3d monolithic precast
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3D Monol i th ic PrecastC o n st r u c t i o n Te c h n o l o g y S o l u t i o n
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Salmon Leap Associates India Pvt. Ltd. has signed aJoint Venture with Green Precast Systems &Technologies International, Offshore Beirut (GPST)the 100% subsidiary of Green Precast Systems &Technology, Australia. GPST brings in the patentedtechnology for residential, commercial, institutional,educational, healthcare and other constructionrelated sectors. The company being formed toundertake this activity in India and the sub-continentregion is hoMMfactor India Pvt. Ltd.
hoMMfactor would provide comprehensive threedimensional modular concrete structure buildingsystems that will revolutionize the way construction iscurrently undertaken in country.
GPST is currently implementing this technology invarious countries including Australia, UAE and Beirutand will be implemented throughout the GCCcountries, MENA and North African countries.
GPST has developed a sophisticated pre-cast modularbuilding system that reduces overall constructiontime, cost, labour and gives superior acoustic,thermal and fire rating properties. The patentedtechnology system – Australian Patent No. 741667 –that produces the module is fully automated and
hydraulically driven which monitors the mould tomaintain the production process within the finetolerances (±2mm) that ensure accurate repetitiouscasting on a daily basis.
The unique technology application is summarizedbelow
The modules unlike traditional flat pre-castpanels, uses a patented process of producing fivepanels in a single pour, or a three- dimensionalshape creating a pre-designed shaped room.
The moulds are customizable during the modules’design process. All openings - doors and windows,access points—piping and conduit and insulationare designed into the mould. Building all thefeatures into the mould's design reduces projectturnaround time and costs.
This method is replicated and the modules arefitted together—side-by-side or atop of eachother. This allows the roof of the first module tobecome the floor of the second module as theyare vertically stacked, similar to Lego blocks orbricks. The ability to fit the modules togetherreduces construction time.
THE TECHNOLOGY SOLUTION
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THE CONSTRUCTION TECHNOLOGYEnabling Paradigm Shift
1. Reinforcing & insulation
2. High – tech steel computerized mould system
3. Reinforcement l ifted & placed
4. First and Second fix MEP positioned
5. Concrete - super plasticized, low-shrinkage 40 Mpa concrete
6. Lift at strength of 16.20 Mpa
7. Cure & commence fit out
8. Transport to erection position
9. Lift modular unit into place & assemble
10. Finish
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THE TECHNOLOGY ADVANTAGE
Unlike the conventional and traditional 1D and 2DPrecast methods, Green Precast is the new uniquetruly 3D, monolithic, Modular solution that can bepoured complete with window and door frames,electrical and plumbing conduits already inlaid.
The major advantages the technology offers over itscompetitors are
Rapid construction on-site
Quality & accuracy (+/- 2mm – 5 mm)
Long term strength and durability
Fire, water, cyclone, earthquake, termite, marineand corrosion proof
Fire rating / sprinkler concessions
All weather production facility
Reduces scaffold and formwork
No propping, caulking, brackets
Clean and neat construction site
Windows, doors and other modular furniture canbe ordered straight from the drawings due theaccuracy.
The external and internal walls painting can bedone without the need to plaster or render
The doors, windows along with their frames can befitting at the time of casting the modules.
Value engineering can add cost and time savings ofup to 20% on the overall construction.
Transportable factory – the moulds can betransported
The above advantages enables savings of 20 – 30% onthe average cost per project and can build 20 – 30%faster per project.
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A D V A N T A G E S
80%upto FASTERthan traditional construction methods
50%upto STRONGEReach unit 1 piece
90%upto WASTE FREEtotally relocatable recyclable
50%upto CHEAPERmaterial and labour cost
On-site manufacturingeliminates transportation & multiple handling
Stronger, one piece, stackable3D monolithic concrete construction
Improvedthermal & acoustic performance
Reducedoperating & ongoing maintenance costs
Note:Depending on 1. Design 2. Time Frame 3. Project Size
TECHNOLOGY DETAILS
The building system is a sophisticated modular precastbuilding method providing a concrete structure finishwhich is accurate and with a high quality whichdramatically reduces overall construction time andprovides superior acoustic, thermal and fire ratingproperties.
