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CONSOLIS IN BRIEF
Consolis is the largest manufacturer of prefabricated concrete elements in Europe. The company has more than 50 factories and operates in 11 countries: Finland, Sweden, Norway, Germany, the Netherlands, Estonia, Russia, Latvia, Lithuania, the Czech Republic and Poland. Consolis produces a wide range of prefabricated concrete products such as floors, structures and walls. These products are used in the construction of buildings. Consolis also makes products for infrastructure, such as railway sleepers and structures for bridges and tunnels. In addition Consolis provides services ranging from planning to erection of its products. Through its market leadership and international presence, Consolis offers customers the benefits of: the latest solutions and technology transfer within the Group unique benchmarking possibilities pan-European purchasing power extensive design and engineering resources production capacity sufficient to deal with the largest projects. Consolis works actively with environmental issues associated with construction. By prefabrication Consolis can reduce environmental burden both during the construction period and the total building life cycle. In 2003 Consolis had net sales of EUR 620 million and employed 5,000 employees at the year end. Consolis was formed in December 1997 following the merger of Partek Precast Concrete and the Swedish company Strngbetong. Consolis major shareholders are the Swedish private equity fund Industri Kapital, KONE and various Finnish insurance companies. Management also has a shareholding in Consolis.
E-Betoonelement
Betonika
CONTENTS
1
1.1 1.2 1.3 1.4
General
Consolis potential Quality guarantee Prefabrication, when and why Standards and technical guidelines Concrete quality Fire resistance Performance curves Notations
9
9.1
Bashallen
System description TT-roof slabs Faades Details and connections
6
6.1 6.2 6.3 6.4
10
10.1 10.2 10.3
Faades
Sandwich faades Cladding panels Special architectural elements Details and connections
2
2.1
Frame structures
Low-rise utility buildings
2.1.1 2.1.2
10.4
2.1.3 2.2
Multi-storey buildings
2.2.1 2.2.2 2.2.3
11
Infrastructural projects
Precast bridges Culverts Railway products
11.3.1 11.3.2 11.3.3
11.1 11.2
7 3
3.1 3.2 3.3 3.4 3.5 3.6
Double-T-slabs
Standard profiles Characteristics TT-2400 Characteristics TT-3000 Performance curves TT-2400 Performance curves TT-3000 Connections Holes and voids Production tolerances Handling and transport
11.3
Columns
Characteristics Corbels Performance curves Connections Tolerances Betemi columns
12
Special products
12.1
12.2 12.3
7.9
5
5.1
8
8.1 8.2 8.3 8.4 8.5 8.6
Residential buildings
Architectural freedom Structural systems Sound insulation Bathroom floors Foundation units Stairs
13
Addresses
5.1.5
1.
General
GENERAL
The aim of the Group is to offer its customers the most advantageous comprehensive solutions for various types of buildings and infrastructure projects, based on precast concrete products together with related services.
2
The strength of the Group relies on a large staff of design engineers and a research laboratory to raise the quality of end products and the efficiency of the construction process by continually developing and applying state of the art technologies.
Apartment building
Office building
Industrial building
Sport complex
Opportunities for good architecture Fire resistant material Healthy buildings Reduced energy consumption through the ability to store heat in the concrete mass Environmentally friendly way of building, with optimum use of materials, recycling of waste products, less noise and dust etc. Cost effective solutions
General
General
The calculation of the performance curves given in this Technical Guide are based on the following European Standards and Technical Guidelines: CEN European Committee for Standardization, EN 1992-1-1 Eurocode 2: Design of concrete structures Part 1: General rules and rules for buildings. CEN European Committee for Standardization, EN 1992-1-2 "Eurocode 2: Design of concrete structures - Part 1.2 General rules - Structural fire design. CEN European Committee for Standardization, CEN/TC 229 Precast concrete product standards.
FIP Commission on Prefabrication, "FIP Recommendations Precast Prestressed Hollow Core Floors", Thomas Telford Ltd, London 1988. FIP Commission on Prefabrication, "Planning and design handbook on precast building structures", - SETO Ltd, London 1994. fib Commission on Prefabrication, Guide to good practice "Special design recommendations for precast prestressed hollow core floors", fib bulletin 6.
1.8 NOTATIONS
a b bw d h support length total width cross section web width camber height cross-section partial length warping characteristic variable loading characteristic compressive cylinder strength of concrete at 28 days cd C H L Md Mu design compressive stress in the concrete allowable stress strength class of concrete (expressed as cylinder strength of concrete at 28 days) horizontal force length precast unit design value of bending moment ultimate bending moment N Nd Nu R axial force design value of axial force ultimate axial force standard fire resistance
Hall for prefabrication of hollow core slabs
l
u qk fck
General
2.
Frame and skeletal structures
Skeletal structural systems are very suitable for buildings which need a high degree of flexibility, because of the possibility of using large spans and to achieve open spaces without internal walls. This is very important in industrial buildings, shopping halls, parking structures and sporting facilities, and also in large office buildings.
The roof can be made with prestressed hollow core elements or with light TT-units or steel sheet deck. The distance between the portal frames is governed by the span of the roof and faade construction - normally between 6 and 9 m for hollow core roof slabs and from 9 to 12 m for light TT-roof units. When steel sheet deck is used, the distance between the portal frames can be larger - up to 12 m and even 16 m- because of the lighter weight of the roof. Secondary beams are generally needed to support the steel sheet deck.
