New Construction Alternatives

CONTENTS
Contents................................................................................................................................ i
Introduction ........................................................................................................................ iii
1.BAMTEC System (Prefabricated Reinforcement) ........................................................... 1
Introduction ...................................................................................................................... 1
Idea ................................................................................................................................... 1
Dimensions ....................................................................................................................... 2
Procedures ........................................................................................................................ 3
Advantages & Disadvantages ........................................................................................... 6
Examples Worldwide ........................................................................................................ 6
2.COFFOR System (Stay in place forms) ............................................................................. 8
Introduction ...................................................................................................................... 8
Idea ................................................................................................................................... 8
Components ..................................................................................................................... 9
Dimensions ..................................................................................................................... 10
Procedures ...................................................................................................................... 11
Advantages & Disadvantages ......................................................................................... 15
Examples Worldwide ...................................................................................................... 16
3.EMMEDUE (M2) System (Light Weight Structures) ...................................................... 18
Introduction .................................................................................................................... 18
Idea ................................................................................................................................. 18
Components ................................................................................................................... 19
Equipment ...................................................................................................................... 22
Procedure ....................................................................................................................... 23
I
4.BSB System (Prefabrication Revolution) ....................................................................... 32
Introduction .................................................................................................................... 32
Idea ................................................................................................................................. 32
Objective ......................................................................................................................... 33
Projects ........................................................................................................................... 34
Case Study: T-30 Tower Hotel ........................................................................................ 36
Introduction ................................................................................................................ 36
Procedure .................................................................................................................... 36
Design Stage ................................................................................................................ 37
Industrial Stage ........................................................................................................... 39
Transportation Stage .................................................................................................. 40
Assembly Stage ........................................................................................................... 41
5.3D Printing (Future Revolution-Robotizing the construction) ..................................... 45
Introduction .................................................................................................................... 45
What is 3D Printing ......................................................................................................... 45
History of 3D Printing ..................................................................................................... 46
3D Printing in Construction Industry .............................................................................. 46
Idea ................................................................................................................................. 47
Procedure ....................................................................................................................... 48
3D Printed Material ........................................................................................................ 49
Office of the Future (Dubai) (Prefabricated 3D Printed) ............................................ 50
Lewis Yakich Printed Villa (Philippines) (Printed on Site) .......................................... 53
3D Printed Village of Shamballa (Italy) (Printed on Site) ........................................... 56
Zhuoda Group 3D Printed Houses (China) (Prefabricated 3D Printed) ..................... 58
Conclusion ......................................................................................................................... 60
Sources............................................................................................................................... 61
ii
INTRODUCTION
The research objective is to present some alternative construction ideas that
can develop the construction industry in Egypt, by lowering the construction
costs and decreasing the construction time as possible.
Problem
-The housing problem in Egypt is a Quantity Based Problem as the annual
real-estate demand is nearly 500,000 housing unit, the Egyptian government
is responsible for constructing 40% and the private sector institutions are
responsible for 60% -According to the ministry of housing-
-The Current Supply is less than the demand
-The shortage gape between the supply and the demand creates a lot of
problems such as the huge increase in the housing units prices in addition to
grave residents and many other problems
-New, Fast, and Cost Effective construction systems are needed in order to
build the maximum number of housing units annually at the lowest possible
life cycle cost.
-The objective of the research is to present some construction alternatives
that can be used in order to enhance solving the current problem.
Development of Construction Systems

-The development of construction systems
used was supposed to replace the traditional
and the mechanized systems by the
prefabricated alternatives, but what
happened was different, as the traditional
and the mechanized systems developed in
Type of System
order to survive, while the development was

based mainly on two main point
-Mechanization
-Industrial Prefabrications
the research will present some examples in Time
order to analyze this development process
Development of Construction Systems vs Time
Sources
http://www.mei.edu/content/article/egypt%E2%80%99s-need-low-income-housing ,
Oweida, Mohammed Mahmoud, Modern Technology in Construction, 1948
iii
Even in the traditional construction system, the labors was replaced by
the machine during the last 30 years, we can see some examples for the
machine replacement or the mechanization of the traditional systems as
seen in the following figures:
Excavators Concrete mixers

replaces workers and pumps
Automation technologies such as machine Elevators and cranes
learning and robotics play an increasingly great role
in everyday life, their potential effect on the
workplace has, unsurprisingly, become a major
focus of research and public concern.
The research will study and present some

construction ideas and system in order to estimate
the path of the future construction systems
development.
1- BAMTEC System (Prefabricated Reinforcement)
2-COFFOR System (Stay in Place Formworks)
3-EMMEDUE (M2) System (Light Structure Systems)
4-BSB Developments (Prefabs revolution)
5-3D Printing Systems (Future revolution) Plastering Machines
Sources
http://www.builtool.net/
iv
1. BAMTEC SYSTEM
Introduction
Bamtec is the commercial name of a type of a Prefabricated reinforcing
systems that is based on prefabricating and connecting the slabs reinforcing
bars in factory to save time and money
BAMTEC reinforcement Technology was invented in1994. It followed the
worldwide distribution of the flat in site concrete floor based on the finite
elements of floor calculation.
Developed in Germany, BAMTEC is a revolutionary new approach to
placing steel reinforcing in slabs and decks.
BAMTEC is the most sophisticated slab reinforcement system available
today and has already helped to accelerate programs and reduce costs on
many sites through out the British Isles and worldwide.
Idea
With the usual reinforcement process of reinforced concrete floors,
simple reinforcing steel elements such as round bars steel or reinforcement
steel mesh are individually defined in the plan, individually prepared,
positioned and delivered in the bending operation and built in piece by piece
on the construction site using laying columns.
The BAMTEC reinforcement system significantly changes this
procedure. The positioned individual bars and/or individual mesh are no
longer delivered to the construction site. Complete layers of reinforcement
are used in a rolled form so called tailor made reinforcing steel elements.
A separate BAMTEC element is constructed, manufactured, delivered
and installed for each of the two reinforcement directions. The number of
reinforcing steel elements to be installed is dramatically reduced.
These BAMTEC elements are in most cases rolled out at right angles to
each other. The rolls consist of parallel round bars which are combined using
transfer steel bands. This means that two rolls are required in each of the
bottom and top rolled up layer of reinforcements, so a total of four.
Sources
http://www.bamtec.com/
https://www.youtube.com/watch?v=2NCcLV-ny2s
https://www.youtube.com/watch?v=6JL9s8rSI9M
1
Reinforcement Steel Mesh
Dimensions
The layers of reinforcement do not consist of standard elements, rather are
individually produced for the relevant layout and load.
The element width is oriented towards the maximum bar length in the
element. The maximum bar length is 15 m. All lengths, distances and
diameters in between are possible which result in optimized reinforcement
according to the statics calculations.
The maximum weight of a roll is 1.5 tons (approx. 100 kg/m). Therefore it
is guaranteed that a BAMTEC element can be rolled out onto a standard
separator by just two workers.
The length of the BAMTEC elements arises from the layout and the
permitted weight. They can be up to 25 meters long.
Sources
2
Procedures
The procedures of the BAMTEC system consists of 3 main phases:
1-Design and Planning
2-Manufacturing and Production (in Factory)
3-Transportation &installation Laying (in Site)
Design and Planning

