New production concept for precast slabs - Trade Journal for the Concrete … · 2017-11-11 ·...
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PRECAST CONCRETE ELEMENTS CPI – Concrete Plant International – 6 | 2017 www.cpi-worldwide.com 170 A new production concept – MultiSlab – developed by Abeo and Elematic, allows hollow-core producers to also use their existing casting beds for production of pre- stressed SL-decks. An SL-deck is a flexible and light precast slab targeted at the residential market. The slab can handle long spans and built-in value-adding solutions such as bathroom installations and floor heating pipes. The Finnish precast producer, Lujabetoni, is currently implementing the first MultiSlab production system for launch of the SL-Deck to the Finnish market at the start of 2018. Flexible slab production Abeo, the company behind the innovative SL-deck, and Elem- atic, an international acting supplier of precast machinery and equipment, joined forces to develop a new production con- cept allowing precasters to cost-efficiently add SL-decks to their product range. The MultiSlab production concept utilizes existing casting beds. Steel plates are installed on top of those, e.g. two exist- ing 1.2-meter casting beds can be covered with an app. 3.3- meter wide steel plate. This enables production of either 2.4- meter wide SL-decks or two lines of 1.2-meter wide hollow- core slabs. When producing SL-decks, side forms are mounted on the casting bed with magnets. The magnet system means that the sides easily open/close for demoulding and can be removed when doing hollow-core production. All hollow-core machin- ery runs on a permanent outer rail and a removable rail on the middle of the casting bed, while a 3.3-meter wide SL-deck casting machine runs on the permanent outer rails. A competitive edge “The precast industry is a competitive market with many pro- ducers looking for a competitive edge. The ‘MultiSlab’ con- cept is a cost-efficient way for producers to leverage invest- ments in existing facilities and diversify their product portfo- lio,” says Lassi Järvinen, Technical Director of Elematic and continues: “Being able to produce multiple products on the same pro- duction line is not only a benefit in terms of being able to New production concept for precast slabs – improving competitiveness on residential market Abeo, 2640 Hedehusene, Denmark Existing casting beds can cheaply be converted to a ‘MultiSlab’-bed allowing production of either 2.4-meter SL-decks or two lines of 1.2-meter hollow-core slabs.
Transcript of New production concept for precast slabs - Trade Journal for the Concrete … · 2017-11-11 ·...
PRECAST CONCRETE ELEMENTS
CPI – Concrete Plant International – 6 | 2017 www.cpi-worldwide.com170
A new production concept – MultiSlab – developed byAbeo and Elematic, allows hollow-core producers to alsouse their existing casting beds for production of pre-stressed SL-decks. An SL-deck is a flexible and light precastslab targeted at the residential market. The slab can handlelong spans and built-in value-adding solutions such asbathroom installations and floor heating pipes. The Finnishprecast producer, Lujabetoni, is currently implementing the first MultiSlab production system for launch of the SL-Deck to the Finnish market at the start of 2018.
Flexible slab production
Abeo, the company behind the innovative SL-deck, and Elem-atic, an international acting supplier of precast machinery andequipment, joined forces to develop a new production con-cept allowing precasters to cost-efficiently add SL-decks totheir product range.
The MultiSlab production concept utilizes existing castingbeds. Steel plates are installed on top of those, e.g. two exist-ing 1.2-meter casting beds can be covered with an app. 3.3-
meter wide steel plate. This enables production of either 2.4-meter wide SL-decks or two lines of 1.2-meter wide hollow-core slabs. When producing SL-decks, side forms are mounted on thecasting bed with magnets. The magnet system means that thesides easily open/close for demoulding and can be removedwhen doing hollow-core production. All hollow-core machin-ery runs on a permanent outer rail and a removable rail onthe middle of the casting bed, while a 3.3-meter wide SL-deckcasting machine runs on the permanent outer rails.
A competitive edge
“The precast industry is a competitive market with many pro-ducers looking for a competitive edge. The ‘MultiSlab’ con-cept is a cost-efficient way for producers to leverage invest-ments in existing facilities and diversify their product portfo-lio,” says Lassi Järvinen, Technical Director of Elematic andcontinues:
“Being able to produce multiple products on the same pro-duction line is not only a benefit in terms of being able to
New production concept for precast slabs –improving competitiveness on residentialmarket
Abeo, 2640 Hedehusene, Denmark
Existing casting beds can cheaply be converted to a ‘MultiSlab’-bed allowing production of either 2.4-meter SL-decks or twolines of 1.2-meter hollow-core slabs.
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serve more market segments, but also makes it possible forproducers to obtain a higher utilization of the production ca-pacity and better cope with demand fluctuations betweenmarket segments.”
The SL-deck system
The SL-Deck is based on a new combination of self-compact-ing concrete and light-aggregate concrete. While the light-weight concrete is casted as arch shaped blocks in the bottomof the deck, the self-compacting concrete make up the restof the deck thereby constituting two series of crossing beamsthat are stabilized and protected by the light-aggregate con-crete.
In traditional concrete slabs, the same strong concrete is usedfor the entire element. In the SL-Deck, the strong concrete isonly used, where it is of benefit to the structure. The rest ofthe slab consists of a light-aggregate concrete accounting forapp. 45 % of the total volume.