Another solution for large halls is to use large span roof units supported on rows of columns and straight beams. The roof units are saddle TT-slabs or light TT-roof units. The span of the roof units can be up to 32 m. For straight
TT-units, the roof slope is obtained by alternating the height of the supporting beam rows. At the faades, the walls. roof slabs can be supported on beams, or on load bearing
In buildings basically constructed as single-storey structures, it may be necessary to insert intermediate floors in some parts or in the whole building. This is commonly achieved by adding a partly separate beam/column assembly to carry the intermediate floor slabs. The loads on the floors are generally much larger than on the roof. Consequently, the spans will normally be shorter. Span A - as indicated on the Figure - will normally be between 6 m and 18 m, depending upon the live loads and the type of floor slab selected. A good module for span B is 7.20 m to 9.60 m.
A
foundation bars with nuts. With projecting reinforcement, projecting bars from the foundation or from the column are fixed into grouted openings in the columns or in the foundation respectively. In the case of pockets, the column is fixed into the pocket with grout or concrete.
Projecting reinforcement
Pocket foundation
The cantilever action of the columns is used to stabilize low-rise buildings with to about 3 floor levels. The columns are normally continuous for the full height of the structure. Horizontal forces acting on the building are transferred through the faade to the internal frame structure. Other horizontal actions - for example from overhead cranes - are taken up directly by the columns. It is important to spread the acting forces over all the columns in the building to avoid different cross-sections.
Actions and resulting moments/forces on a portal frame structure
Roof beam
Horizontal stiffness
Faade
Horizontal forces parallel to the beams are distributed directly through the beams of the same row, whereas forces in the transverse direction are transferred through the in-plane action of the roof. For buildings with high slender columns, the horizontal stiffness of the structure can be secured by diagonal bracing between the columns of the external bays with the help of steel rods, angles or
Column
concrete beams.
Expansion joints
Socle
The design and detailing of frame structures takes into account the dimensional dilatations due to temperature changes, shrinkage and creep. Expansion joints are chosen in conjunction with the length and the cross-section of the columns. Generally, the distance between expansion joints
Pocket foundation
is not larger than 60 m. They are realized either by using double columns or special bearing pads.
beam-column systems, up
Multi-storey precast concrete frames are constructed with columns and beams of different shapes and sizes, stair and elevator shafts and floor slabs. The joints between the floor elements are executed in such a way that concentrated loads are distributed over the whole floor. This system is widely used for multi-storey buildings.
The structural frame is commonly composed of rectangular columns of one or more storeys height (up to four storeys). The beams are normally rectangular, L-shaped or inverted T-beams. They are single span or cantilever beams, simply supported and pin-connected to the columns. Hollow core floor slabs are by far the most common type of floor slabs in this type of structure.
2.2.1 Stability
For buildings up to 3 or 4 storeys, horizontal stability may be provided by the cantilever action of the columns. They are normally continuous for the full height of the structure. However, for multi-storey skeleton stuctures, braced systems are the most effective solution, irrespective of the number of storeys. The horizontal stiffness is provided by staircases, elevator shafts and shear walls. In this way, connection details and the design and construction of foundations are greatly simplified. Central cores can be cast in-situ or precast.
3.
COLUMNS
Precast columns are manufactured in a variety of sizes, shapes and lengths. The concrete surface is smooth and the edges are chamfered. Columns generally require a minimum cross-sectional dimension of 300 x 300 mm, not only for reasons of manipulation but also to accommodate
300 400 500
Columns
the column-beam connections. The 300 mm dimension provides a two-hour fire resistance, making it suitable for a wide range of buildings. Columns with a maximum length of 20 m to 24 m can be manufactured and erected in one piece, i.e. without splicing, although a common practice is to work also with single-storey columns.
3.1 CHARACTERISTICS
3.1.1 Rectangular columns
Profile 300/300 300/400 400/400 400/500 500/500 500/600 600/600 h mm 300 300 400 400 500 500 600 b mm 300 400 400 500 500 600 600 Weight kN/m 2.20 2.94 3.92 4.90 6.12 7.35 8.82
300 b 300 h
3.2 CORBELS
Precast columns may be provided with single or multiple corbels to support floor or roof beams, girders for overhead cranes, etc. The corbels are either completely under the beam or within the overall depth of it. This may occur, for example, where it is unacceptable for the connection to project below ceilings or into service zones. Standard dimensions for normal corbels are given in the table. The indicated values for the allowable support load "N" are characteristic values without partial safety margins.
b h
h
b b
300 300
Hidden corbels
The BSF system consists of a hidden steel insert in the beam-to-column connection, enabling a beam support without underlying corbel. A sliding plate fits into a rectangular slot in the beam. A notch at the end of the plate fits over a lip at the bottom of a steel box cast into the column. The system can be used for both rectangular and round columns. The types of corbels and corresponding bearing capacities are given in the table.
Plate type height/ thickness 150/20 200/20 200/30 200/40 200/50 250/50
Minimum beam dimensions mm Height 200 200 300 400 400 400 Width 400 500 500 600 700 900
BSF application
Columns
and 3M to 6M for round columns. The indicated values for Nd and Md are design values at ultimate limit state, which means that the permanent and variable actions are multiplied by the appropriate safety margins.