Calculation
The statics calculation of the reinforced
concrete floors is carried out using a finite
element program. In this way the required
reinforcement in x and y direction for the upper
and lower layers is known separately.
After separating the floor area into the least possible number of
elements the BAMTEC software automatically defines the construction of the
elements, therefore the position, length and bar diameter of each bar in the
element. Recesses and supplementary reinforcements can thereby be taken
into account. The element conforms precisely, the softwares output is 3 types
of plans such as:
The overview plan shows The production plan The laying plan contains
the layout and calculated contains the individual the layout, the measured
round steel bar position. It elements, the steel list element release point, the
serves to control planning and accompanying element roll direction with
and implementation. production data description. The elements
description for the will be rolled out according
production. to the laying plan.
Sources
3
Production
The machine control data and the plans are sent to the BAMTEC
manufacturers electronically.
The fully automatic BAMTEC machine is controlled using this data. The
system welds the bars into the calculated distances and positions on the
transverse steel band. Hereby bars of 8 mm to 20 mm are processed from
the coil. All thicker bars up to 36 mm are processed manually from round
steel bars.
The BAMTEC machine is constructed for one man operation.
BAMTEC Production Machines
Sources
4
Transportation & Installation (Laying)
The BAMTEC elements are transported to the construction site with
trucks that can carry a load of 25t.
The assembly of BAMTEC elements is conceivably easy!
Without a cross beam the rolled out element can be conveyed to its starting
point with the crane. Due to the minimum number of reinforcing steel
elements and the rapid roll out the laying is greatly accelerated and
simplified. This can also lead to a reduction of the total construction time.
An element with a total weight of up to 1.5 t can be rolled out effortlessly
by two workers. The time to install the reinforcement will be minimized. As the
laying of every BAMTEC element is exactly defined.
1-Transportation and Placement 2-Laying the First mesh carpet
3-Installation of the rebar chairs 4-Installation of the second

(perpendicular) mesh carpet
Sources
5
Advantages
-Reduction of laying time by 80-90% due to quick rolling out of few reinforcing
steel elements
-Reinforcement steel savings of up to 40% due to selectable bar diameter, bar
distance and bar length
-Higher laying quality due to easy positioning and exact bar length
Quality assurance and high level of performance due to computer controlled,
fully automatic production.
-Simple reinforcement plans
-Ergonomic working method on the construction site
-Reduction of total construction time
-Energy and CO2 reduction due to material efficiency
Disadvantages
- Requires Cranes and elevating equipment
- Requires high technology Mechanized Factories
- Maybe ineffective in small projects (Economically)
- Requires specific transportation due to its weight
EXAMPLES WORLDWIDE
RWE Tower, Dortmund, Germany
-Highest building in Dortmund! 91 height,
lenticular floor plan with 55 m length and
26 m width
-20 floors superposed
-2 tons of BAMTEC per floor
The crucial factor during this building's
construction was the reduction of the
construction time due to BAMTEC. In 1 days
each of the floors was reinforced with
RWE Tower, Dortmund, Germany
BAMTEC.
Sources
http://www.pfeifer-structure.com/portfolio/new-buildings/business-and-administration/rwe-
tower-at-the-platz-von-amiens-dortmund-germany/ 6
Ferihegy Airport, Budapest Hungary
-New construction "Skycourt" between terminal A and B
-Floor surface to reinforce: 22.000 m2
-BAMTEC tonnage: 550 tons
-Estimated total construction time 2009-2017
-Opening: 15th April 2010
Ferihegy Airport, Budapest Hungary
Kempten Hospital
Construction time: 2001 - 2003
-Construction costs: appr. 18,7 Mio.
-Traditional: 3'000 tons
BAMTEC: 2'145 tons
Architect:
Rappmannsberger, Rehle & Partner;
Mnchen, DE
Constructor: Klinikum Kempten- Oberallgu GmbH Kempten Hospital
Sources
http://www.kesz.hu/
http://rrp.de/
7
2. COFFOR SYSTEM
Introduction
COFFOR is a structural stay-in-place formwork system to build
constructions in concrete.
COFFOR is patented and received certification in several countries.
COFFOR is composed of two filtering grids made of rib lath and reinforced by
vertical stiffeners . The grids are connected by articulated rebar loops that
fold for cost effective transport. The volume used by COFFOR is 7 times less
than the equivalence in bricks, concrete blocks or Insulated Concrete
Formwork (ICF).
COFFOR can be carried by hand : it weighs less than 11 kg/m2 (2.25 lb/sq ft). A
standard panel 1.10 m x 2.70 m (3' 8'' x 9') weighs 32.7kg (72lbs) and can easily
be carried by 1 or 2 persons.
Idea
The system consists of an integrated formwork, with draining facing
panels, self-bracing with relation to the pressure from the fresh concrete.
The formwork consists of two panels with vertical stiffening framework
of press-formed steel sheet sections and skin of expanded metal, connected
to each other by articulated loops in zigzag pattern. The panels are
manufactured and assembled in the factory.
Due to its constitution and to its implementation, the COFFOR structural
formwork system makes it possible to build vertical walls, straight or curved,
bearing or non-bearing, outside or inside.
The complementary reinforcing bars can be installed on the worksite if
the bars come singly or in pairs, or in the factory at the assembly of the
formwork panels in the case of welded wired fabric.
Coverings:
Outside: Spread coating or insulated cladding elements.
Inside: Spread coating or facing of bonded or screwed panels.
Sources
http://www.coffor.com/
https://www.youtube.com/watch?v=EGw9KCvF8RA
Coffor System, a research submitted in Cairo university 2013 by Eng.Ahmed Hashem
8
Components
Longitudinal rebar
Vertical stiffening sections:

formed sheet steel sections
Steel Connecting Bars
Expanded Metal Sheets
-The main components of the stay in place COFFOR form as seen in the
previous figure are the metal sheets that prevent the concrete from spoiling
out, the longitudinal rebar as the main structure element of the form, and
additional Optional sections and rebars
Expanded Metal Sheets Longitudinal Rebar & bracing elements
Sources
9
Complete COFFOR form Foam-steel Forms to architraves
Dimensions
Width: standard panel widths are 1100 mm (44") and 900 mm (36").
Height: panel heights are according to order but up to 4500 mm (15'').
Panels can be delivered with the exterior side higher than the interior side to
eliminate edge formwork on site.
Thickness: once unfolded, standard panel thickness are 160 mm (6"),
200 mm (8") and 250 mm (10"). Other thickness available on
request. Thickness is 0.42 mm.
Rib lath is expanded metal with rib produced from commercial quality
cold rolled and hot galvanized steel in accordance with ASTM C 847.
C-shaped vertical stiffeners are produced from commercial quality cold
rolled and hot galvanized steel in accordance with ASTM C 847. Thickness is
0.6 mm.
Longitudinal rebar are steel Fe 400 (French Norm) or equivalent.
Diameter is minimum 5 mm. Elasticity limit is 500 N/mm2, traction strength is
700 N/mm2. The longitudinal rebar are spaced every 200 mm.
Connectors are made from steel in coil grade B DIN 17 223 or equivalent.
Width is 19 mm and thickness is 16 mm
Sources
10
Procedures
Every step of the construction process is simplified:
1- Placement, alignment, bracing.
2- Setting of openings.
3-Rebar insertion (if necessary).
4- Service conduit penetration.
5-Concrete pour.
Workers are trained on the COFFOR technology in just 2-3 days training is
performed quickly and directly on-site. In addition, workers are keen to learn
since COFFOR is by far less physically demanding than other construction
methods such as heavy formworks, bricks, concrete blocks, etc.
Easy rebar insertion (if necessary):
Grouped in pairs, vertical rebar are inserted from the top into the axis of the
C profiles.
Horizontal rebar are then slid between the C profiles and vertical rebar.
As the horizontal and vertical rebar are secured, the necessity to tie them is
eliminated.
Visual inspection of the pour enables control of the concrete setting and
eliminates segregation risks. It is possible to pour concrete in the walls and
upper slab at the same time.
1- Placement, alignment, bracing.
Placement of the COFFOR form on the foundations deck
Sources
11
Placement of the corner edges
Alignment using temporary sections Bracing using Temporary scaffold

(Ruler) sections
2- Setting of Openings
Placing architrave panels Placing End sheets
Sources
12
Installing windows and doors frames
4- Service conduit penetration.
Installing Service Conduits
5- Placing the roof slab panels
Ceiling sheets
Sources
13
6- Concrete Pouring
Pouring slabs and walls at the same time
Knocking on panels to avoid air gaps Cleaning the surface
Sources
14
Advantages
-COFFOR is 2 to 3times faster than other traditional construction
systems. As a general rule, it takes 18 to 29 hours to install and pour 1m3 for
column and beam while it takes 3 to 4 hours with COFFOR walls.
-No stripping as COFFOR stays in the wall.
-Possibility to pour a whole floor in one pass: reduces preparation time
and eliminates lost time in rotating standard formwork. (Walls and slabs are
pured together)
-Time spent placing thermal insulation is eliminated: COFFOR INSULATED
already integrates the insulation material - eliminating the necessity to come
back to place it.
-All types of finishing bond exceptionally well due to the COFFOR
herringbone rib lath.
-Anti-cracking welded wire is no longer necessary: given the presence
of the C profile, the rib lath, their proper bonding to the concrete and their
respective steel section, the anti-cracking welded wire ( a requirement with
traditional waterproof formwork) is eliminated. In addition, the rapid
elimination of excess water decreases concrete shrinkage, dramatically
reducing the occurrence of cracks.
Disadvantages
- Need finishes (plastering) compared to alternative solutions like the
tunnel forms and the slipping forms
- can be inefficient economically compared to light weight structures in
the single floor projects
- Requires training courses to labors
-Manufacturers in Egypt needs to be upgraded (cannot supply large
amounts yet)
-need a supporting structures in high-rise buildings (more than 15
floors)
Sources
15
EXAMPLES WORLDWIDE
Family Housing Project (EGYPT)
The project scope of work: building 3000
housing units, 63m for each unit. 500 housing
units were built with a total cost EGP 30 million.
It was executed within 6months. The second
phase comprises 2100 housing units with a
total value is EGP 200 million and its execution
period is 18 months.
Worldwide Projects
Sources
http://www.arabcont.com/english/projects/project-423.aspx
16
12 Storey Building (Italy)
12 storey residential building was built in
12 weeks only in Seismic area (Italy)
Placing Panels Additional Rebar, Service Conduits
Multistorey Slabs and Walls are Poured Together
Pouring Concrete Pouring Concrete
Before Finishing After Finishing

