Post on 23-Jan-2021
Ing. Ismo Kallio
ELEMATIC FinlandiaVicepresidente de Ventas
SOLUCIONES, ATRIBUTOS Y CASOS DE ÉXITO PARA LA CONSTRUCCIÓN INDUSTRIALIZADA CON ELEMENTOS
PREFABRICADOS DE HORMIGÓN
1 de Diciembre de 2020
Ing. Vaibhav Singhal
ELEMATIC IndiaVicepresidente de Diseño
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CONTENIDO
1- Construcción de viviendas prefabricadas de hormigón en Europa: sistemas constructivos y tecnologías de prefabricación• Presentación institucional• Desarrollo histórico de los sistemas de
prefabricación en Finlandia.• ¿Por qué elegir sistemas modernos de
prefabricación? Ahorros típicos vs construcción tradicional: costo, plazo, mano de obra.
• Respuesta frente a acciones sísmicas.• Presentación de casos de éxito. • Directrices para el diseño y aplicación BIM
Ing. Ismo KallioELEMATIC FinlandiaVicepresidente de Ventas
2- Soluciones para el diseño estructural para la construcción industrializada con elementos prefabricados• Sistemas para la construcción de edificaciones
de uso residencial, comercial e industrial• Soluciones típicas para conexiones: columna-
viga, muro-losa, muro-muro, viga-losa • Casos de éxito en India.• Bases para el diseño estructural
Ing. Vaibhav SinghalELEMATIC IndiaVicepresidente de Diseño
CONSTRUCCIÓN DE VIVIENDAS PREFABRICAS DE HORMIGÓN EN EUROPA. SISTEMAS CONSTRUCTIVOS Y TECNOLOGÍAS DE PREFABRICACIÓNING. ISMO KALLIO,ELEMATIC, VICE PRESIDENT, SALES
Elematic provides precast concrete technology, production lines, equipment and related services.
We are the global technology and market leader in precast concrete technology for residential and non-residential buildings.
ELEMATIC
Over 4 000 deliveries worldwide to more than 100
countries
• Founded 1959
• Head office: Akaa, Finland
• 3 production units: Finland, India
• Customer service centers:UAE (Dubai), Finland and USA
• Subsidiaries and sales offices:UAE (Dubai), USA, Germany, Hong Kong, Russia, India, China
• Representatives:In over 50 countries
FACTS IN BRIEF
• Production lines and machines
• Walls
• Floors
• Foundations
• Frames
• Services
• Consultation
• Structural engineering
• Spare and wear parts
OUR RANGE OF SOLUTIONS
FINLAND. THE HOME OF PRECAST
DEVELOPMENT OF PRECAST IN FINLAND
• The use of precast concrete started in the 50s.
• First precast skeleton:
• University of Helsinki Porthania building, 1952 (in the right)
In 1968 – 1970 a common system for precast construction, BES
• Based on load-bearing end and partition walls, non-load bearing sandwich walls in the exterior and long slabs in intermediate floors.
• Common standards made it easy for the builders to buy precast products from different manufacturers
• Boost for the use of precast
1970’S: BREAKTHROUGH FOR
PRECAST CONCRETE IN FINLAND
WHY MODERN PRECAST CONSTRUCTION?
TRADITIONAL CAST IN SITU VS PRECAST
• High housing demand
• Cost-pressure, need for affordable housing in cities
• Low productivity of traditional building methods
• Construction time pressure in projects
• Need for better quality
• Higher demands for safety
• Increased need for sustainability, environmentally-friendlyways of working and decreased amount of waste in allproject phases
WHY INDUSTRIALIZED CONSTRUCTION?
• Cost efficiency
• Speed of construction
• Better productivity
• High quality of construction
• Sustainability
• Less need for transportation
• More safety at the site
• Less waste
BENEFITS OF PRECAST
20 – 30 % LESS steel, cement & concrete
2 – 3 timesFASTER
50 % lesswork force
SAVING STEEL
0
5
10
15
20
25
4 6 8 10
Re
info
rce
me
nt
[kg
/m^
2]
Span [m]
Amount of total reinforcement depending on span and floor type
HCS prestre
Half Slab prestre
Cast in Situ reinf.
Filigran reinf.
Loads:Self weightDead load 0,5 kN/m^2Live load 2,0 kN/m^2Slab fields:4,0*4,8; 6,0*4,8; 8,0*4,810,0*4,8Concrete:HCS, FP: C40/50
SAVING TIME
Case Hyderabad, India
Conventional way:
15 apartments per month on average size of apartment of 1000 sq.ft
Composite precast structure:
45 apartments per month of same size
SAVING LABOR
Case Hyderabad, India
450 people team:
for CIS work including scaffolding & shuttering, rebar work, concreting, geometry formation, conducting and piping work in structure ,etc.
