Hollow Core Slabs & Panels Prestressed/Precast Definition & Advantages 2) Applications 3) Examples – Commercial & Industrial 4) Examples – Low Cost Housing 5) Green Building – LEEDS 6) Weiler Gmbh – Precast Engineering & Machinery Panorama Dubai 2008 – Burj Dubai Tower

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. evitar encofrados, cimbras, apuntalamientos, sin capa de compresión en muchos casos, listo para pintar (superficie inferior), listo para utilizar como plataforma por gremios (superficie superior), hasta 1000m2 facilmente colocados por día con tres obreros y grúa

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 – 700-900 kgs/cm2 (10000-12500 psi Weiler extruder) - Maximum Economy in materials (40 - 50%), 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.

evitar encofrados, cimbras, apuntalamientos, sin capa de compresión en muchos casos, listo para pintar (superficie inferior), listo para utilizar como plataforma por gremios (superficie superior), hasta 1000m2 facilmente colocados por día con tres obreros y grúa Menor riesgo financiero – acortar duración de edifiacación

2) Applications Rail Landing Docks & Moorings Earth Retention

Tunnel & Canal Coverage 2) Applications Tunnel & Canal Coverage

Warehouse, Storage & Light Industrial Buildings 2) Applications Warehouse, Storage & Light Industrial Buildings

2) Applications Walls for Warehouses/Storage

2) Applications Silos

2) Applications Parking

2) Applications Stadiums Stands / Seating

Liguid Storage / Water Treatment 2) Applications Liguid Storage / Water Treatment

Al Jazeera Tower – Qatar 3) Building Examples Al Jazeera Tower – Qatar Hollow Core Slabs - 11,000 m2 - 15cm slab - 680 m2 - 26cm slab

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

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

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

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

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

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

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

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

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

3) Examples Public Works: Schools Generalitat Catalunya Spain

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”).

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

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

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

5) Green Building – Savings Example Jeddah Building - Area 32000 m2 Original Design Capacity Air Conditioning: 2200 Tons + 550 Tons safety margin Revised Design with Green Radiant Panels: 750 Tons + 250 Tons safety margin Peak Consumption with Radiant Panel, August 2004: 530 Tons

Since 1954 – Engineering & Machinery for Precast Concrete 6) WEILER Gmbh Since 1954 – Engineering & Machinery for Precast Concrete 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

Weiler Gmbh (Germany) – 300 Plantas Instaladas a Nivel Mundial -- Número Uno en el Oriente Medio – 50 Plantas Instaladas

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

Extruder minimum cement consumption – 320-350 kgs/m3 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 – 320-350 kgs/m3 highest compressive strength in the market - 650-900 kg/cm2 (12,500 psi)

Slipformer maximum production flexibility: solid & hollow core slabs/panels, beams, cement piles, posts, lintels, etc. 20-30% savings compared with wet mix precast 14-16 hours cure to cut (with heated bed & dry mix concrete) cement consumption - 340-380 kgs/m3 (575- 640 lbs/cu yrd) high compresive strength 450-550 kgs/cm2 (6400 psi)

T Beams – up to 40 cm height (16”) Piles – up to 50 X 50cm (20 X 20”) 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

Compaction Systems Slipformer Extruder

Direct Cost Comparison – Slab / Panel Production – Extruder / Slipformer Peralte 16" x 48" - 40 x 120 cm 16" / 40cm area cm² volumen m³/m² diferencia % peso/m² costo hormigón/m² costo hormigón 100k m² Weiler 2262 0.1885   446.93 MXN 127.76 MXN 12,775,902 Spancrete 2857.1 0.2381 26.31% 564.52 MXN 193.81 MXN 19,380,525 51.70% 401 in² 12" x 48" - 30 x 120 cm 12" / 30 cm costo 100,000 m² 1806.12 0.1505 356.86 MXN 102.01 MXN 10,201,066 2038 0.1698 12.84% 402.67 MXN 138.24 MXN 13,824,336 35.52% 316 (Ultra Light Spancrete) 10" x 48" - 25 x 120 cm 10" / 25 cm 1459.6 0.1216 288.39 MXN 82.44 MXN 8,243,902 1667 0.1389 14.21% 329.37 MXN 113.08 MXN 11,307,737 37.16% 277 in² 8" x 48" - 20 x 120 cm 8" / 20 cm 1218 0.1015 240.66 MXN 68.79 MXN 6,879,332 1513 0.1261 24.22% 298.94 MXN 102.63 MXN 10,263,111 49.19% 251 in² 6" x 48" - 15 x 120 cm 6" / 15cm 930 0.0775 183.75 MXN 52.53 MXN 5,252,692 1170 0.0975 25.81% 231.17 MXN 79.36 MXN 7,936,444 51.09% 197 in² 4" x 48" - 10 x 120 cm 4" / 10 cm 672.2 0.0560 132.82 MXN 37.97 MXN 3,796,623 890 0.0742 32.40% 175.85 MXN 60.37 MXN 6,037,124 59.01% 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 320-350 kgs/m³, compared to 400-450 kgs/m³ for the slipformer. Cement savings of 100 kgs/m³ . 3) Extruded slabs have higher compressive strengths, 10000 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.

Battery Mold for Walls & Panels

Tilting Tables

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

Mini Slabs & Panels for DIY Construction / Low Cost Housing

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 Looking 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%.

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