Sources
http://www.dailymotion.com/video/xt4dww_construction-with-coffor_tech
17
3. EMMEDUE (M2) SYSTEM
Introduction
The Emmedue construction system is a type of light structure systems
types and it is based on a series of foam polystyrene panels and galvanized
steel wire meshes. The shape has been especially designed for the
introduction of traditional or structure plaster during on-site panel
installation.
Emmedue provides a system of industrialized modular panels lowing
for faster assembly than conventional systems. The Emmedue system fulfills
the required structural and load-bearing functions, offering high thermal and
sound resistance and wide range of shapes and finishes to provide versatility
in the design compaction process
Idea
Emmedue is an innovative anti-seismic and insulating building system
with load bearing walls, thanks to which it is possible to realize buildings up
to 20 floors, of any building typology or architectural structure, ranging from
the most simple to the most complex one.
The idea on which this building system has been based, appreciated
and used in the entire world for over 30 years, is the industrial manufacturing
of the panel, which has to be subsequently assembled and installed by means
of projected concrete.
Emmedue has a complete range of building elements: load bearing walls,
floors, roofing, stairs, partition and curtain walls. In this way the buildings can
be integrally realized with our building system, permitting to optimize the
supply phases, time-study and workers.
Sources
http://en.mdue.it/
https://www.youtube.com/watch?v=9xyJo4-VIhM
https://www.youtube.com/watch?v=f9FYBscvDfw
http://www.slideshare.net/IngridPortocarrero/68785108-manualetecnico2009esp
18
Components
Single Panels Double Panels Double Panels
Stair Panels Landing Panels Floor Panels
Single Panels
The Emmedue single panel is made up of a spatial steel lattice
enclosing an expanded polystyrene slab that is then finished on site with
plaster.
This panel is perfect for walls, partitions, claddings, floors and roofing of both
civil and industrial applications.
Used as a load-bearing structure, for buildings of up to 6 floors, with
structural plaster placed on both sides; as partitions and claddings, in new
buildings or in those in need for renovation; as curtain walls and partitions in
large-sized industrial and commercial buildings; as insulating frameworks
for roofing and moderate spam floors, prepared with or without pre-cast
beams.
Sources
http://en.mdue.it/
19
Double Panels
The double panel consists of two basic panels, suitably shaped and
joined to one another by double horizontal connectors, creating a cavity to be
filled with concrete having appropriate characteristics and strength.
The panel is then finished by external plaster. The double panel comes
with reinforcement certified by an Official Laboratory in accordance with the
Law 5/11/1971 no. 1086 -D.M. 14/01/2008, complying with the provisions
concerning reinforced concrete structures as stated by the EUROCODE 2 (EC2).
According to the Italian building codes
Curved Panels
The Curved Panel is a special panel having big dimensions and
thickness, manufactured in the factory in a flat form and pre arranged in order
to be bent after at the job site.
The panel produced in the factory is easily transported and is bent
manually at the job site, or by a semi-automatic and pneumatic equipment
designed by Emmedue in the requested shape.
The main advantage offered by this panel is the possibility to cover big
areas in a fast and convenient way. The structure grants a high thermal
insulation as well as a resistance to earthquakes.
Floor Panels
A panel used to build floors and roofing with reinforced concrete joists,
providing significant advantages in terms of lightness, insulation and speed
of assembly.
The Emmedue pre-formed polystyrene foam slab, reinforced with suitable
steel joists and then adding cast-in-place concrete, can be used to construct
floors or roofing when reinforced with suitable steel joists and then adding
cast-in-place concrete.
Sources
http://en.mdue.it/
20
Stair Panels
A panel for the fast construction of a lightweight and resistant stairs.
(Emmedue Exclusive Patent)
Made up of a polystyrene foam block the panel is shaped to design
requirements and sandwiched between two metal meshes by welded steel
wires. When reinforced and cast-in-place it is ideal to build stairs that can be
externally finished with traditional plaster, tiles or any other finishing
material. The stair panel is quick and easy to install and offers particular
lightness and strength.
Landing Panels
A panel used to build landings, floors and bidirectionally reinforced
plates. It provides continuous insulation to the panel intrados.
The Emmedue landing panel is an excellent solution to build landings
next to the stairs made with the Emmedue stair panels.
The landing panel can also be used for any plate or slab made of
concrete to be reinforced in two directions, offering the advantage of both
reduced weight, when compared to a full slab, and continuous insulation
when used also as a formwork.
Bracing Meshes
Designed with 1 Inch
galvanized steel wire, the
meshwork is used to reinforce
openings and corner-joints
between panels so to confer
continuity to the structural
mesh. Joints or cramps are
used to attach the mesh to the
panels
Bracing Meshes
Sources
http://en.mdue.it/
21
Equipment
1- Coating machines
In fact, Emmedue coating machines, which can be controlled even by
unqualified staff, allow for the spraying of the coat on walls and ceilings
obtaining an adhesion that is impossible to obtain manually, with savings of
up to 50%.
2- Staplers
For the application of clamps supplied on a strip. With a weight of only
2Kg., this manual tool ensures the maximum maneuverability, while it
reduces the risks that come from repetitive movements.
An innovative planning, which includes the use of mixed material, lost
wax casting and a facilitated pneumatic system make this tool a world famous
product.
3- Thermo-blowers
It is used to make conduit paths inside the panels by blowing up hot air
that can make the paths with minimum amount of energy and time
Coating machines Staplers Thermo-blowers
Sources
http://en.mdue.it/
22
Procedure
1-Placing of wall panels, tying them together
2-Placing Stair panels, landing panels, and slab panels
3-Reinforcing Corners and joints and openings using the bracing meshes
4-Preparing chasing for plumbing and electrical systems
5-Applying the plaster, pouring the slabs
The Emmedue panel can be easily transported by hand by one/two
workers, even when panels are assembled and exceed 4 m.
During the assembly phase, the panel can be worked on and manually
positioned by only one worker without the use of lifting equipment. This
facilitates and speeds up the installation of the panels in all situations.
Skilled workers are not required to carry out the work.
-Preparing chasing for plumbing and electrical systems
Installing the wiring and plumbing systems is easy, fast and clean, as
no masonry work is needed.
The chases in the polystyrene are made by a hot-air gun, and the wiring
and plumbing systems are run behind the metal mesh.
To accommodate rigid or semi rigid pipes, the metal mesh is cut to the
required length by using cutters, and then restored with reinforced flat mesh.
-Applying the plaster
Building Method Once the panels are joined together after they are
plumb and straight, in the case of double panels sprayed in concrete, and the
electrical and plumbing systems installed, the plaster can be applied directly
onto the panel.
Once again, the Emmedue system offers clear advantages when
compared with other systems, as all types of plaster can be used with the
galvanized steel support mesh. Moreover, when the plaster is applied on
closely abutted walls and reinforced with metal mesh, the result is a solid
monolithic block that is able to withstand cracks due to either thermal or
mechanical strains.
What is more, as there is no visible trace of the plumbing and electrical
system chases, which are always visible in traditional systems, the plaster
has a high quality, smooth, even finish and is aesthetically pleasing.
Sources
http://en.mdue.it/
23
1-Placing of wall panels, tying them together
Panels Placement on a pre poured concrete deck with anchor rebar along the walls path
Tying Panels together using the staplers
2-Placing Stair panels, landing panels, and slabs
Stair panels are placed on anchors in order to

increase its strength and stability
Sources
http://en.mdue.it/
24
Landing panels are put on a temporary scaffold until poured
Placing Flooring Panels and Ceiling

3-Reinforcing Corners and joints and openings using
the bracing meshes
Adding extra bracing meshes to reinforce openings
Sources
http://en.mdue.it/
25
Adding bracing meshes to openings and corners
4-Preparing chasing for plumbing and electrical systems
Easy use of Thermo-Blowers (hot air gun) to make the service chases
Installing the service fixtures and conduits

Sources
http://en.mdue.it/
26
5-Applying the plaster, pouring the slabs
First hand Coat to cover the mesh
Second hand Coat for leveling and finishing
Pouring Slabs and Landing panels