Columns
8000 7000 6000 5000 4000 3000 2000 1000 0 0 100 200 300 400 500 600
400x300 300x300 400x400 500x500 500x400
6000 5000 4000 3000 2000 1000 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
300 400 500
Md (kNm)
Performance curves for round columns
3.4 CONNECTIONS
Precast columns are fixed to the foundations with pockets, projecting reinforcing bars or holding down bolts. The first solution is mainly used for foundations on good soil; the second and third in the case of foundation piles.
Grout filling or alternative polyurethane filling Corner pockets with anchor bars welded to plate
Injection with shrinkage free grout Joint fill with grout or concrete Projecting reinforcement in grouted tube
Foundation pocket
Grouted connection
Columns
Column-to-column splices
Column-to-column splices are made either by bolting mechanical connectors anchored in the separate precast components or by the continuity of the reinforcement through a grouted joint.
Columns
Leveling shims
3.5 TOLERANCES
1. Length (L): 2 3 4 5 6 7 8 9 Cross-section (b, h, d): Curvature (a): Orthogonality cross-section (p): Orthogonality end face (s): Position corbel: (l k): Dimensions corbel (l k , bk, hk): Orthogonality corbel face (r): transversal: depth: 10 Position holes, voids:
1)
1)
1)
r hk p h a L b
tl
3.6.2 Applications
Load-bearing columns
3.6.3 Connections
Connections are easy to make in Betemi columns. Two methods can be applied: Steel pocket cast into the column for bolted connections Protruding bars anchored in the column core with cast in-situ concrete.
Column reinforcement welded to steel corners
Columns
4.
POCKET FOUNDATIONS
h
Precast pocket foundations realize the site-work faster and cheaper. Indeed, site-cast pockets need a rather complex moulding and reinforcement, and the working conditions are more unfavourable. Consolis has developed a series of pocket foundations for different column sizes. The precast pocket foundations may only be used in conditions of firm and level ground. The pockets are positioned by means of leveling bolts. The baseplate is cast on site. The whole unit can also be precast.
Pocket foundations
Characteristics
a mm 700 800 800 1000 1000 1100 1100 b mm 700 700 800 900 1000 1000 1100 c mm 150 150 150 200 200 200 200 h mm 550 700 700 850 850 1000 1000 Max. column section 300/300 300/400 400/400 400/500 500/500 500/600 600/600
5.
BEAMS
5.1 GENERAL
5.1.1 Types
Overview of the types of prestressed beams for different applications
RF-beams: rectangular floor beams for composite action with floor slabs
The cross-section of the beams is standardized. The prestressing force and the beam length is adapted to each specific project. The units are provided with details and
inserts for connections and other specific purposes - for example, for fixings, openings, etc.
Beams
5.1.2 Supports
Large precast elements are normally supported on elastomeric supporting pads in neoprene rubber to ensure a good distribution of the stresses over the contact area. The effective bearing length is determined by the ultimate bearing stress in both the abutting components and the bearing pad, plus allowances for tolerances and spalling risk at the edges. The maximum allowable stress on neoprene pads in the serviceability limit state is normally: For non-reinforced elastomeric pads: For reinforced elastomeric pads: = 6 N/mm
2 2
The pads should be placed at some distance from the support edge as load transfer at the edge may result in damage. The pad should allow for beam deflection so that direct contact between the beam and the support edge is avoided.
= 12 N/mm
5.1.3 Inserts
Inserts are details embedded in a precast unit for the Steel plates, profiles and steel angles Rolled channel Openings, etc. The possible location and load capacity of inserts depends on several parameters and will be dealt with on request by Consolis.
Beams
purpose of fixings, connections to other components, etc. There are many types of inserts, including: Projecting bars Anchor rails Threaded dowels or bolts
1)
L t t d
l l
i
1)
b1 b2
a u h2 h1
5.2 PURLINS
Purlins are used as secondary beams for roof structures with light roof cladding. The distance between the portal frames is maximum 12 to 16 m. The units are in prestressed concrete. The fire resistance is normally 60 minutes. The standard cross-section is shown in the figure below.
276
400
l
L
152
Purlins are mainly used in industrial storage buildings where light roof coverings such as steel sheet decking, corrugated slabs, cellular concrete slabs, etc. are used. The span of these elements is generally limited to about 3 bridge the distance between the portal frames. The latter can be at larger distances, up to 12 and even 16 m. In this way large open halls can be constructed in an economical way. to 5 m and secondary prestressed beams are needed to
Purlins
14 12 10 8 6 4 2 0 7,0 7,5 8,0 8,5 9,0 9,5 10,0 10,5 11,0 11,5 12,0
12,5
12,5
Purlins
Span l in m
The allowable loading is the sum of the weight of the roof cladding and the variable load (snow and life load), excluding the self-weight of the purlin.
5.2.2 Connections
The elements are connected to the supporting beam with protruding bars and cast in-situ concrete. For light roof structures where diaphragm action can not be achieved by the roof structure itself, the distribution of horizontal forces on the gable walls, over the external and internal columns, can be secured by diagonal bracing between the beams of the external bays, with the help of steel rods or angles.
