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Hollow Core Slabs & Panels Prestressed/Precast 1)Definition & Advantages 2) Applications 3) Examples – Commercial & Industrial 4) Examples – Low Cost Housing.

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Presentation on theme: "Hollow Core Slabs & Panels Prestressed/Precast 1)Definition & Advantages 2) Applications 3) Examples – Commercial & Industrial 4) Examples – Low Cost Housing."— Presentation transcript:

1 Hollow Core Slabs & Panels Prestressed/Precast 1)Definition & Advantages 2) Applications 3) Examples – Commercial & Industrial 4) Examples – Low Cost Housing 5) Green Building – LEEDS 6) Weiler Gmbh – Precast Engineering & Machinery

2 1)Hollow Core Definition: A prestressed, precast, hollow core concrete element, flat with constant slope, with minimized weight through the use of longitudinal voids, strengthened with stressed steel cable.

3 1) Hollow Core Slabs: Advantages: - Speed, simplicity & flexibility of production & assembly – 1000 m2 / day - Controlled & Consistent Quality – Production takes place under controlled conditions, year round. - High Compressive Strengths – kgs/cm2 ( psi Weiler extruder) - Maximum Economy in materials ( %), labor & time. - Design Flexibility – clear spans up to 22 meters (70 ft) without columns - Immediate Use when placed as floors on site. - Fire Resistance - 2 to 4 hours - Thermal & Acoustic Resistance - Resistance to humidity, mold, insects and infestations - No need for forming, supports or scaffolding on site. Build in weeks, not months. - No need for compressive layer of concrete (depending on application and regulation)

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5 2) Applications Docks & Moorings Rail Landing Earth Retention

6 2) Applications Tunnel & Canal Coverage

7 2) Applications Warehouse, Storage & Light Industrial Buildings

8 2) Applications Walls for Warehouses/Storage

9 Silos 2) Applications

10 Parking 2) Applications

11 Stadiums 2) Applications Stands / Seating

12 Liguid Storage / Water Treatment 2) Applications

13 3) Building Examples Hollow Core Slabs - 11,000 m2 - 15cm slab m2 - 26cm slab Al Jazeera Tower – Qatar

14 3) Building Examples Hollow Core Slabs - 38,000 m2 - 22cm slab Burj Residences – Dubai

15 3) Building ExamplesHollow Core Slabs - 37,000 m2 - 26cm slabs Al Salam Tower & Parking

16 3) Building Examples Hollow Core Slabs : - 100,700 m2 - slabs 20, 26 & 32cm Wafi Hotel Dubai

17 3) Building Examples Hollow Core Slabs - 25,000 m2 15 & 20cm slabs Twin Towers Qatar

18 3) Building Examples Hollow Core Slabs - 100,900 m2 various slab sizes Dubai Doha Tower

19 3) Building Examples Hollow Core Slabs - 15,300 m2 - 15cm slab - 2,400 m2 - 20cm slab Bahrain Chamber of Commerce

20 3) Building Examples Hollow Core Slabs - 360,000 m2 – various sizes - 1,200 m2 floor placed per day. Barwa City Residences Qatar

21 3) Building Examples Hollow Core Slabs - 59 floors, 6 days per floor Brilliant Star Towers

22 3) Building Examples Hollow Core Slabs - 45,000 m2 - 26cm slab - 75,000 m2 - 22cm slab - 6,900 m2 - 40cm slab Emirates Commercial Centre

23 3) Examples Public Works: Schools Generalitat Catalunya Spain

24 4) Low Cost Housing Mini Slabs and Panels for DIY Construction: Super light sections, slab heights 8, 10 & 12cm (3”, 4”, 5”) & variable widths of 30, 60 & 120 cm (12”, 24” & 48”).

25 4) Low Cost Housing – Optimized Design for Hollow Core Slabs & Panels

26 5) Green Building – Energy Consumption Savings of 30-50%

27 5) Green (Hybrid) Buildings Use thermal mass and hollow cores of concrete slabs for night pre cooling and pre heating Release stored heat/cooling to minimize peak load demand Displace energy consumption to off-peak electricity rates Energy consumption savings of 30-50% in hot and cold climates Reduced HVAC machinery & ducting saves 50% on equipment costs In wide use in Europe and Middle East All building types, industrial, commercial, schools, institutions, residencial Leeds Certification

28 5) Green Building – Savings Example Jeddah Building - Area m2 Original Design Capacity Air Conditioning: 2200 Tons Tons safety margin Revised Design with Green Radiant Panels: 750 Tons Tons safety margin Peak Consumption with Radiant Panel, August 2004: 530 Tons