Sources
http://en.mdue.it/
27
Advantages
-Lightness, ease of transport and handling, Prior to an application of
shortcrete, an Emmedue panel weighs between 3.5kg/mq to5 kg/mq which
means that a single worker can easily handle a *3sqm wall, that is, a panel as
high as the storey height.
-Load resistance, load performed on a single finished panel, 270cm high, have
shown they withstand a maximum load of up to 1530 kn/m 156 ton/m.
-Sustainability and Energy efficiency, The Emmedue building system
constructs buildings which achieve high levels of energy efficiency which
conform to energy efficiency regulations
-Cost effectiveness, Compared to traditional products, Emmedue panels
achieve far better results, at considerably reduced cost. A building framework
constructed using the Emmedue building system costs roughly 30%* less
than a traditional one with similar features. The shorter build timescales
represent additional savings.
-Rapid installation, The Emmedue system has been used in countless
building experiences, in diverse conditions, and with all types of labor in
many countries worldwide. 3 floors residential building can be constructed
finished in 2 weeks
Disadvantages
- Need finishes (plastering and spraying) compared to alternative
solutions like the tunnel forms and the slipping forms
- Requires training courses to labors
-Manufacturers in Egypt needs to be upgraded (cannot supply large
amounts yet)
-Need a supporting structures in high buildings (more than 4 floors)
-Its hard to do modifications in the walls or the service conduits due to
the light weighted walls, it needs a professional efforts
Sources
http://en.mdue.it/
28
EXAMPLES WORLDWIDE
Montecielo Residential Project, Italy
MUNICIPAL MATAGALPA Theatre , Italy
Sources
http://en.mdue.it/
http://www.slideshare.net/sjnavarro/conferencia-m2-y-las-construcciones-ms-seguras-en-nicaragua
29
AMPLIACION CATEDRAL DE GRANADA, Italy
Several Examples Worldwide
Sources
http://en.mdue.it/
30
3 floors as a vertical extension of a Mall in Egypt
Sources
http://en.mdue.it/
31
4. BSB SYSTEM
(PREFABS REVOLUTION)
Introduction
Broad Sustainable Building Co., LTD (BSB) (Chinese:) is a
construction company and a wholly owned subsidiary of Broad Group,
specializing in developing prefabricated buildings. Several of its projects
from BSB drew media attention after being erected in weeks, assembling up
entire floors in a single day, while reducing costs. One of its projects, which is
currently on hold, was to assemble the Sky City, a 220 floor building in
Changsha in only 90 days. Once completed, the building can become the
tallest in the world. BSB intends to license its technology worldwide and
currently has six franchises in China with plans to 150 worldwide.
Idea
For the past century, all walks of life have undergone tremendous
changes, with the construction industry as the only exception - designers
working behind the closed doors, unfixed contractors and migrant workers,
and ''ants moving'' construction mode. Whether in developing or developed
countries, they are all alike. Since 2009,BROAD has invested RMB 4 billion to
the invention of Sustainable Buildings featuring industrialized building R&D,
streamlined production, container-like transportation and standardized
installation, reaching no collapse in 9-magnitude earthquake, 90% factory-
made, 5 times more energy saving and 100 times better air purification. It has
advanced the world architecture technology 100 years forward, and has
improved the living quality of mankind overall. When the video of ''a 57F
building constructed in 19 days'' went viral in 2015, people with high
sensitivity are aware that the world history is about to be changed
dramatically.
Sources
http://en.broad.com/
https://www.youtube.com/watch?v=rwvmru5JmXk
https://www.youtube.com/watch?v=acLSbNxUP3s
https://www.youtube.com/watch?v=Hdpf-MQM9vY
32
BSB Objectives
The main objectives of the BSB invented systems can be simplified as
the following:
-Technology: Factory Made
The main objective of the studies of the company is to expand the
factory made components and widen the mass production systems in order to
decrease the efforts made at the construction site and decrease the
construction time in addition to ensuring the quality
-Quality: Verified
The factory mass production will decrease the human effort and
minimize it while maximizing the mechanical and the machinery efforts by
which the quality can be verified
-Efficient Costs
One of the main objective of the research is to minimize the
construction and the life cycle cost of the project by using the mass
production technologies, so that it is quicker, and also cheaper.
-Sustainability
Restoring the environmental resources is reflected as a financial
benefit, the main environmental aims of the BSB mass production system is
to:
1-Decrease the construction wastes on site (less than 1%)
2-Build energy efficient buildings in order to decrease the life cycle costs
3-Land Saving (Vertical Projects)
4-Usage of Recyclable Materials
Sources
33
BSB Projects
1-57 storey skyscraper
Broad Sustainable Building spent
four and a half months fabricating the
buildings 2,736 modules before
construction began. The first 20 floors were
completed last year, and the remaining 37
were built from 31 January to 17 February
this year, Xiao said.
The company had honed its
technology to speed up its construction
from two floors to three floors a day.
2-S30 Apartment
Feature:
the current biggest BSB single-building
with different decoration styles
Layout:
stories: 30; building height: 99.9m; building
area: 54000m2; rooms: 710 (staff dormitory).
The main part of the building was
constructed in 12days.
3-Broad Pavilion
BROAD pavilion has stood up in one day.
From the 3 minute movie, visitors can see that
on March 6, 2010 BROAD built this 6 floor,
2000m2 building, including external walls,
windows, floors and roofs, in 24 hours. All
components were factory made and assembled
by bolts, without traditional civil engineering
and decoration. This is one miracle in human
history.
Sources
34
4-New Ark Hotel
New Ark Hotel has stood up in Two day.
And the Exterior Finishes took about 90 hours for
the 15 floors hotel tower to be built.
5- Sky City One (Changsha)

Sky City (Chinese: ; pinyin:
tinkng chngsh), or Sky City One, was an
838-metre-tall (2,749 ft) planned skyscraper
in the city of Changsha, Hunan in south-
central China.[10] The prospective builders,
Broad Sustainable Building, estimated it
would take just 90 days to construct.
Including the 120 days required for
prefabrication before on-site work
commences, the sum of time needed is 210
days. Pre-construction activities were halted
in August 2013 after government regulators
required additional approvals.
Sources
35
CASE STUDY:T-30 TOWER HOTEL
Introduction
In late 2011, Broad built a 30-story
building in 15 days; On New Years Day 2012,
Broad released a time-lapse video of its 30-
story achievement that quickly went viral:
construction workers buzzing around like
gnats while a clock in the corner of the screen
marks the time. In just 360 hours, a 328-foot-
tall tower called the T30 rises from an empty
site to overlook Hunans Xiang River. At the
end of the video, the camera spirals around
the building overhead as the Broad logo
appears on the screen: a lowercase b that
wraps around itself in an imitation of the @
symbol.
The main characteristics of the process
was as the following:
-Only 200 Workers.
-17,000 SQM Built-up Area.
-Capacity to withstand an earthquake that
measures up to 9 on the Richter Magnitude
Scale.
-Sustainable and Environmental Friendly.
Procedures
The main procedures of the tower
erection process can be simplified as the
following:
1-Design Stage
2-Industrial Stage
3-Transportation Stage
4-Assembly Stage (Construction)
Sources
https://www.wired.com/2012/09/broad-sustainable-building-instant-skyscraper/ 36
DESIGN STAGE
The Design Ideas was based mainly on easing the assembly of the
building to reduce the construction type.
Components
The Form of the building
components is the secret of its success,
standardizing the columns shape and
making it plug into the slabs like a puzzle
eased the assembly of the project and
reduced the construction time, even
though, it did not affect the architectural
design of the building . The winged
columns enhanced the structure system
preventing any bending moment in
addition to enhancing the plugging and
the bolting to the prefabricated slabs.
Floor Plans
Ground Floor Plan
Sources
First Floor Plan Typical Floor Plan
15th Floor Plan (Mechanical Floor) Last Floor Plan (Club)
The standardized axes and grid did not affect the variation of the design
spaces and activities, the good architect -in my point of view- is the architect
who can respect the structural grid to provide a well functioned building. In
addition to the precious plan, the basement floor plan is for the underground
parking that fits 75 cars in addition to the machine rooms.
Sources
INDUSTRIAL STAGE
The Industrial Stage is the most important stage, the buildings
components are pre-fabricated totally in the factory, including the floorings and
the MEP fixtures in addition to the false ceiling finishes.
Constructing the slabs Pre-Installation for the flooring
The Service Conduits are installed in the factory, except for the joining fixtures and the vertical conduits
Pre-Installing 95% of the false Ceiling Preparing Components for Transportation