Steel deck Insulation Roofing
Protruding reinforcement
l
L
Compression flange
Rectangular beams
10 90 00 80 0/ /5 40 0/ 70 00 4 0 0/ 0 0 40 0
60 50 40 30 20
40 0/ 30 0
Rectangular beams
10
11
12
13
14
15
16
17
18
19
20
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the selfweight of the unit. For example, the allowable loading of a beam supporting a floor, should be calculated as the sum of the self-weight and the permanent and imposed loading of the floor, without partial safety margins, and without the self-weight of the beam.
5.3.2 Connections
nut washer
l
L max. 900
200
l
L max. 700
Changes in floor level may be accommodated by either an L-beam or by building up one side of an inverted T-beam, as shown in the figure. If the change of floor level exceeds about 750 mm, a better solution is to use two L beams back to back and separated by a small gap for easier site fixing.
90 80 70 60 50 40 30
40 0* /3 00 /7 00
20 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Span l in m
5.4.3 Connections
The tie reinforcement between the beam and the floor is made with double bars anchored in slots in the flange of the beams.
T12 / T16
T16
5.5 SI-BEAMS
SI-beams with variable height are particularly suited for roofs with large column free spans - for example, in industrial halls. The I-shaped cross section is typical for prestressed beams. The slope of the top face is 1:16. According to Eurocodes, the SI-beam types have a fire resistance up to 120 minutes. Standard cross-sections are show in the table below.
slope 1/16
f e h bw d c
l
L
e 95 95 95 95 95 95 95 95
5.5.2 Connections
neoprene pad
SI-Beams
5.5.1 Characteristics
SI
SI
00 15
70
SI
00 12
60 50 40 30
SI 0 90
50 10
SI-Beams
20 8 10 12 14 16 18 20 22 24 26 28 30 32 34
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the self-weight of the unit.
400
SI 2700
150 100 50 0 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
SI 1200 SI 1050 SI 900
Beam length L in m
5.6 I-BEAMS
I-beams are used for flat and sloped roof structures and for floor beams with heavy loading and large spans. The beams are in prestressed concrete and the fire resistance is, according to Eurocodes, up to 120 minutes.
f e h bw d c
l
L
5.6.1 Characteristics
Profile I 900/500 I 1200/500 I 1500/500 I 1800/500 h 900 1200 1500 1800 b 500 500 500 500 c 150 150 150 150 d 190 190 190 190 e 95 95 95 95 f 150 150 150 150 bw 120 120 120 120
5.6.2 Connections
neoprene pad
I-Beams
90 80 70 60 50 40 30
I1 80 0
00 12
I-Beams
20 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the self-weight of the unit.
I 900
0 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Beam length L in m
6.
Prestressed hollow core slabs are the most widely used type of precast flooring. This success is due to the highly efficient design and production methods, choice of unit
125,5
189
265
152
220
The hollow core slabs are manufactured on long-line beds. The units may be manufactured with a thermal insulation layer on the under side - for example, for floors at ground level.
320
The slabs are cut to length using a circular saw. A square end is standard but skew or cranked ends, which are necessary in a non-rectangular framing plan, may be specified. Longitudinal cutting is possible for match plates.
180
280
275
400
The hollow core slabs are manufactured on long-line beds. The units may be manufactured with a thermal insulation layer on the under side - for example, for floors at ground level.
The slabs are cut to length using a circular saw. A square end is standard but skew or cranked ends, which are necessary in a non-rectangular framing plan, may be specified. Longitudinal cutting is possible for match plates.
150
100 98,5
250
100 98,5
180
100 98,5
300
186 200
225
186
225 1196
1196 mm
1196 mm
6.2 CHARACTERISTICS
Extruded hollow core slabs
Weight b (joints filled) Joint filling 2 (mm) kN/m l/m2 (*) 1196 1196 1196 1196 2,60 3,80 4,10 4,65 7,0 10,0 12,0 17,0
Weight b (joints filled) Joint filling 2 (mm) kN/m l/m2 (*) 1196 1196 1196 1196 1196 1196 2,57 3,87 3,18 3,85 4,55 5,24 4,7 5,9 6,8 8,9 10,4 14,7
14
2
13 12 11
HC
10 9 8 7 6 5 4 3 2 1 4 5
10
11
12
13
14
15
16
17
Span l in m
16 15
H CE
CE H
H CE
E 20 0
5 26
32 0
0 40
16 15 14 13
2
12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17
0 20 S HC 80 S1 HC 50 S1 HC
S HC 0 25
S HC 0 30
CS H 0 40
Span l in m
6.5 PRECAMBER
Prestressed concrete units are subjected to precamber, depending on the magnitude and centroid of the prestressing force, modulus of rigidity of the cross section and length of the unit. The graph below gives an indication of the minimum and maximum expected average deflection of non-loaded elements after 1 month of storage. Possible tolerances are given in clause 6.11. The design should take account of the precamber in determining the thickness of the topping and screeds and the final levels after finishing - for example, for door thresholds, etc.
mm
40
30 20
10
0 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Span l in m
L2 + L3 x 20 kN/m 70 kN 2 A A B B
L3
L2
L1 x 20 kN/m 70 kN 2 C C 70 kN L2 + L3 x 20 kN/m 70 kN 2
L1
L1 x 20 kN/m 70 kN 2
20 kN/m
6.8 OPENINGS
Holes in hollow core floors are made as indicated in the figure. The dimensions are limited to the values given in the table. Small holes may be formed at the center of the longitudinal voids. The maximum size is limited to the width of the void. Holes are normally made in the fresh concrete during the production process. The edges of the openings are rough. The possible dimensions for openings are given in the table.
l /b
Corner (1) Front (2) Edges (3) Center (4) - round holes - square openings
4 4
2 1
Larger voids which are wider than the width of the precast units are 'trimmed' using transverse supports such as steel angles or concrete beams. The steel angles can be supplied by Consolis on request.
