Prefab components lead to precision execution

By Jason Rabasse

Many Amrize projects are centered around building and upgrading critical infrastructure, as demonstrated by the Red Deer Regional Hospital Parkade Addition. In collaboration with Shunda Consulting & Construction Management, Amrize brought its full capabilities to the project with the supply and installation of the precast components required for the expansion.

The first construction phase of the parkade, completed in 2015, included a five-level precast structure providing 1,000 parking stalls. Originally designed with future expansion in mind, the parkade's structural system accommodated vertical growth without requiring major retrofits.

In 2024, the planned expansion was realized with the addition of two more levels and 500 additional stalls, bringing the structure to its full design capacity and making it one of the tallest precast parking structures in Alberta. This foresight demonstrates how precast concrete can be used to design scalable infrastructure from the outset, maximizing long-term investment.

Precast concrete’s modularity made it ideal for this phased expansion. The ability to pre-manufacture 500 structural elements off-site with tight tolerances allowed seamless integration of the new levels without affecting the structural integrity of the existing facility.

The combination of double tees, shear walls, spandrel panels, lite walls, stair and elevator cores, stair flights and landings, columns, and beams demonstrated the full versatility of precast in both vertical and horizontal applications.

This approach not only ensured speed and efficiency but also minimized disruption to critical health operations — something few materials could achieve as effectively.

One of the most challenging aspects was site access. In conventional parkade construction, precast components are installed from ground level, progressing from one end to another. In this case, components had to be hoisted from the perimeter of an existing five-storey structure, three bays deep, to add two additional levels — all while maintaining uninterrupted access to hospital facilities. The process required exceptional planning, coordination, and precision execution by the installation team.

The speed and accuracy of precast installation minimized downtime, reduced site labour requirements, and helped maintain a predictable construction schedule — critical factors in keeping the project on time and within budget.

Despite the complexities, the project was executed safely, efficiently, and to the highest standards of quality. Moreover, the durability and low maintenance needs of precast concrete further reduce ongoing operational costs, delivering long-term value to the owner.

MEETING SUSTAINABILITY NEEDS

Amrize’s concrete integrates supplementary cementitious materials such as fly ash, reducing cement consumption without compromising performance. Precast production relies on reusable moulds, minimizing waste, while prestressed components allow for longer spans and material efficiency. Off-site fabrication minimizes construction traffic, reduces the number of on-site trades, and significantly lowers labour requirements and energy consumption during installation. The long lifespan and low maintenance requirements of precast components result in a reduced whole-life carbon footprint and lower operational costs—aligning with the long-term sustainability objectives of Alberta Health Services.

JASON RABASSE C.E.T. IS BUSINESS DEVELOPMENT MANAGER, PRECAST AT AMRIZE AND A CPCI FELLOW.

PLANNED EXPANSION ACHIEVES MINIMAL DISRUPTION

By Frank Cavaliere

The Red Deer Regional Hospital parkade expansion was a unique structural challenge. We were adding two new levels atop an active, five-level parking structure—while keeping four levels of parking fully operational and ensuring the safety of hospital staff, patients, and visitors.

The schedule was tight, driven by upcoming hospital construction, and required meticulous coordination. Even though the original structure had been designed to accommodate expansion, real-world conditions and updated codes meant we had to rethink key connection details in real time. Our team worked closely with the precast supplier and contractors to validate as-built conditions, sequence deliveries, and maintain site access. Through careful planning and collaboration, we turned a highly compressed schedule and complex site into a seamless structural integration — expanding the facility’s capacity without interrupting critical hospital operations.

FRANK CAVALIERE BSC, P.ENG., FEC, FGC (HON.), LEED® AP, PARKSMART ADVISOR IS MANAGING PRINCIPAL AT RJC ENGINEERS.

Photos courtesy of Amrize Precast