2 Hollow Core Definition: A prestressed, precast, hollow core concrete element,flat with constant slope, with minimized weight through theuse of longitudinal voids, strengthened with stressed steel cable.evitar encofrados, cimbras, apuntalamientos, sin capa de compresión en muchos casos, listo para pintar (superficie inferior), listopara utilizar como plataforma por gremios (superficie superior), hasta 1000m2 facilmente colocados por día con tres obreros y grúa
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)Maximum economy in materials, labor and time.
4 evitar encofrados, cimbras, apuntalamientos, sin capa de compresión en muchos casos, listo para pintar (superficie inferior), listopara utilizar como plataforma por gremios (superficie superior), hasta 1000m2 facilmente colocados por día con tres obreros y grúaMenor riesgo financiero – acortar duración de edifiacación
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 heatingRelease stored heat/cooling to minimize peak load demandDisplace energy consumption to off-peak electricity ratesEnergy consumption savings of 30-50% in hot and cold climatesReduced HVAC machinery & ducting saves 50% on equipment costsIn wide use in Europe and Middle EastAll building types, industrial, commercial, schools, institutions, residencialLeeds Certification
28 5) Green Building – Savings Example Jeddah Building - Area 32000 m2 Original Design Capacity Air Conditioning: Tons Tons safety marginRevised Design with Green Radiant Panels: 750 Tons Tons safety marginPeak Consumption with Radiant Panel, August 2004: 530 Tons
29 Since 1954 – Engineering & Machinery for Precast Concrete 6) WEILER GmbhSince 1954 – Engineering & Machinery for Precast ConcretePioneer and leader in long bed precastconcrete technologyOver 230 plants y 500 installed machinesaround the worldA complete range of machinery andengineering services adapted to theneeds of individual clientsTough, precision machinery, designed andbuilt to last a lifetimeHighest European quality standards – all componentssupplied by leading global brands (Siemens, Bosch, SKF, ABB etc.)Local service programs supporting clients during all stagesof factory growth
30 Weiler Gmbh (Germany) – 300 Plantas Instaladas a Nivel Mundial -- Número Uno en el Oriente Medio – 50 Plantas Instaladas
31 ProductsExtruder – exclusively for prestressed hollow core slabs & panelsSlipformer – solid and hollow core slabs, beams & other prestressedproductsTilting Tables – for walls and panelsProduction Equipment – batching plants, saws, overhead cranes, bed cleaners, concrete transport systems, prestressing equipment, accessorios etc.ServicesComplete engineering and support services, turnkey plants, training, parts etc
32 Extruder minimum cement consumption – 320-350 kgs/m3 maximum productivity at lowest production costhollow core slabs 8 to 50 cm thick6-8 hours cure to cut (w/ dry mix concrete & heated beds)hollow voids to 50% of volumeminimum cement consumption – kgs/m3highest compressive strength in the market kg/cm2 (12,500 psi)
34 T Beams – up to 40 cm height (16”) Piles – up to 50 X 50cm (20 X 20”) Slipformer – ProductsSolid and hollow core slabs, to 50cm (2.5 to 20”)T Beams – up to 40 cm height (16”)Piles – up to 50 X 50cm (20 X 20”)LintelsWalls & sound barriersSandwich PanelsRoofing elementsCustom Products
36 Direct Cost Comparison – Slab / Panel Production – Extruder / Slipformer Peralte16" x 48" - 40 x 120 cm16" / 40cmarea cm²volumen m³/m²diferencia %peso/m²costo hormigón/m²costo hormigón 100k m²Weiler22620.1885446.93MXNMXN 12,775,902Spancrete2857.10.238126.31%564.52MXNMXN 19,380,52551.70%401 in²12" x 48" x 120 cm12" / 30 cmcosto 100,000 m²0.1505356.86MXNMXN 10,201,06620380.169812.84%402.67MXNMXN 13,824,33635.52%316(Ultra Light Spancrete)10" x 48" x 120 cm10" / 25 cm1459.60.1216288.39MXN 82.44MXN 8,243,90216670.138914.21%329.37MXNMXN 11,307,73737.16%277 in²8" x 48" x 120 cm8" / 20 cm12180.1015240.66MXN 68.79MXN 6,879,33215130.126124.22%298.94MXNMXN 10,263,11149.19%251 in²6" x 48" x 120 cm6" / 15cm9300.0775183.75MXN 52.53MXN 5,252,69211700.097525.81%231.17MXN 79.36MXN 7,936,44451.09%197 in²4" x 48" x 120 cm4" / 10 cm672.20.0560132.82MXN 37.97MXN 3,796,6238900.074232.40%175.85MXN 60.37MXN 6,037,12459.01%138 in²1) 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 .3) Extruded slabs have higher compressive strengths, psi (extruder) compared to 8000 psi (slipformer)5) Combining lighter slabs using less concrete, higher compression & minimal cement consumption, savings on production costs are 30 to 60% when using the extruder.
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 productionOne machine or a complete plant – Weiler is a committed, long-term partner for growth & profitLooking at the quickly climbing costs of cement and steel, and the immense need of new structures in this country, poured-in-place construction is outdated. Weiler provides equipment and engineering services that will give you new project possibilities, higher efficiencies and bigger cost savings, and gross margins over 70%.
43 Hollow Core Slabs & Panels Advantages and Examples June 2010 A. Powell Jacquier Lic. MBA
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