6.9 CONNECTIONS
6.9.1 Bearing length
The nominal bearing length of simply supported hollow core floor units is given in the table. Neoprene strips ensure a uniform bearing.
Support length a Supporting material Concrete or steel Brick masonry Slab thickness 265 mm 300 mm 265 mm 300 mm Nominal length 70 mm 100 mm 100 mm 120 mm Minimum effective length 50 mm 80 mm 80 mm 100 mm
In-situ concrete tie beam a
Tie bar placed in longitudinal joints through opening in beam Tie bar for diaphragm action Topping Tie bar floor diaphragm Tie steel in joint
Neoprene In-situ concrete Lifting loops or vertical bars used for connection with floor slabs
In-situ concrete
In-situ concrete
1)
1)
6. Warping: 7. Flatness (y) : 8. Steel inserts, installed in the factory (t): 9. Holes and recesses (t): cut in fresh concrete: cut in hardened concrete:
1) 2)
10 mm or L /1000
3)
20 mm 50 mm
l
L
15 mm
Whichever is the larger Deviated from the calculated deflection (including precamber and calculated deflection under loading circumstances) Valid for slabs h 300 mm p a y
t t t
3)
h b
1m
clamps hanging on a steel spreader beam. The use of a sling alone is strictly forbidden.
6.13 ERECTION
The erection of the hollow core floor slabs should be done according to the instructions of the design engineer. If needed, Consolis can second him to supervise the construction methods. Consolis will supply written statements of the principles of site erection, methods of making structural joints and materials specification on request.
Drainage holes
Drainage holes are drilled into the voids at the slab ends to evacuate any rainwater that might penetrate during site erection. After erection, the contractor should check that the holes are open.
are used to compact the concrete. The screed may be power floated or rough tampered in the usual manner, depending on the type of floor finish. The topping screed should contain a shrinkage reinforcement mesh.
joints immediately prior to the casting of the screed. The workability should give a slump between 50 and 100 mm. The wet concrete should be spread evenly over the floor area as quickly as possible. Mechanical vibrating beams
Fixings
There are several ways of fixing hanging loads to the hollow core floor - for example, special sockets drilled into the voids, anchors placed into the longitudinal joints, etc. Consolis will supply detailed information on request.
7.
DOUBLE-T SLABS
Double-T floor units in prestressed concrete have a ribbed cross-section and a smooth under face. The units are mainly used for greater spans and imposed loading. The units are manufactured with two standard widths: 2400 and 3000 mm. The standard cross-sections are given in the tables. The ends of the units can be notched to reduce the overall structural depth. A structural topping can be used to ensure both vertical shear transfer between adjacent units and horizontal diaphragm action in the floor plate. The standard double-T units have a minimum fire resistance of 60 to 120 minutes. Anchor rails can be cast into the soffits of the webs.
b2
b1
b2
TT- slabs
b0
General
TT- slabs
Super market with TT-roof
TT 2400-500
TT 2400-800
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Span l in m
TT 3000-800
TT 3000-500
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Span l in m
TT- slabs
General
7.6 CONNECTIONS
7.6.1 Support connections
Connections between TT floors and supporting beams are made through lapping reinforcement in the structural topping or by bars welded to plates fully anchored in the units.
Car park
TT- slabs
between adjacent double-T units are normally realized by lapping reinforcement in the structural topping or by steel strips or bars welded to fully anchored steel angles or plates in the units.
Welded connection
l
b
l /b
Center Edge Corner
1)
v t2
1)
t1
t3 t4 a L p b h
1)
8. Steel inserts, holes, and voids (t): - top surface: length- and cross wise: - webs: longitudinal and vertical: - depth of steel parts:
1)
Whichever is the larger 2) Deviated from the calculated deflection (including precamber and calculated deflection under loading circumstances)
b0
The units are provided with four cast-in lifting hooks, each over the line of the webs. The slings or chains should be long enough to enable an inclination to the slab of not less than 60.
TT- slabs
tw
General
8.
RESIDENTIAL BUILDINGS
Residential buildings constitute an important activity within the Consolis Group. A construction system has been developed for single family houses, low rise and high-rise apartment buildings. The total structure includes complete outer walls, inner walls, hollowcore flooring, stairway towers and stairs, roof and balconies.
Residential buildings
The recently developed jointless faade is composed of internal panels in grey concrete, carrying the hollow core floors, and an insitu external skin in a special decorative concrete mix, reinforced with synthetic fabric. The thermal insulation is either placed on site, or incorporated in the precast panel.