Underpinning the construction method is the uniquesmart moulds employed to produce each module. Eachmould is an intricate piece of machinery,manufactured to Green Precast’s patented design andspecifications and is fully customizable, except for itsfixed internal dimensions.
This means every time a new unit is made, the mouldcan be customized to meet the architecturalrequirements. Furthermore the doors, windows andany provision for services (electrical, plumbing, etc.)can be cast into the outer concrete walls. Each mouldis fully automated and hydraulically driven with finetolerances (+/- 2mm – 5 mm) to allow accurate,repetitious casting on a daily basis.
Durable concrete, reinforced with steel, super-plasticized with a low shrinkage rate is poured into apre-made three dimensional mould and when setforms the block containing the main components ofthe structure – the walls and ceilings or walls andfloor. These monolithic 3D modules can then be
simply arranged and stacked as rooms to produce aself-supporting building structure up to 10 storeyshigh.
The system is ideal for repetitious building projectssuch as apartments; high end, as well as medium tolow end villas, motels / hotels, labour camps, housingunits, age-care villas, student accommodation, siteoffices, industrial building and schools – all built to thehighest environmental specifications.
The salient features of the building technology isdetailed out in the following sections
SPEED
The technology delivers construction times up to 80%faster than traditional superstructure systems and isideal for large and repetitious projects where onsitemanufacturing delivers optimum benefits.
STRENGTH
The inherent load bearing strength of each modulemeans that multi-level constructions of up to 10storeys can be economically and more safely achievedthan using tilt slab or traditional practices. The systemprovides a highly flexible precast building that isstrong, durable, fire, termite, cyclone, water andweather proof.
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DURABILITY
The structure has a longevity of 50+ years with lowMaintenance and operating costs. Precast concrete ismore durable than other materials; it is fire-proof,termite proof and water-proof. The superior finishesGreen Precast achieves with controlled manufacturingprocesses means that the concrete may be left in itsnatural state and not finished, painted or covered atall, if so required.
SAFETY
The self-supporting system provides a safer workenvironment than traditional tilt slab constructionmethods requiring no propping, brackets or expensivescaffolding.
DESIGN FLEXIBILITY
The technology provides architects and developerswith endless design options with wall openings andwindows, doors and stairwells that can be pre-moulded into each module. The Green Precastmodules are assembled on the site according to theplans and the rest of the structure is added - roofing,veranda, façade decoration, flooring, plumbing andfinishing touches such as light fittings, final painting,tiles, carpet etc.
Modules can be arranged to create design structuresincluding multi-level.
ONSITE PRODUCTION
Daily controlled production, fully committed to eachindividual project with a customized plant per project.
PRODUCTION EFFICIENCY
The factory is an all-weather production facility andprovides faster construction time regardless ofweather conditions.
Onsite factory controlled fit-outs such as windows,doors, joinery, insulation and even painting can bepre-installed prior to installation to reduce onsitelabour and construction costs.
RE-LOCATABLE
Both the manufacturing plants and the individualmodules can be re-located to another location.
The mobile factories can be set up on site to save ontransport and gas emission, to secure a betterproduction rate, a faster delivery rate, a better pricingoutcome.
SURFACE FINISHES
With a Class 1 finish, the off-form quality of wall andceiling means that plasterwork can be in mostinstances eliminated.
The surfaces are so well finished that it is ready toreceive paint.
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Surface FinishThermal Insulation
Wastage Free Precise Engineering
The flooring also does not require screeding and thetiles can be fitted directly.
THERMAL & ACOUSTIC
The thermal and acoustic qualities of the modulesare tremendous, with insulation being embeddedwithin each concrete sandwich.
High external finishes further enhance efficiencies.
WASTAGE FREE
Virtually wastage free, the system utilizes leanmanufacturing processes incorporating precisecontrol of mix formulations, materials and labourinput.
Tight controls of quantities of materials and precisemix proportions mean the optimum use ofmaterials. The modules are manufacturedrepeatedly in the same moulds meaning little or nowastage of materials.