Morten Rasmussen, technical manager at Abeo explains:“The SL-Deck exploits the flexibility of self-compacting con-crete with the low weight and fantastic insulating propertiesof light-aggregate concrete. This gives a light and flexible slabthat can handle long spans and is cheap to transport and in-stall. In addition, the slab has very high sound and fire insula-tion properties”.
The automatic light-aggregate concrete casting machine iscapable of casting up to 3 meter per minute and thus complete a 100-meter casting bed in app. 30 minutes.
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Built-in bathroom installations in the SL-deck makes it possible to construct a thin slab/floor structure comparable to an in-situ built structure.
Apartment project in Copenhagen with built-in bathroom installations.
Targeting the residential market
The SL-Deck has been developed for the residential marketbridging the gap between hollow-core slabs and half slabswith in-situ topping.
“Up until today, a contractor’s choice between slab systemshas typically been a choice between in-situ/filigree with highflexibility or hollow-core slabs with fast and cost-efficient in-stallation. With the SL-Deck, a producer can offer the flexibilityand quality of in-situ and filigree slabs at the speed and costof a hollow-core slab,” says Peter Hertz, Director of Abeo.
The MultiSlab concept allows hollow-core producers to com-plement their product portfolio and become more competi-tive on the growing market for multilevel residential develop-ments. The same production line can be used for offering SL-decks for residential projects while still offering hollow-coreslabs for industrial and commercial projects.
“Following the joint development work with Elematic, we nowhave a concept that allows for perfect complementarity - notonly product and market wise, but also in production plan-ning,” says Peter Hertz.
Integrated value-adding solutions
Recently, Abeo developed a new solution for the SL-deckmaking it possible to integrate bathroom installations in theslabs at the factory – a solution with great potential on the res-idential market.“When using precast concrete slabs for apartments, it has tra-ditionally been necessary to place installations for bathroomson top of the slabs. This gives a high and expensive floorstructure in the whole apartment, as the bathroom and therest of the apartment have to be in the same level,” says PeterHertz.With integrated installations, it is possible for the contractorto construct a thin slab/floor structure comparable to an in-situ solution - using a 100% precast slab. The solution couldhelp fuel the use of precast in markets that are still dominatedby in-situ and half slabs.
Competing with filigree and in-situ
Around the world, precast concrete is generally accepted tobe the fastest and cheapest way to build. Nonetheless, filigreeand in-situ slabs continue to dominate the residential marketin many countries. The SL-Deck can enable a precast pro-ducer to become more competitive in the residential seg-ment and take market share from filigree and in-situ.
“Filigree is probably the most widespread prefabricated slabproduct today. However, being just a ‘half slab’, the systemdoesn’t provide the advantages that a fully precast slab does,
Casting bed after production of the lightweight concrete blocks.
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nor does it contribute with much sales to the industry because it is sold at low pricesleaving most of the work to the onsite contractors and concrete suppliers. With theSL-deck, producers get a unique opportunity to increase sales volumes and profitability in existing projects while increasing the overall market share of precastconcrete,” says Peter Hertz.
Installation of 2.4-meter wide SL-decks.
12-storey apartment project with SL-decks in Copenhagen, Denmark.
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Lujabetoni starts SL-deck MultiSlab production
Following the Danish market launch, Abeo has reached100.000 m2 SL-decks in Denmark and recently started to license the SL-deck to producers outside Denmark.
Among coming licensees are the Finnish precaster, Luja-betoni, who plans to make the SL-deck their primary offeringfor residential projects. With app. 750 employees and annualsales of more than € 140 million, Lujabetoni is among theleading suppliers of precast concrete for the Finnish buildingindustry. CEO of Lujabetoni, Mikko Isotalo, says: “We see SL-decks as a major opportunity of better serving our residentialcustomers with an improved structural slab that combinesbuilt-in value-adding solutions, such as bathroom installationsand floor heating pipes, seamlessly to the slab”.
So far, the SL-deck has been produced in a standard width of2.4-meter, but for the Finnish market, Lujabetoni is introduc-
ing a new 3-meter wide version. The wider version helps re-duce installation costs even further by making craning, instal-lation and casting of grouts more efficient. For the producer,the larger width is also an advantage, as it gives a higher m2-output per production cycle, thereby lowering the cost price.
“The Finnish market has relied heavily on 1.2-meter wide slabsin apartment constructions and recessed slabs for bathrooms.With the SL-Deck, we can provide 3-meter wide slabs thatgreatly simplify our customers’ on-site jobs, as installations arefinalized in the factory. We have more value-adding solutionsin our pipeline with a target of providing turnkey ready floorsto our precast customers. We are so convinced of the systemand its benefits that we have named it Superlaatta (Super slabin English)”, says Mikko Isotalo.
The MultiSlab system is currently being installed by Luja-betoni with production expected to start in January 2018.
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One of 2016’s biggest apartment projects in Copenhagenused 15.000 m2 SL-decks with fixed-end connections enabling 10.5-m long spans including heavy loads from prefabricated bathroom units using just 220mm thick slabs.
AbeoBeredskabsvej 122640 Hedehusene, DenmarkT +45 [email protected]
ElematicAirolantie 2P.O. Box 3337801 Akaa, FinlandT +358 3 549511F +358 3 [email protected]
FURTHER INFORMATION
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