Sources
TRANSPORTATION STAGE
-Standardized truckloads
Each load carries two modules to the site, with the necessary columns,
bolts, tools, and other peripherals to connect them stacked on top of each.
Even the Truck loading is studied and designed to help performing the
fastest assembly process, every slab is truck loaded with the amount of columns
it will carry, the box of bolts will be used to join the columns to the slabs, the wall
panels that will be needed to in the interior wall partitioning in addition to the
vertical MEP fixtures.
In the construction process, the slab will be elevated using the cranes
and hence, we have all the needed fixtures in the working floor in order to be
assembled at the shortest possible time.
Sources
ASSEMBLY STAGE
Installing the elevating cranes.
Assembling the Columns, then bolting them.
The slab rests on the column head on one corner, and the other corner on the
column wing in order to be joined to the next slab.
Sources
ASSEMBLY STAGE
Bolting the Slabs to the Columns and to the joining slabs
Assembling the Columns, then bolting them.
Installing the Interior wall panels and partition boards, the panels are
prefabricated scaled to fit in its designed place, only bolting are required on site
Sources
ASSEMBLY STAGE
The Curtain walls panels are

designed to be plugged in in its place
just by pushing it slightly into its place
life a puzzle or a Lego toy
The interior
finishing and the
furnishing Stage
took about extra
30 days for the
Hotel to start its
service. Finishing works are in parallel
with erecting the building
Sources
Advantages
-Time Efficiency, Since time is equal to money, saving time is one of the
most important objectives in the construction industry. The building that is
talking about 2 years by normal ways, needs only 90 days to be erected,
finished and furnished
-Cost Efficiency, in addition to the extra cost benefits resulting from
minimizing the construction time, the construction cost of BSB towers is less
than the construction costs of any similar project, due to the reduction of the
construction wastes.
-Waste Reduction, Construction wastes are about 1% of the traditional
construction systems wastes.
-Life Design of Building Structure, The company guarantees the
building for 600 Years, with a maintenance cycle once every 60 years
-Unique Structure , Unique diagonal bracing steel structure that can
resist 9 magnitude earthquakes
-Quality Assurance, The factory mass production will decrease the
human effort and minimize it while maximizing the mechanical and the
machinery efforts by which the quality can be verified
-Life Cycle Cost Reduction, increasing the life cycle of the building,
decreasing the energy consumption, using recyclable materials such as the
steel components are the main reasons that reduced the life cycle costs of
the system.
Disadvantages
-Needs Mass Production Factories with high level of technology
-Needs highly educated professional labors and stuff
-Cost effective in high-rise buildings only , so it is ineffective in small
projects (Economically)
-Needs a high performed designs and manufacturing as no errors can
be accepted.
- Requires specific transportation due to its weight
Sources
5. THREE DIMENSIONAL PRINTING
(FUTURE REVOLUTION)
Introduction
3D printing (sometimes referred to as Additive Manufacturing (AM)) is
the computer-controlled sequential layering of materials to create 3
dimensional shapes. It is particularly useful for prototyping and for the
manufacture of geometrically complex components.
It was first developed in the 1980's, but at that time was a difficult and
expensive operation and so had few applications. It is only since 2000 that it
has become relatively straight forward and affordable and so has become
viable for a wide range of uses such as; product design, component and tool
manufacture, consumer electronics, plastics, metalworking, aerospace
engineering, dental and medical applications, footwear and so on.
What is 3d Printing
3D printing is a form of additive
manufacturing in which components are
fabricated in an additive fashion by adding
successive layers of material together
It is a process of making three
dimensional solid objects from a digital file
(CAD model).
The creation of a 3D printed object is
achieved using additive processes.
In an additive process an object is
created by laying down successive layers of
material until the entire object is created.
Each of these layers can be seen as a thinly
sliced horizontal cross-section of the eventual
object
Sources
https://www.sculpteo.com/blog/2015/10/07/3d-printing-construction/
http://www.lboro.ac.uk/enterprise/case-studies/3d-concrete-printing/
http://www.slideshare.net/NithinN4/applications-of-3d-printers-in-construction-industry-nithin-n
45
History of 3d Printing
The technology for printing physical 3D objects from digital data was
first developed by Chuck Hull in 1984. He named the technique as Stereo
lithography and obtained a patent for the technique in 1986 , the industry
grown rapidly during the following years as the following:
-At 1986-Hull coined the term Stereo lithography when he patented his new system
-At 1992-The first Stereolithographic Apparatus (SLA) is made by 3D Systems
-At 1999-The first ever 3D organ, a bladder, is created with the patients own cells. This means that
there is little chance of the organ being rejected by the body
-At 2002-A miniture kidney is created that can filter blood and produce diluted urine in an animal.
-At 2006-The Selective Laser Sintering machine is built and allows for mass customization in
manufacturing industrial parts
-At 2008-A prosthetic leg is created with a complex structure that requires no assembly. This opens
the doorway to customized prosthetic limbs. Revolution in technology by rooting of REPRAP concept
-At 2009-Innovative bioprinting company, Organovo, creates the first blood vessel to be bio printed
-At 2011-Printing Service, I - materialize, starts offering 14K gold and sterling silver as a printable
material.
-At 2012-Alternative 3D printing processes were introduced at the entry level of the market
-At 2014-New era of industrial revolution - Big firms started acquiring start-ups. Theoretical and
practical structures were aimed at.
3d printing in construction Industry

As modern architecture makes ever
greater demands on construction specialists,
meeting these developments creatively and
cost effectively poses a range of testing
challenges.
A research Funded by the EPSRC and
IMCRC, researchers in the School of Civil and
Building Engineering Loughborough university
have been developing 3D printing technology
for the construction industry for almost a
decade.
The team have developed computer
controlled 3D printers that precisely deposit
successive layers of high-performance
concrete to form complex structural
components such as curved cladding panels
and architectural features that cannot be
manufactured by conventional processes.
Sources
https://www.sculpteo.com/blog/2015/10/07/3d-printing-construction/
http://www.lboro.ac.uk/enterprise/case-studies/3d-concrete-printing/
46
Idea
Y Direction Track
Concrete Pouring Pump
Concrete Mixer
X Direction Track Z Direction Track
The idea of the concrete 3d printer is very simple and it is quite similar
to the normal paper printer as it works on a fixed track bar, that can allow the
pump to move automatically according to the input data of the printed shape,
the main difference between the 3d printer and the normal paper printer is
that the 3d printer pump can move is the three directions, x, y and z.
the plumb start moving and layering the concrete as a contour plan
until the full shape is formed is seen in the following figures:
Sources
https://buildingradar.com/construction-blog/how-3d-printing-could-revolutionise-the-
construction-industry/
https://www.youtube.com/watch?v=DQ5Elbvvr1M
47
Procedures
Every step of the 3d printing process is simplified:
1- Modelling
2-Printing
3-Finishing
The printer forms the item by