PRECISE ENGINEERING
The System delivers a highly accurate output within2mm – 5mm of exact specifications.
Internal dimensions being with a tolerance of 1-3mm, enables pre-ordering of all joinery work whichresults in savings throughout the constructionmanagement process.
ENVIRONMENTAL BENEFITS
Unlike traditional building methods that utiliseprecious raw materials that are highly wasteful,highly labour intensive and costly, the Green PrecastSystem is a unique - highly flexible 3 dimensionalmodular precast building system that utilizes leanmanufacturing processes to produce an eco-efficient, energy efficient, acoustically efficient,structurally efficient more durable low maintenancebuilding solution.
Precast concrete is environmentally friendly in avariety of ways. The ingredients of concrete (water,aggregate and cement) are abundant in supply andtake a lesser toll in their extraction than otherconstruction materials.
As a nearly inert material, concrete is an idealmedium for recycling waste or industrial bi-products. Many materials that would end up in alandfill can be used instead to make concrete; blastfurnace slag, recycled polystyrene and fly ash areamong materials that can be included in the recipefor concrete and further enhance its appeal. GreenPrecast regularly incorporates fly ash and slagcement into the modules.
ENERGY EFFICIENT
Another environment plus for concrete is energyefficiency. From manufacture to transport toconstruction, is modest in its energy needs andgenerous in its payback. Additionally, once in placeconcrete offers significantly higher energy savingsover the lifetime of a building. In homes andbuildings concrete thermal mass, bolstered byinsulating materials, affords high R-factors andmoderates temperature swings by storing andreleasing energy when needed for heating andcooling and the light reflective nature of concretemakes it very easy to illuminate.
RECYCLING
Further commendable characteristics of concreteare waste minimization and long life. Whether cast-in-place or precast, concrete is used on as neededbasis. Leftovers are easily reused or recycled andconcrete is a durable material that actually gainsstrength over time, conserving resources byreducing maintenance and the need forreconstruction.
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TECHNICAL DETAILS
CONCRETE
The concrete used in the production of the modules isa maximum of 40 MPa, low shrinkage, super-plasticized mix with steel reinforcement.
Class 1 & 2 finish is achieved on all internal andexternal surfaces which is suitable for direct finishapplication.
TRANSPORTATION & INSTALLATION
Centre of Gravity: The manufactured units are verystable rectangular structures with a centre of gravityjust over half way up their height. This is affected bythe number and configuration of openings for doorsand windows.
Each unit during the shop drawing phase has its ownspecific centre of gravity calculated and located on theshop drawing so that the lifting points can bepositioned to ensure that the modules lift level fromthe mould are easy to install.
Lifting: the cast in lifting points are usually from aproprietary precast lifting supplier. The modules arelifted from 4 points located depending on the COGcalculated. The lifting chains are 60 degrees or morefrom horizontal and in some instances a liftingspreader is used.
Transport: in the event the units are not cast on site,large steel transport frames are used across a
traditional truck tray to transport the units around themanufacture site to their installation position or toanother site (up to several hundred kilometers away).
Chains are generally used to secure the loads eitherover the top or to specifically designed anchor pointscast into the underside of the units. This transportmethod generally has to be decided prior tomanufacture so that the relevant cast in points arecatered for.
LOAD TESTING
Load testing has been undertaken in a factoryenvironment under supervision by Kinhill Engineers(South Australia) of a 5 storey building. Finiteelements analysis has been performed by ConwellWagner Engineers (South Australia).
PENETRATIONS / OPENINGS
These can also be cast into each individual module(preferred) or cut out later should extensions to thebuilding be desired. The corner columns and theperimeter top beam are the structural elements andshould not be compromised, although someexceptions are possible. The walls on all sides canhave block outs / penetrations wherever required. Theroof slab can also be moulded for stair openings,skylights, service ducts, lifts etc.
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PRODUCTION CAPACITY
Each mould can produce one module per day.
Production can commence approximately one weekafter the shop drawing of the individual is approved. Adetailed production program is produced for every jobto ensure critical path and onsite production programsare met.