200 people team:
including precast element production, rebar work, storage -transportation - erection of precast elements, shuttering for slab at site, rebar work, connection work at site, crane operator, etc.
Compared to cast-in-situ, precast concrete uses less of everything – less cement, less water, and less steel.
Precast elements have good insulation and thermal properties that decrease the total CO2 load of the building during its lifetime.
SUSTAINABILITY: USE ONLY WHAT YOU NEED
EXAMPLE COST OF MODERN PRECAST
80
A DESIGN-EFFICIENT CHOICE
Load-bearing walls and long span floors
Beams-and-columns and long span floors
Beams-and-columns and short solid slabs
COST
100 120
NAYA RAIPUR, INDIA: 4000 HOUSING UNITS
Company BSBK got the project at the rate of 1450 Rs/sq ft. (214€/sq. m)
The structure + finishing cost was be
170 eur/sq m (15 697,02 ARS /sq. m)
Price is move in price
SEISMICITY AND PRECAST
SEISMICITY VERSUS PRECAST
Local regulation
Urban planning
Floor layout design
Architecture / Outlook
Structural design
Detailing
Building services
Sustainability
Cost evaluation
Checking of results by third party
Structural institute, China
Holms Consulting, New Zeeland
CASE STUDY, CHINA: INDUSTRIALIZED CONSTRUCTION IN SEISMIC ZONES
• seismic loads and actions are big compared to non-seismicsituations
• seismic design is more demanding than standard structuraldesign
• seismic design expertise is often local
• local codes often follow the principles of cast-in-situ
• precast buildings can be used in seismic conditions
• shear wall system can be used in seismic areas
• the design of connections is the key point
CONCLUSION
EXAMPLES OF PRECAST BUILDING
KM Ankudinov Park, Nizhnyi Novgorod, RussiaResidential housing
27 high-rise residential blocks
19 to 35 storeys
12 500 apartments
650 000 m2
Precast products used: Sandwich panels, ventilation shafts,lift shafts, staircases and piles
Flooranaukio apartments, Helsinki, FinlandNational Concrete Structure of the year 2011 Award WinnerGross Area: 3,787 m²
(48 apartments)
Structural Engineer: Sweco Ab
Amount of the elements: • 7,000 m² of facade & balcony • 10,000 m² of wall panels &
solid slabs• 12,000 m² of hollow-core slabsCeramic: Arabia, Iittala Group
Ph
oto
: An
ders Po
rtman
, Ku
vatoim
isto K
uvio
Oy
IKEA Penang, Kuala Lumpur, Malaysia. Opened in 2019
Size: Around 100,000 m² (sales area approx. 40,000 m²)
Amount of concrete elements: 7,500 precast products • 62,000 m² of hollow core slabs• 15,000 m² of T-slabs • 3,200 pcs of other reinforced
concrete products
Highest ever Industrialized Building System (IBS) score recorded to date in Malaysia.
Sokos Hotel Torni, Tampere, Finland Year of construction: 2014
Facade: 500 concrete sandwich panels with 10,000 steel objects and special black pigment on the surface
Facade surface: 8,000 sq. m.
DESIGN OF MODERN PRECAST
WHY IS DESIGN IMPORTANT ?
Project time
Designing Construction
Cost 100%
100%
Fast design
Detailed design
80 – 90% of total building cost is determined during the design
• Large apartment area per gross floor area
• Optimized number of corners
• More apartments per staircase and its area
• Minimized number of loadbearing walls = long floor spans
• Thin partition walls = more usable area
• Diverse floor plans for different levels possible
EFFICIENT PRECAST DESIGN
EFFICIENT PRECAST DESIGN
BIM (BUILDING INFORMATION MODELING)
BIM BENEFITS
• Better Collaboration and Communication
• Model-Based Cost Estimation
• Improved Coordination and Clash Detection
• Reduced Cost and Mitigated Risk
• Improved Scheduling/Sequencing
• Increased Productivity and Prefabrication
PRECAST DESIGN SOLUTION FOR BUILDINGS
Vaibhav Singhal, Vice President-Design
Elematic India
• Precast concrete is a construction product produced by casting concrete in either reusable molds or by using highly advanced machinery which is then cured in a controlled environment, transported to the construction site and lifted into place.