Load bearing cross-wall system with hollow core floors spanning over 10 to 12 m
Lay-out of apartment building with load bearing faades and internal load-bearing cross-walls
Floors are usually made of hollow core elements. The latest tendency is to span the floors over the full width of the apartment. In this way one obtains not only more flexibility for the internal lay-out, but also the possibility to modify it later without major costs. The faades are normally sandwich elements. The inner leaf of the units may be load-bearing. A variant solution is to precast only the inner leaf of the faade and to clad it on site with brick masonry or any other added finishing.
Schematic view of load bearing sandwich faade with window frame. The thermal isolation is continuous over the whole surface to avoid cold bridges.
Residential buildings
In Europe, bathroom floors usually have an increased floor screed thickness to install pipes and conduits. A solution with reduced floor thickness in the bathroom enables one to avoid the step between the bathroom and the adjacent floor. The load bearing floor is between 60 mm and 170 mm lower at the bathcell than elsewhere. After installation of the pipes, a structural topping is cast to provide for the needed bearing capacity.
8.6 STAIRS
Precast concrete stairs are very interesting products for domestic and other buildings, because of the quality of finishing and the cost efficiency. Various types of precast stairs are available at Consolis, going from individual steps to straight or helicoidal monobloc units. The first category comprises straight stair units. They are made out of both individual precast flights and landings or The second category comprises monobloc staircases. They can be used either in the stairwells or individually between the different storeys. combined flight and landings. In the latter solution there may be differential levels at floors and half-landings, necessitating a finishing screed or other solution.
Residential buildings
8.8.1 Characteristics
Dimensions wall units: maximum length: maximum height: thickness: Fire resistance: 180 minutes (Eurocode 2) 14 m 3.50 m 200 mm
8.8.2 Connections
Vertical wall-to-wall connections are generally designed to transmit shear forces. The vertical joint faces of the panels are profiled. Horizontal joints between walls and floors are either with direct floor support on the walls for mediumrise buildings or with floors supported on corbels, for high rise buildings. It is advisable to concentrate the tie reinforcement in the horizontal joint between the units.
Floor support on wall
Neoprene
8.9.1 Installation
The main benefit of the Acotec wall element is its easy and light handling at the construction site. A two-man team can easily install Acotec walls with a speed of 6 m
2
per hour. The tongue and groove structure assures a perfect straight wall alignment and the flat surface needs only a thin coating (1-2 mm) without normal plastering. The cores inside the elements can be used for installation of electrical wires and pipes. Cutting and drilling of the product is also easy. Compared to other materials, savings up to 40% on the cost of the installed wall can be made.
8.9.2 Applications
The Acotec walls resist moisture very well, have good fire resistance and durability. A single wall structure has an airborne sound insulation capacity of over 40 dB. Acotec walls have a wide range of applications. In the first place they are used for bathrooms, kitchens, shower rooms, and other areas with a high degree of moisture. Another field of application is for rooms where good sound insulation is needed, for example apartments, hotels, schools, etc. Their high fire resistance makes Acotec walls very suitable for garages, parking buildings, etc. Acotec walls can also be produced with coloured concrete for applications such as fences and boundary walls.
9.
BASHALLEN
The "Bashallen" system is composed of two modulated components: a saddle roof slab and load-bearing faades in architectural concrete. The solution offers large internal open spaces, with free spans up to 32 m, and a variable length modulated on 2.4 m. The internal height can vary up to 8 m. Intermediate floors may be installed over a part or the whole surface. The aesthetic outlook of the faade has been carefully studied. Rounded corners and cornices in a panoply of surface finishing and colours give the building a prestigious outlook . Thermal capacity and insulation of the complete concrete building ensures a stable indoor climate with low energy consumption.
Bashallen
h mm 700 880
b mm 2396 2396
Welded connection
Corner solution
Bashallen
General
10.
FAADES
not always need to have the appearance of concrete. Buildings clad in precast architectural cladding can give the impression of being constructed in brickwork, polished marble or granite. Alternatively, if the architect wishes to maintain the appearance of concrete, the elements can be produced in a vast range of self finishes - an array of profiles and textures which bring out the natural beauty of the aggregates from which the elements are made. As a matter of course, such finishing requires a high level of technology and workmanship, available at, and steadily further developed by Consolis.
Consolis specializes in the production of faade elements in architectural concrete. There are two concepts: sandwich panels and cladding units. The units are generally one storey high and the normal standard widths are 2.40 m, 3.00 m and 3.60 m. The term "architectural concrete" refers to precast units which are intended to contribute to the architectural effect of the faade through finish, shape, colour, texture and quality of fabrication. Precast concrete offers an extremely wide range of visual appearances. Although the basic structural material is concrete, the finished elements do
Faades
The Consolis Group has developed a new faade panel with an air void between the outer cladding and the insulation, enabling the evaporation of any seeping water or condensation that has penetrated.
Window opening
Faades
General
11.
INFRASTRUCTURAL PROJECTS
tunnel linings, railway sleepers, concrete piles, water treatment systems, elements for agriculture, etc.
The Consolis Group produces a wide range of precast concrete elements for infrastructural projects such as bridges,
80 n x 1000
Consolis has more than fifty years experience in precast bridge construction. Several systems have been developed of which the most important are solid slab bridges, girder bridges with cast in-situ deck and complete precast box girder bridges.