29  Pioneer and leader in long bed precast concrete technology  Over 230 plants y 500 installed machines around the world  A complete range of machinery and engineering services adapted to the needs of individual clients  Tough, precision machinery, designed and built to last a lifetime  Highest European quality standards – all components supplied by leading global brands (Siemens, Bosch, SKF, ABB etc.)  Local service programs supporting clients during all stages of factory growth Since 1954 – Engineering & Machinery for Precast Concrete 6) WEILER Gmbh

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31 Products  Extruder – exclusively for prestressed hollow core slabs & panels  Slipformer – solid and hollow core slabs, beams & other prestressed products  Tilting Tables – for walls and panels  Production Equipment – batching plants, saws, overhead cranes, bed cleaners, concrete transport systems, prestressing equipment, accessorios etc. Services  Complete engineering and support services, turnkey plants, training, parts etc

32 Extruder  maximum productivity at lowest production cost  hollow core slabs 8 to 50 cm thick  6-8 hours cure to cut (w/ dry mix concrete & heated beds)  hollow voids to 50% of volume  minimum cement consumption – kgs/m3  highest compressive strength in the market kg/cm2 (12,500 psi)

33 Slipformer  maximum production flexibility: solid & hollow core slabs/panels, beams, cement piles, posts, lintels, etc.  20-30% savings compared with wet mix precast  hours cure to cut (with heated bed & dry mix concrete)  cement consumption kgs/m3 ( lbs/cu yrd)  high compresive strength kgs/cm2 (6400 psi)

34 Slipformer – Products  Solid and hollow core slabs, 6 to 50cm (2.5 to 20”)  T Beams – up to 40 cm height (16”)  Piles – up to 50 X 50cm (20 X 20”)  Lintels  Walls & sound barriers  Sandwich Panels  Roofing elements  Custom Products

35 Compaction Systems Extruder Slipformer

36 Direct Cost Comparison – Slab / Panel Production – Extruder / Slipformer Peralte16" x 48" - 40 x 120 cm 16" / 40cmarea cm²volumen m³/m²diferencia %peso/m² costo hormigón/m²costo hormigón 100k m²diferencia % Weiler MXN MXN 12,775,902 Spancrete %564.52MXN MXN 19,380, % 401 in² Peralte12" x 48" - 30 x 120 cm 12" / 30 cmarea cm²volumen m³/m²diferencia %peso/m² costo hormigón/m²costo 100,000 m²diferencia % Weiler MXN MXN 10,201,066 Spancrete %402.67MXN MXN 13,824, % 316(Ultra Light Spancrete) Peralte10" x 48" - 25 x 120 cm 10" / 25 cmarea cm²volumen m³/m²diferencia %peso/m² costo hormigón/m²costo 100,000 m²diferencia % Weiler MXN 82.44MXN 8,243,902 Spancrete %329.37MXN MXN 11,307, % 277 in²(Ultra Light Spancrete) Peralte8" x 48" - 20 x 120 cm 8" / 20 cmarea cm²volumen m³/m²diferencia %peso/m² costo hormigón/m²costo 100,000 m²diferencia % Weiler MXN 68.79MXN 6,879,332 Spancrete %298.94MXN MXN 10,263, % 251 in² Peralte6" x 48" - 15 x 120 cm 6" / 15cmarea cm²volumen m³/m²diferencia %peso/m² costo hormigón/m²costo 100,000 m²diferencia % Weiler MXN 52.53MXN 5,252,692 Spancrete %231.17MXN 79.36MXN 7,936, % 197 in² Peralte4" x 48" - 10 x 120 cm 4" / 10 cmarea cm²volumen m³/m²diferencia %peso/m² costo hormigón/m²costo 100,000 m²diferencia % Weiler MXN 37.97MXN 3,796,623 Spancrete %175.85MXN 60.37MXN 6,037, % 138 in² 1) For the same slab height, extruded slabs are 12 to 32% lighter than slipformed slabs. 2) Extruded slab cement consumption is minimized, from kgs/m³, compared to kgs/m³ for the slipformer. Cement savings of 100 kgs/m³. 5) Combining lighter slabs using less concrete, higher compression & minimal cement consumption, savings on production costs are 30 to 60% when using the extruder. 3) Extruded slabs have higher compressive strengths, psi (extruder) compared to 8000 psi (slipformer)

37 Battery Mold for Walls & Panels

38 Tilting Tables

39  Plant conception & design  Production Management  Custom precast products  Plant modifications & expansions  Transition to semiautomatic & automatic production systems  Turn Key installations, startup, personnel training etc. ENGINEERING

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41 Mini Slabs & Panels for DIY Construction / Low Cost Housing

42  A complete range of products and services from a top tier supplier  50 years of global experience in long bed precast production  One machine or a complete plant – Weiler is a committed, long-term partner for growth & profit

43 Hollow Core Slabs & Panels Advantages and Examples June 2010 A. Powell Jacquier Lic. MBA


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