PRECAST CONCRETE
38
Production
• Stage I
Curing
• Stage II
Storage
• Stage III
Transportation
• Stage IV
Installation
• Stage V
Finishing
• Stage VI
Production
• Stage I
Curing
• Stage II
Storage
• Stage III
Transportation
• Stage IV
Installation
• Stage V
Finishing
• Stage VI
ON-SITE / CAST-IN-PLACEOFF SITE / FACTORY ENVIRONMENT
PRECAST PROJECTS
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Residential Industry Mid/High Rise
Sports Commercial Public Works
RESIDENTIAL BUILDING
40
Load bearing Wall Frame Structure
1. Insulated Façades (Optional)
2. Slab
3. Load bearing wall
4. Beams, columns and solid floors (few
elements as per design)
5. Stairs and shafts
6. Partition walls
COMMERCIAL BUILDING
41
Central core
Precast skeletal structure with hinged connections
Floor diaphragms to transmit horizontal forces to core
INDUSTRIAL BUILDING
42
Roof Beam (Precast or Steel) Roof
Precast Column
Precast Footing
Precast cladding walls
PRECAST ELEMENTS
43
Hollow Core Slab
Wall
Column
Beam
Staircase
SLAB SOLUTION
44 Double T Slab
HCS
Solid Slab
Half Slab
Selection Criteria
Span
Loading
Availability
CONNECTION/JOINT
COLUMN-BEAM
46
WALL-SLAB
47
WALL-WALL
48
BEAM-SLAB
49
PRECAST PROJECTS
EXAMPLES IN INDIA
MAHARASHTRA POLICE HOUSING COLONY
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Location: Pune, India; Seismic Zone 34.0 M sq.ft. residential apartments60 Towers, G+14 buildingsTypes: 1RK, 1BHK, 2BHK, 3BHK, 3.5/4.5 BHK
Precast Elements:- Wall- Prestressed solid slab- Stair flights
MAHARASHTRA POLICE HOUSING COLONY
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MAHARASHTRA POLICE HOUSING COLONY
53
GALAXY TOWER
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Location: Hyderabad, India; Seismic Zone 21.9 M sq.ft. Office Building24 storey above ground105 meter height
Precast Elements:- Hollow Core Slab- Prestressed Beam- Column- Wall- Stair flights
GALAXY TOWER
55
GALAXY TOWER
56
GALAXY TOWER
57
HOSTEL BUILDING
58
Location: Delhi NCR, India; Seismic Zone 4Multiple Hostel Buildings G + 5 to 9
Precast Elements:- Hollow Core Slab- Wall- Stair flights
HOSTEL BUILDING
59
DESIGN SERVICES
DESIGN TEAM: A SNAPSHOT
61
• EXPERT TEAM OF Structural Engineers, BIM
Modelers (ASMEPF)
• TEAM MAJOR EXPERIENCE is in design and
BIM for precast/cast in-situ RCC and
Structural Steel projects in India and
abroad
• DESIGN CODE IS, ACI, EN, NZS, BS
Tools
• Analysis and Design: ETABS, SAFE, STAAD.Pro, SAP2000, Concise Beam
• BIM: Tekla, Revit, Civil 3D
Team Strength
Integrated Project
Delivery (IPD)
Precast Expert
Structural Design Expert
BIM ExpertDesign for
Manufacture and Assembly
(DfMA)
Software Development
Time & Cost Optimization
PRECAST SERVICES
Concept Design
• Precast feasibility
• Architectural layout optimization for precast construction
• Precast structural scheme
• Typical floor plans and connection details
• Quantities
Detailed Design
• Coordination with other disciplines
• Design optimization
• Good for construction floor plans and details
Construction Documentation
• Erection plans
• Element shop drawings
• PXML files
• Bar bending schedule (BBS)
• Bill of material (BOM)
Precast Construction
• Recommendation for precast mould and machinery
• Factory layout & sub-structure design
• Method statements for
• Element production
• Element handling and transportation
• Element installation
• Element jointing
BIM SERVICES
LOD 100-300
• ASMEPF early stage modelling
• Clash detection, resolution and coordination
• Design development through BIM
• preliminaryQuantity extraction
LOD 400
• ASMEPF detailed modeling
• Extraction of good for construction drawings
• Extraction of shop drawings along with bill of material
LOD 500
• ASMEPF As-Built Modelling
• Facility Management (FM) integration with BIM models
• FM data extraction
4D/5D/VR
• 4 D - project progress visualization as per project construction schedule
• 5 D – project progress and quantity consumption visualization as per project construction schedule
• VR – Virtual Reality
SOLUCIONES, ATRIBUTOS Y CASOS DE ÉXITO PARA LA CONSTRUCCIÓN INDUSTRIALIZADA CON ELEMENTOS
PREFABRICADOS DE HORMIGÓN
MUCHAS GRACIAS
Ing. Ismo KallioELEMATIC Finlandia
Vicepresidente de Ventas
Ing. Vaibhav SinghalELEMATIC India
Vicepresidente de Diseño
Representante en Argentina: Mauno Mantykoski mauno.mantykoski@mmauber.com