Precast solid deck bridge system with inverted T-beams placed side by side
11.1.1 Systems
only for collision resistance
Solid slab bridges are constructed with precast units and a cast in-situ topping, acting together as a composite structure. They are used for decks of bridges, viaducts, culverts, tunnel decks, etc. For small spans up to about 8.00 to 13.00 m, solid precast slabs can be used. They are modulated on 1200 mm width, and the thickness varies from 150 to 350 mm. The slabs are positioned side by side and a structural topping varying from 150 to 200 mm is cast on site. In a more advanced solution, the deck is composed of small inverted T-profiles placed side by side, and connected with a cast in-situ topping and infill concrete. Girder bridges are composed of inverted T-beams or I-shaped beams. The inverted T-beams can be placed side by side, to obtain a closed underside with a high resistance to collision by trucks. The elements may also be placed at a distance. The beams are connected by transversal diaphragm beams at each support and also in the span when needed. The deck is cast in-situ. The system is suitable for spans between approximately 15 and 35 m. I-shaped bridge girders are used for bridges up to 55 m span. The weight of the beams may be up to 70 tons. After erection of the beams and casting of the transversal diaphragm beams, the deck slab is cast on site, mostly with concrete shuttering planks positioned on a notch at the top of the beams.
Girder bridge with inverted T-beams placed side by side and in-situ deck slab
Infrastructural projects
In box beam bridges, the elements are placed side by side or at a small distance. After erection the site work is limited to the filling of the longitudinal joints and the transversal post-tensioning of the bridge. The slenderness ratio is in the order of 30; however, spans of 50 m have already been realized with box beams of 1.50 m height. Protruding reinforcement is available in the beams for connections to cast in-situ edge profiles, joint constructions, screeds, etc. Precast bridges are well suited for projects where the realization of classical scaffolding supported on the ground is prohibitively expensive and where the speed of construction is mandatory: watercourses, railways, roads and motorways in use, in order to limit traffic restrictions.
Precast viaduct with box beams
Infrastructural projects
General
11.2 CULVERTS
Culverts are used for underpasses, tunnels, protection against avalances, etc. The system is composed of two or more vault units.
Infrastructural projects
Systems such as the Slab Track, ensure the companies of the Consolis Group a secure market both for the present and the future.
Infrastructural projects
General
12.
SPECIAL PRODUCTS
The Consolis Group manufactures special products and develops techniques and know-how in the domain of water treatment and specific structures for agriculture. In addition to this, exclusive products and projects are regularly realised for specific applications such as monuments and other one-off projects. They are merely the fruit of imagination and creativity in the collaboration between architects and our technical staff.
e1 / e2
d2
e3
d3
Water supplying and sewerage Large wastewater collection pipes up to 4 m diameter are used in these systems. Consolis also manufactures high precision reinforced concrete segmental rings for large sewerage conduits, as well as complete shaft and pipe systems with diameters of 300 mm to 4000 mm. Waste-water purification The systems developed by Consolis optimise waste-water purification by using different processes, such as: Rainwater / waste-water collection tanks from 2.5 to 100 m , to store domestic and commercial sewage. Multichamber sedimentation and digestion tanks for mechanical waste-water purification, for small applications
3
Special products
Multichamber septic tank with floating filter and anaerobic final treatment, also for one-family houses and small apartment buildings. Biological sewage treatment plants for domestic wastewater. The application ranges from local communities, residential estates, schools, hotels, camping sites, commercial enterprises, and barracks.
Big separator tank
Aqua protection The Consolis Group also offers suitable water protection systems for a wide range of types of waste-water. The various separator systems are designed to purify and/or protect water from pollution by oils, petrol, greases and other harmful substances. The systems work on the principle of coalescence, gravity and filtration, as well as the separation of sedimentary constituent parts.
Retaining elements for storage Open silos for the storage of animal food, dung, etc. The structure comprises a cast in-situ bottom slab and precast retaining walls. The silos are modulated on the standard width of the elements.
Floor slats for live stock Floors for animal stables are built with floor slats, provided with longitudinal slits for the evacuation of manure. The width of the slits differs depending on the animals.
