1. 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

2. 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

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), 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

5. 2) Applications
Rail Landing
Docks & Moorings
Earth Retention

6. Tunnel & Canal Coverage
2) Applications
Tunnel & Canal Coverage

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

8. 2) Applications
Walls for
Warehouses/Storage

9. 2) Applications
Silos

10. 2) Applications
Parking

11. 2) Applications
Stadiums
Stands / Seating

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

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

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

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

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

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

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

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

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

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

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

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 32000 m2
Original Design Capacity Air Conditioning: 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. 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

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

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 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 – 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
14-16 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. T Beams – up to 40 cm height (16”) Piles – up to 50 X 50cm (20 X 20”)
Slipformer – Products
Solid 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”)
Lintels
Walls & sound barriers
Sandwich Panels
Roofing elements
Custom Products

35. Compaction Systems
Slipformer
Extruder

36. 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
MXN 12,775,902
Spancrete
2857.1
0.2381
26.31%
564.52
MXN
MXN 19,380,525
51.70%
401 in²
12" x 48" x 120 cm
12" / 30 cm
costo 100,000 m²
0.1505
356.86
MXN
MXN 10,201,066
2038
0.1698
12.84%
402.67
MXN
MXN 13,824,336
35.52%
316
(Ultra Light Spancrete)
10" x 48" 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
MXN 11,307,737
37.16%
277 in²
8" x 48" 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
MXN 10,263,111
49.19%
251 in²
6" x 48" 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" 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 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.

37. Battery Mold for Walls & Panels

38. Tilting Tables

39. 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

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
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%.

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