ACOUSTIC PROPERTIES
Mass is the greatest influence on the response of wallto sound. The heavier a wall/partition, the greater thesound insulating it can provide to the increase ofenergy required to set in motion.
Acoustic separation by a physical gap is the mosteffective means to stop acoustic vibrations as they donot have a medium by which to transmit thefrequency.
For the reason above the Green Precast “double skin”concrete wall becomes one of the most effectiveacoustic insulation systems.
Acoustic requirements for different classes of buildingvary considerably and are often a governing designrequirement in modern buildings today. An acousticconsultant can be engaged to give project specificadvice as to the requirements, especially in a multi-occupancy building, however, the double skinconcrete system satisfies most building classrequirements.
As a guide the following values are expected for asingle or double skin wall element.
• 90mm precast concrete wall 45 RW
• 2*90 walls with 20mm gap 55 RW
THERMAL PROPERTIES
Thermal insulation in building design has becomeimportant, due to heating and cooling energy costsover the life of a building.
One of the most important properties in determininginsulating characteristics of a building product is thethermal mass. Concrete has great thermal mass butpoor insulating ability. One of the most effectiveprinciples then is to insulate the thermal mass fromthe extremes of the environment and keeping itstemperature ambient.
The Green Precast System is well suited to severalmethods of applied, or cast in situ insulation such asfoam and render, or sandwich panel construction,which help insulate the concrete against temperaturevariations while keeping the internal thermal massambient.
Sandwich panel construction used extensively in theMiddle East, Europe and North America and involvescasting an inner structural layer of concrete, a centralcore of foam insulators, and an outer layer of concretesimultaneously in one operations. The cores are held
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Thermal Properties
together by a patented thermoplastic resin and shearconnector that bridges the 3 layers.
This is not the most cost effective solution but themost permanent solution. It is quite heavy andrequires a high level of factory supervision to achieve.
The mould must be designed and modified specificallyto allow the system to be poured; so the exact extentof the insulation requirements must be known prior tomanufacture.
Post Fixed Form and Renders the most versatilesystem as is done independently of the modularmanufacture process and can be placed on any wall,returns required can be done in the factory or on site.
The insulation value can also be varied quite simply byincreasing the thickness of the foam layer at minimalextra cost.
This process is recommended for villa construction.
STUCTURAL DESIGN
The Modular product has been developed since 1987by engaging some of the most sophisticated FiniteElement method analysis techniques by some of theworld’s largest and most respected engineering firmssuch as Connell Wagner and GHD.
Basically, the module acts as a 3 dimensional frame
where the horizontal roof element ties all the wallstogether and stiffens the unit. Although penetrations,doors, windows etc. can be placed practicallyanywhere, there is a beam on all sides and the cornercolumns that should not be compromised if possible,especially for multistory construction. A general guideis that the columns should not be reduced to within600 mm from the corners and the perimeter beamshould be a minimum 500 mm deep. Individualstructural certification is required if these conditionsare compromised.
FIRE RATING
The fire rating of a particular building is a directfunction of the design and will need to be calculatedon an individual basis. However, the controlled coverto reinforcement, double skin concrete wall and highlyvibrated concrete of the technology gives themaximum possible fire rating (up to 4 hours) betweenrooms) for particular wall thickness.
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RESEARCH AND DEVELOPMENT
GPST as a company is committed to a continual R&Dprogram to ensure adherence to the ever changingbuilding code requirements and different types ofapplications.
GPST has embarked on an ambitious approach toincrease thermal, acoustic and fire rating propertieswhile maintaining the existing benefits of modularsystem.
Current Research & Development includes
Lightweight Concrete
Colored Concrete
Polished Floors
Sandblasted Finishes
Carbon Credit Trading
Causes of Low fire Rating
Smoke propagation kills more people in highdensity fires than the actual fire or structurecollapse itself.
The fire and the smoke spread is generally throughthe breakdown of the joints from room to room andfloor to floor.
