkstra Precast’s hollowcore can perform under the
IBC / MBC code.
Kerkstra Precast Hollow Core Values
Hollowcore Cross
Section
8” Standard
10” Standard
10” Heavy
12” Standard
16” Standard
Cross-sectional
Area, (in2)
196
244
264
281
349
Equivalent
Thickness, (in2/in)
4.07
5.08
5.49
5.86
7.27
Strand
Height, (in)
PCI Design by Rational Analysis
PCI MNL-124 allows a method defined as “rational analysis” for determining the fire rating of the precast and prestressed members. This is the
preferred method for determining a fire rating of our precast cross sections for both walls and floor members. Actual practice has provided
evidence that this method is conservative when compared to the IBC and UL methods. This method utilizes elevated temperatures in the
prestressing strands to determine the moment capacities based on reduced capacities in the strand. Those reductions are compared to the
moments required for service loads. Prestressing strand temperatures are based on the amount of cover provided and the standard fire exposure
as defined by the time-temperature relationship provided in ASTM E-119. Unlike the IBC and UL rating, the PCI design does not require the
distinction of restrained vs unrestrained. A few ways to gain higher fire endurance rating than that shown below is to raise the strain height, add
composite topping, or use light weight aggregates.
1.500
or
1.625
1. Equivalent concrete thickness. All of Kerkstra Precast’s hollowcore sections are made with a carbonate concrete type. This value can be
found in the table above under “Equivalent Thickness”. Equivalent thicknesses can be calculated by dividing the cross-sectional area
by the nominal plank width (48”). To obtain a higher slab thickness, normal carbonate concrete field topping can be added to gain
a higher total slab thickness. Other topping materials such as gypcrete can added to achieve a fire endurance using different tables.
Example: Slab thickness = 10” Hollowcore + 2” of topping = 5.08 in + 2.0 in = 7.08 in ≥ 6.6 in. Therefore, we meet the requirement for a 4 hour slab thickness, but the strand clear cover
needs to be met too!
Table 722.2.2.1
Minimum Slab Thickness (inches)
Fire-Resistance Rating (hours)
1
1.5
2
3.5
4.3
5
3.2
4
4.6
2.7
3.3
3.8
2.5
3.1
3.6
Concrete Type
Siliceous
Carbonate
Sand-lightweight
Lightweight
3
6.2
5.
4.6
4.4
*Openings and non-uniform loads will effect this design.
4
7
6.6
5.4
5.1
Underwriters Laboratories Fire Ratings
IBC, 2012, pp. 172
2. Bottom strand clear cover over the prestressing strand is typically 1.5”. If a higher endurance is required, the strand can be raised to give a
clear cover of 1.625”. Fire ratings utilizing this method are also impacted by the bearing condition, which can be restrained or unrestrained.
Example: Unrestrained hollowcore bays that requires a 4 hour rating. High strand cover = 1.625 in ≤ 2.25 in. Therefore, we only meet the requirement for a 2 hour cover thickness.
Example: Restrain every hollowcore bay that requires a 4 hour rating. Standard strand cover = 1.50 in ≥ 0.75 in. Therefore, we meet the requirement for a 4 hour cover thickness.
Concrete
Aggregate Type
Siliceous
Carbonate
Sand-lightweight
or lightweight
IBC, 2012, pp. 174
Table 722.2.3 (2)
Cover Thickness for Prestressed Concrete Floor or Roof Slabs (inches)
Fire-Resistance Rating (hours)
Restrained
Unrestrained
1
1.5
2
3
4
1
1.5
2
3
0.75
0.75
0.75
0.75
0.75
1.125
1.5
1.75
2.375
0.75
0.75
0.75
0.75
0.75
1
1.375 1.625 2.125
4
2.75
2.25
0.75
2.25
0.75
0.75
0.75
0.75
1
1.375
1.5
2
Prior to codes covering the ratings of floors and walls any member that carried a rating was actually tested in a laboratory and provided a UL
number. This number was specific to the plank cross section, mix design and other properties of that section. Once a rating was achieved
other cross sections can be evaluated by UL, compared to the tested section, and if warranted qualify for an existing UL number. The process of
actually testing and receiving a UL number is extremely costly and time consuming. If a UL fire rating is required, then the answer is Kerkstra
Precast’s 10” heavy section. Below is how to achieve different UL hours using this method.
Hollowcore Section
10” Heavy
(J995)
Kerkstra Precast’s UL J995 Fire Resistance Rating
Topping Thickness, (in) Unrestrained Rating, (hr)
0
2
1.5
2
1.625
2
Restrained Rating, (hr)
2
3
4
Additional Resources
Need help with design sources or fire rating design? Give us a call at 616-224-6176
Visit our website for technical resources http://kerkstra.com/design
Also see: 2012 International Building Code, 2012 Michigan Building Code, PCI MNL-120-10 Design Handbook, PCI Manual for the Design of
Hollow Core Slabs Second Edition, PCI MNL-124-11 Design for Fire Resistance of Precast Prestressed Concrete.
PAGE 13
2014 Projects
422
PROJECTS WERE
AWARDED TO US IN
2014.
We couldn’t have
done it without you!
PAGE 15
Kerkstra Precast
3373 Busch Drive
Grandville, MI 49418
www.kerkstra.com