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

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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

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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

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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