depositing the material in
A person creates a 3D image
layersstarting from the
of an item using a computer- The CAD information is sent
bottom layeronto a
aided design (CAD) software to the printer.
platform. In some cases light
program.
or lasers are used to harden
the material.
1- Modelling
Additive manufacturing takes virtual blueprints from computer aided
design (CAD) or animation modeling software and "slices" them into digital
cross-sections for the machine to successively use as a guideline for printing
2- Printing
To perform a print, the machine reads the design and lays down
successive layers of concrete, liquid, powder, or sheet material to build the
model from a series of cross sections. These layers, which correspond to the
virtual cross sections from the CAD model, are joined together or
automatically fused to create the final shape.
The primary advantage of this technique is its ability to create almost
any shape or geometric feature
3- Finishing
Though the printer-produced resolution is sufficient for many
applications, printing a slightly oversized version of the desired object in
standard resolution, and then removing material with a higher-resolution
subtractive process can achieve a higher-resolution
Sources
https://buildingradar.com/construction-blog/how-3d-printing-could-revolutionise-the-
https://www.youtube.com/watch?v=DQ5Elbvvr1M
48
3d Printed Material
The real obstacles are, as always, materials. The concrete and cement
materials need to be well suited to constructing with large-scale 3D printing
robots, and they need to be able to dry quickly to support themselves and
bond together firmly. Thai cement maker Siam Cement Group (SCG) has
developed an amazing new cement that is mixed with a special combination
of powder materials and fibers that allow it to quickly be printed into non-
traditional shapes. It binds quickly enough that it can be printed with
dramatic curves and twists, and it can remain freestanding while drying
without the need for support material.
SCG used their new formula to 3D print six structural beams that
essentially mimic the anatomy of a bone. They are strong on the outside, while
remaining partially hollow and spongy on the inside, which results in a
structure far more resilient than traditional concrete. The columns were used
to create a beautiful pavilion structure designed by Thai architect Pitupong
Chaowakul. Its called Y-Box Pavilion 21st-century Cave, which is Southeast
Asias first 3D printed structure.
Sources
https://3dprint.com/131560/scg-3d-printable-cement/
49
EXAMPLES WORLDWIDE
Office of the future (Dubai)
The Office of the Future is the most advanced 3D printed building in the
world. It is also the first fully functional, inhabited 3D printed building ever. It
was inaugurated on May 23, 2016 by His Highness Sheikh Mohammed bin Rashid
Al Maktoum, Vice President and Prime Minister of the UAE and Ruler of Dubai.
Inauguration
The Office of the Future was inaugurated on May 23, 2016 by His Highness
Sheikh Mohammed bin Rashid Al Maktoum, Vice President and Prime Minister of
the UAE and Ruler of Dubai.
"Today we announce the opening of the first 3D-printed office in the world,
after less than a month of launching Dubai 3D printing strategy, said Sheikh
Mohammed at the inauguration of the building.
The initiative comes as part of Dubai 3-D Printing Strategy, which was
launched on April 27th, 2016 and focuses on the development of 3D printing to
improve peoples lives. It will tackle three sectors: real estate and construction,
medical, and consumer, and commits the Emirates to the use of 3D printing in
25% of its buildings by 2030.
We see this project as a case study that will provide valuable lessons for
the entire construction industry, said Sheikh Mohammed. It will also benefit
governments around the world as they seek to better understand and take
advantage of this important technology.
Sources
https://www.youtube.com/watch?v=aZBLj3Vs-Oo
https://www.youtube.com/watch?v=KwVUmAPd-8s
http://officeofthefuture.ae/
50
Procedures
1-Precast Printing the Building Components in Factory
A huge 3D Printer with 20 feet tall, 120 feet long and 40 feet wide was used,
it took 17 days for the printing process
2-Transportation
The components size was designed to be transported easily to the

construction site for assembly
Sources
51
3-Assembly
The Assembly Process took only Two days

4-Finishing
Even the Furniture was 3d printed

Sources
52
EXAMPLES WORLDWIDE
Lewis Yakich Printed Villa (Philippines)
In the Philippines, Lewis Yakich has informed 3DPrint.com that he has
successfully 3D printed their building which measures 10.5 m x 12.5 m
(approximately 34.5 feet x 41 feet) in dimensions with a height of 3 meters
(approx. 10 feet), making it about 130 square meters (1500 square feet). It is a
two bedroom villa with a living room and jacuzzi room (with 3D printed jacuzzi),
all of which will be part of the prestigious Lewis Grand Hotel. In all, the structure
took approximately 100 hours of print time to complete, although the process
was not a continuous one.
unlike Dubai's office, the whole hotel was casted and printed in the
construction site by a huge 3d printer
Sources
https://3dprint.com/94558/3d-printed-hotel-lewis-grand/
https://www.youtube.com/watch?v=g6u5FPdPMWE
53
Procedures
1-Three Dimensional Modelling
The modelling was made by a simple software (Google Sketchup), and was Modelled according to the
design drawings, the twisted columns was a challenge to show that the printer can build any form
2-Installing the Huge Printer and Caravan
3-Printing the Building
The Printing time took approximately 100 hours
Sources
54
The MEP works was done in parallel with the printing works for the wet
areas and the printed jacuzzi
4-Interior and Exterior Finishing
The Structure can be finished by any type of finishes
Sources
55
EXAMPLES WORLDWIDE
3D Printed Village of Shamballa (Italy)
the Italian municipality of Massa Lombarda, in collaboration with WASP,
announced that they would be constructing the worlds first 3D printed village.
With any undertaking of this scale, particularly something so
unprecedented, there are naturally going to be a few challenges and snags but
the Shamballa team has done an excellent job at solving any problems that
arise. A giant printer is going to have the same issues as any other printer
print interruptions, material loading, etc. A giant outdoor printer, working
continuously to print a village, is also going to have its own challenges
weather, the need for someone to be supervising the printing process at all
times but overall, the project is going swimmingly.
The Printer Used: WASP Delta 3D Printer
The worlds largest delta-style 3D printer,
the BigDelta. The BigDelta measures a
staggering 12 meters tall, and it will make
its official debut at the three-day rally
event which will include conferences,
workshops, concerts and theatrical
shows.
The Printer looks a bit different
than the usual 3d printer studies before
Sources
https://3dprint.com/94334/wasp-bigdelta-3d-printer/
https://3dprint.com/145439/shamballa-3d-printed-construction/
56
3D Printing The Village
Extremely little money isnt an exaggeration, either. So far, the team has
printed 270 centimeters of wall from clay and straw, five meters in diameter,
using an incredible 40 tons of material. Each layer, weighing approximately 300
kilos, takes about 20 minutes to print. With all that material, costs and energy
consumption have stayed remarkably low.
Here are some of the numbers, broken down:
Water usage: 2 cubic meters, 200 kwh, 3
Overall energy cost: 32
Straw: 10
Gasoline for the motorized hoe: 3
Thats a total of 48. Clay, of course, is plentiful in the landscape, so no
additional cost there plus, by kneading the clay with the feet rather than by
machine, energy consumption is reduced by 90%.
Compare all of that to the cost, time and material involved in a typical
construction project, and its even more amazing. In terms of quality, the
structure is solid and capable of withstanding high levels of stress.
Sources
https://3dprint.com/94334/wasp-bigdelta-3d-printer/
https://3dprint.com/145439/shamballa-3d-printed-construction/
57
EXAMPLES WORLDWIDE
Zhuoda Group 3D Printed Houses (China)
The houses are built from
individual 3D printed modules,
90% of which are all fabricated in
a factory setting and then
transported to the construction
site. Because of this, very little
information regarding the exact
techniques being used for their
creation have been revealed.
However, this morning in China
reporters gathered to witness the
construction of a 2-story villa
being built with 6 of these 3D
printed modules, each weighing
approximately 100kg (220
pounds) per square meter. Using
cranes, the individual modules,
consisting of a living room,
bedroom, kitchen, bathroom, and
more, were all lifted and stacked
on top of each other, resulting in a
fully constructed home. The
process took just 3 hours to
complete, upon which the public
and the media were permitted
inside.
Testing has shown that these buildings can withstand average wear and
tear for at least 150 years in virtually any environment here on earth. The
company says that a typical 500 square meter villa could completely be
constructed in just 15 days time.
Sources
https://3dprint.com/82322/chinese-3d-modular-homes/
58
Advantages
The benefits of 3D printing include:
Since the 3d printing systems in construction is still in the trial and error
phase, we can predict its benefits as the following:
-Reduced materials usage
-Increasing the ability to design a larger variety of customized homes
and buildings
-Savings of 30%-60% in construction waste
-Reduction of production time by 50%-70%
-Reduction of construction labor costs by 50%-80%
-Any Form or Shape Can be Done
-It is the next revolution in construction
Disadvantages
-Needs high Technology
-Needs accurate designs, since no errors can be done
-Needs time to be a mass production industry since it is still in its first
phases
Sources
https://blog.dragoninnovation.com/2014/12/30/top-10-benefits-3d-printing-salient-technologies//
59
CONCLUSION
The Main Concluded Properties of the future construction development
can be summarized as the following:
-Less Human Effort
-Minimizing Number of Labors
-Maximizing the use of Machine and labors
-Minimizing the construction time
-Lowering the construction costs
-Lowering the life cycle costs
-Minimizing the construction wastes and disposal
-Minimizing the construction energy and the buildings usage of energy
-Prefabrications or the buildings components and the whole buildings
-Robotizing the construction operation in factory and in site
-Replacing the traditional materials with technological smart materials
-Increasing the constructed product quality
The three dimensional
printing will be the next
generations construction
Type of System
Robotized
revolution side by side with the Prefabs
prefabricated ideas, as the while 3d Printing