The collapse mechanism in majority of fires inprecast structures is the yielding of the steelbrackets and support structures.
hoMMfactor Advantage
Fully integrated vertical and horizontal joints givecomplete and contained 3 hour+ fire and smokecontainment per room
There are no brackets, bolts, exposed steel fittingsthat will yield
The egress distance is small as there are exists atthe end of each corridor
Coupled with other aids like smokecompartmentalization doors it can obtain a 3+ firerating without a need for the fully reticulatedsystem.
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CONSTRUCTION SYSTEM COMPARISON
hoMMfactor
A single trade and subcontract package
Cast complete rooms in one piece and installwith a single lift
Sub-terrain structures
Requires separate structures of beams,columns and floor system using precast
Wall in-fills need more jointing detail
Must use separate floor system for multi-level
Flat elements cast on flat table and installedindividually and require numerous joints, bracketsand grouting
Block Work 2D Precast
BUILD CONCEPT
Factors
Monolithic cast of wall and ceiling which isequivalent to 5 and 14 flat panels
No brackets, props or vertical joints required
Customizable for penetrations and openings
Repetitious production of a module
More on-site trades, reinforcement, brick orblock laying and rendering
Onsite labour intensive
Concrete pump and untidy
Larger factory area for equivalent production andmany more vertical joints
FACTORY PRODUCTION
Closed joints reducing locations for airtransfer
Internal foam layer sandwich panel (200-210mm)
External UV Reflective coating (up to 100%),available in 45 colours
N/A
Must be cast in foam, walls have a perimeterboarder not containing insulation
Many vertical joints
Cast in foam layer does not extend to full area ofpanel
INSULATION
Walls and roof act together structurallyminimizing the volume of concrete, steel andreinforcing bars leading to less wastage
Excessive site wastage, clean-up, disposal, cutting of bricks and blocks, pallets, mortar, sand piles, hoses and water
Minimum 2 layers of reinforcing for insulated walls
Requires extra 12m of vertical jointing per roomWASTAGE
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CONSTRUCTION SYSTEM COMPARISON
Internal and external paint can be applied inthe production process
Only achieved by site application, increasedlabour cost and interior accuracy
Coloured bricks available but generally needto apply another finish or lining
Factory painting not possible due to multiple joints
Colour variation as panels are poured separately
More visible joints
FINISHES
Factors
Hydraulic mould requires 8 men to operateup to 80 m2 per 12 hours
Installation requires 3 people
Labour intensive
Requires more site amenities, supervision,temporary services and scaffolding
Each panel requires 2 man-days (~ 10 man-days for5 panels)LABOUR
A single lift
No propping or levelling
Minimal site fittings, brackets and dowels
Solid working platform immediately availablefor subsequent levels
Erect 4-5 levels in one day
Greater accuracy, monolithic constructionreduces bracket and joint costs ~ $ 100 perroom
Multiple small lifts causes delays, 2 levels per daymax
5 crane movements to install one panel
Individual propping and levelling
Less accuracy with accumulating errors
No immediate working platform until all jointing iscompleted
INSTALLATION
1 crane to extract and place for yard and site Extensive scaffolding, materials hoist and safety provisions
Need approximately 8 cranes on siteTRANSPORT & LIFTING
Slow
Labour intensive
Greater overhead costs
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hoMMfactor Block Work 2D Precast
CONSTRUCTION SYSTEM COMPARISON
Windows and door frames, electrical andplumbing conduits built into mould
Can cast holes in roof slabs for verticalplumbing service running from top to bottomof building
Most be progressively manually built in orchased in later
Impractical to factory install windows
Corner electrical joining impossible
Plumbing service holes more difficult
SERVICES
Factors
Pipes can be cast into floor for efficientcooling / heating
Not possible Difficult / impossible to do with hollow core planksHYDRONIC COOLING / HEATING
Modern lifting techniques
Safe working platforms
Limited access to external surface required
Installation requires temporary phase (propping)with added safety requirement.SAFETY
Excessive site labour with potentially highinjury risk
Loose power leads, hoses and scaffoldingcreates safety risks
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hoMMfactor Block Work 2D Precast
M/s. Sa lmon Leap Assoc iate s Ind ia Pr i vate L imi ted2 n d F loor , Sana P laza, 21/14-A, MG Road, Bangalore 560 001
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