Special products
General
Special products
Control tower at Arlanda airport in Sweden, rising 83 metres above the ground. The faade in highly polished architectural precast panels is ornamented with carefully selected quotations from Antoine de Saint-Exupry
FINLAND Consolis Oy Ab yritie 12 b FIN-01510 Vantaa Tel: +358 20 577 577 Fax: +358 20 577 5110 Email: info@consolis.com www.consolis.com President and CEO: Bengt Jansson Consolis Technology Oy Ab yritie 12 b FIN-01510 Vantaa Tel: +358 20 577 577 Fax: +358 20 577 5152 Managing Director: Olli Korander Parma Oy P.O. Box 76 FIN-03101 Nummela Tel: +358 20 577 5500 Fax: +358 20 577 5699 E-mail: info@parma.fi www.parma.fi Managing Director: Hannu Martikainen Parastek Oy P.O. Box 76 FIN-03101 Nummela Tel: +358 20 577 5500 Fax: +358 20 577 5625 Managing Director: Aapo Rahkjrvi Elematic Oy Ab P.O. Box 33 FIN-37801 Toijala Tel: +358 3 549 511 Fax: +358 3 549 5300 Email: info@elematic.com www.elematic.com Managing Director: Leo Sandqvist Rimera Oy Tehtaankatu 3 a FIN-11710 Riihimki Tel: +358 19 720 318 Fax: +358 19 720 636 E-mail: rimera@kolumbus.fi Managing Director: Antti Lahti THE CZECH REPUBLIC Dywidag Prefa Lys nad Labem a.s. Jedlickova 1190 / 1 CZ-289 22 Lys nad Labem Tel: +420 325 510 010 Fax: +420 325 551 326 Email: info@dywidag-prefa.cz www.dywidag-prefa.cz Managing Director: Michal Miksovsky
ESTONIA AS E-Betoonelement Tammi tee 51 EE-76902 Harku Harju maakond Tel: +372 6 712 500 Fax: +372 6 712 555 E-mail: ebe@betoonelement.ee www.betoonelement.ee Managing Director: Jaan Valbet AS Swetrak Tammi tee 51 EE-76902 Harku Harju maakond Tel: +372 6 712 500 Fax: +372 6 712 555 E-mail: taimi@betoonelement.ee Managing Director: Ove Johansson GERMANY DW Beton GmbH Stadthausbrcke 7 D-20355 Hamburg Tel: +49 40 360 9130 Fax: +49 40 3609 1379 Email: info@dw-beton.de www.dw-beton.de Managing Directors: Heikki Haikonen, Thomas Krmer-Wasserka DW Betonrohre GmbH Zinkhttenweg 16 D-41542 Dormagen Tel: +49 2133 2773 Fax: +49 2133 277 545 Email: info@ dw-betonrohre.de www.dw-betonrohre.de Managing Director: Heinz-Toni Dolfen DW Schwellen GmbH Pareyer Strasse 4a D-39317 Gsen Tel: +49 3934 4920 Fax: +49 3934 492 215 Email: info@ dw-schwellen.de www.dw-schwellen.de Managing Director: Heinz-Hermann Schulte-Loh DW Systembau GmbH An der B 19 D-98639 Walldorf / Meiningen Tel: +49 36 93 8830 Fax: +49 36 93 883 314 Managing Director: Heinz-Hermann Schulte-Loh
VERBIN Baufertigteile GmbH P.O. Box 170341 D-47183 Duisburg Tel: 0800 181 5939* Fax: 0800 181 5938* *(In Germany only. From abroad please call VBI BV.) E-mail: verbin@verbin.de www.verbin.de Managing Director: Lambert Teunissen Elematic GmbH Kleebergstrasse 1 D-63667 Nidda Tel: +49 6043 961 80 Fax: +49 6043 6218 E-mail: info@elematic-gmbh.com Managing Director: Simo Lperi LATVIA SIA Consolis Latvija Katlakalna iela 1, 4 floor LV-1073 Riga Tel: +371 7 138 777 Fax: +371 7 138 778 E-mail: office@consolis.lv www.consolis.lv Managing Director: Vladimirs Chamans LITHUANIA UAB Betonika Naglio 4 A LT-3014 Kaunas Tel: +370 37 400 100 Fax: +370 37 400 111 E-mail: info@betonika.lt www. betonika.lt Managing Director: Vytautas Niedvaras THE NETHERLANDS Spanbeton BV P.O. Box 5 NL-2396 ZG KOUDEKERK AAN DEN RIJN Tel: +31 71 341 9115 Fax: +31 71 341 2101 (office) E-mail: info@spanbeton.nl www. spanbeton.nl Managing Director: Lambert Teunissen VBI Verenigde Bouwprodukten Industrie BV P.O. Box 31 NL-6850 AA Huissen Tel: +31 26 379 7979 Fax: +31 26 379 7950 E-mail: vbi@vbi.nl www.vbi.nl Managing Director: Lambert Teunissen
Leenstra Machine- en Staalbouw BV P.O. Box 9 NL-9200 AA Drachten Tel: +31 512 589 700 Fax: +31 512 510 708 E-mail: info@leenstra.nl www.leenstra.nl Managing Director: Paul Schut NORWAY Spenncon AS Industriveien 2 N-1337 Sandvika Tel: +47 67 573 900 Fax: +47 67 573 901 Email: post@spenncon.no www.spenncon.no Managing Director: Terje Shoel POLAND Consolis Polska Sp. z o.o. ul. Przemyslowa 40 PL-97-350 Gorzkowice Tel: +48 44 732 7300 Fax: +48 44 732 7301 E-mail: office@consolis.pl www.consolis.pl Managing Director: Piotr Biskup RUSSIA ZAO Parastek Beton 3. Silikatny proezd, 10 123308 Moscow, Russia Tel: +7 095 742 5911 Tel: +7 095 742 5912 Fax: +7 095 946 2680 www.parastekbeton.ru Managing Director: Olli Ruutikainen SWEDEN Strngbetong AB P.O. Box 858 S-131 25 Nacka Tel: +46 8 615 8200 Fax: +46 8 615 8260 www.strangbetong.se Managing Director: Johnny Sthl USA Elematic Inc. 21795 Doral Road Waukesha, WI 53186, USA Tel: +1 262 798 9777 Fax: +1 262 798 9776 E-mail: info@elematic-inc.com Local Manager: Matt Cherba
Frame structures
www.consolis.com
Columns
Pocket foundations
Beams
Hollowcore slabs
Double-T slabs
Residential buildings
Bashallen
Faades
Infrastructural projects