building will be printed and
prefabricated in the mass
production factories before
being transported and
assembled in the construction
Prefabs
site, 3d printing systems is the
first strong step towards Mechanized Systems
robotizing the construction

operations, as the human being Traditional Systems
will only have to design and click Time
on a computer button in order to Development of Construction Systems vs Time
see his project erected.
Sources
60
SOURCES
-http://www.mei.edu/content/article/egypt%E2%80%99s-need-low-income-housing ,
-Oweida, Mohammed Mahmoud, Modern Technology in Construction, 1948
-http://www.bamtec.com/
-https://www.youtube.com/watch?v=2NCcLV-ny2s
-https://www.youtube.com/watch?v=6JL9s8rSI9M
-http://www.pfeifer-structure.com/portfolio/new-buildings/business-and-administration/rwe-
tower-at-the-platz-von-amiens-dortmund-germany/
-http://www.kesz.hu/
-http://rrp.de/
-http://www.coffor.com/
-https://www.youtube.com/watch?v=EGw9KCvF8RA
-Coffor System, a research submitted in Cairo university 2013 by Eng.Ahmed Hashem
-http://www.dailymotion.com/video/xt4dww_construction-with-coffor_tech
-http://en.mdue.it/
-https://www.youtube.com/watch?v=9xyJo4-VIhM
-https://www.youtube.com/watch?v=f9FYBscvDfw
-http://www.slideshare.net/IngridPortocarrero/68785108-manualetecnico2009esp
-http://www.slideshare.net/sjnavarro/conferencia-m2-y-las-construcciones-ms-seguras-en-
nicaragua
-http://en.broad.com/
-https://www.youtube.com/watch?v=rwvmru5JmXk
-https://www.youtube.com/watch?v=acLSbNxUP3s
-https://www.youtube.com/watch?v=Hdpf-MQM9vY
-https://www.wired.com/2012/09/broad-sustainable-building-instant-skyscraper/
-https://www.sculpteo.com/blog/2015/10/07/3d-printing-construction/
-http://www.lboro.ac.uk/enterprise/case-studies/3d-concrete-printing/
-http://www.slideshare.net/NithinN4/applications-of-3d-printers-in-construction-industry-nithin-n
-https://buildingradar.com/construction-blog/how-3d-printing-could-revolutionise-the-
-http://www.slideshare.net/NithinN4/applications-of-3d-printers-in-construction-industry-
nithin-n
-https://www.youtube.com/watch?v=DQ5Elbvvr1M
-https://3dprint.com/131560/scg-3d-printable-cement/
-https://www.youtube.com/watch?v=aZBLj3Vs-Oo
-https://www.youtube.com/watch?v=KwVUmAPd-8s
-http://officeofthefuture.ae/
-https://3dprint.com/94558/3d-printed-hotel-lewis-grand/
-https://www.youtube.com/watch?v=g6u5FPdPMWE
-https://3dprint.com/94334/wasp-bigdelta-3d-printer/
-https://3dprint.com/145439/shamballa-3d-printed-construction/
-https://3dprint.com/82322/chinese-3d-modular-homes/
61

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CONTENTS

Development of Construction Systems

order to survive, while the development was

Excavators Concrete mixers

The research will study and present some

Design and Planning

BAMTEC Production Machines

1-Transportation and Placement 2-Laying the First mesh carpet

3-Installation of the rebar chairs 4-Installation of the second

Ferihegy Airport, Budapest Hungary

Vertical stiffening sections:

Steel Connecting Bars

Expanded Metal Sheets

Expanded Metal Sheets Longitudinal Rebar & bracing elements

Placement of the COFFOR form on the foundations deck

Alignment using temporary sections Bracing using Temporary scaffold

Placing architrave panels Placing End sheets

4- Service conduit penetration.

Installing Service Conduits

5- Placing the roof slab panels

Pouring slabs and walls at the same time

Knocking on panels to avoid air gaps Cleaning the surface

Placing Panels Additional Rebar, Service Conduits

Multistorey Slabs and Walls are Poured Together

Pouring Concrete Pouring Concrete

Before Finishing After Finishing

Single Panels Double Panels Double Panels

Stair Panels Landing Panels Floor Panels

Coating machines Staplers Thermo-blowers

Tying Panels together using the staplers

2-Placing Stair panels, landing panels, and slabs

Stair panels are placed on anchors in order to

Placing Flooring Panels and Ceiling

Adding extra bracing meshes to reinforce openings

4-Preparing chasing for plumbing and electrical systems

Installing the service fixtures and conduits

First hand Coat to cover the mesh

Second hand Coat for leveling and finishing

Pouring Slabs and Landing panels

MUNICIPAL MATAGALPA Theatre , Italy

Several Examples Worldwide

5- Sky City One (Changsha)

Ground Floor Plan

15th Floor Plan (Mechanical Floor) Last Floor Plan (Club)

Constructing the slabs Pre-Installation for the flooring

Pre-Installing 95% of the false Ceiling Preparing Components for Transportation

Installing the elevating cranes.

Assembling the Columns, then bolting them.

Bolting the Slabs to the Columns and to the joining slabs

Assembling the Columns, then bolting them.

The Curtain walls panels are

3d printing in construction Industry

X Direction Track Z Direction Track

The printer forms the item by

The components size was designed to be transported easily to the

The Assembly Process took only Two days

Even the Furniture was 3d printed

The Printing time took approximately 100 hours

4-Interior and Exterior Finishing

The Structure can be finished by any type of finishes

prefabricated ideas, as the while 3d Printing

robotizing the construction

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