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DECivil

GESTEC

PREFABRICATED
Master in Construction and Rehabilitation

BUILDING
Buildings Construction

STRUCTURES
Authors: Eng. Rui Machado, Arch. Filipe Lopes and Prof. Jorge de Brito

Coordination: Prof. F.A. Branco, Prof. Jorge de Brito,


Prof. Pedro Vaz Paulo and Prof. João Ramôa Correia

Translation: Prof. José Dinis Silvestre

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TABLE OF CONTENTS

1. INTRODUCTION
DECivil
GESTEC
2. PRECAST STRUCTURAL ELEMENTS
2.1. Footings
Master in Construction and Rehabilitation

2.2. Columns
2.3. Beams
2.4. Roof beams
2.5. Slabs
Buildings Construction

2.6. Stairs
2.7. Panels
2.8. Fully prefabricated buildings

3. NON-TRADITIONAL FLOOR SYSTEMS


3.1. Advantages and disadvantages
3.2. Types
3.3. Applications

PREFABRICATED BUILDING STRUCTURES 2/119


TABLE OF CONTENTS

3.4. Performance
DECivil
GESTEC 3.5. Execution
3.6. Quality control
Master in Construction and Rehabilitation

4. REFERENCES
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 3/119


DECivil
GESTEC
Master in Construction and Rehabilitation

1. INTRODUCTION
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 4/119


1. INTRODUCTION
The need for achieving ever higher construction rates,
without prejudice to safety and quality conditions, has lead to
DECivil
the search for new solutions for construction, where
GESTEC
prefabrication plays a leading role.
Master in Construction and Rehabilitation

Precast elements have emerged as alternatives to the cast


“in situ” concrete structures, bringing advantages in the
reduction of the execution times and workmanship, and
in structural lightening.
Buildings Construction

Prefabrication is a technique and construction method in


which these elements are totally or partially produced in a
plant, according to industrial methods of serial
manufacturing.

The possibility of reuse and recycling of these elements, in


the deconstruction or dismantling stages of buildings, fits the
perspective of sustainable construction.

PREFABRICATED BUILDING STRUCTURES 5/119


1. INTRODUCTION
Advantages of prefabrication
DECivil
GESTEC • speed of construction;
• production not-dependant on climatic factors;
Master in Construction and Rehabilitation

• less workmanship needs;


• less dependent on local workmanship;
• effective quality control and more precise geometry;
Buildings Construction

• improvement of the construction work planning.

Which results in a

More
economic
solution
PREFABRICATED BUILDING STRUCTURES 6/119
1. INTRODUCTION
Disadvantages of prefabrication
DECivil
GESTEC • need for heavier lifting equipment;
• transportation constraints;
Master in Construction and Rehabilitation

• adequate communication routes;


• geographical location of the site in relation to the prefabrication
plant.
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 7/119


DECivil
GESTEC
Master in Construction and Rehabilitation

2. PRECAST
STRUCTURAL
Buildings Construction

ELEMENTS

PREFABRICATED BUILDING STRUCTURES 8/119


2. PRECAST STRUCTURAL
ELEMENTS
DECivil
GESTEC
Roof
Master in Construction and Rehabilitation

Slabs
Buildings Construction

Roof
beams
Beams

Walls Columns

Footings

PREFABRICATED BUILDING STRUCTURES 9/119


2. PRECAST STRUCTURAL
ELEMENTS
Description: 2.1. Footings
DECivil
GESTEC There are precast footings
comprising a protruding
Master in Construction and Rehabilitation

pedestal on the upper face


of the foundation, box-
shaped, designed to
accommodate the lower end
Buildings Construction

of the column. They allow for


a optimisation of the
concrete and of the footing
excavation.

Some examples of
precast footings

PREFABRICATED BUILDING STRUCTURES 10/119


2. PRECAST STRUCTURAL
ELEMENTS
2.1. Footings
DECivil
GESTEC
In Portuguese
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 11/119


2. PRECAST STRUCTURAL
ELEMENTS
Description: 2.1. Footings
DECivil
GESTEC There are also precast footings with metallic anchor bolts to
ensure the mechanical connection to the column (with additional
Master in Construction and Rehabilitation

concrete, if necessary).
Buildings Construction

v01
PREFABRICATED BUILDING STRUCTURES 12/119
2. PRECAST STRUCTURAL
ELEMENTS
2.1. Footings
DECivil
GESTEC
In Portuguese
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 13/119


2. PRECAST STRUCTURAL
ELEMENTS
Description: 2.2. Columns
DECivil
GESTEC
Precast columns usually have a rectangular
section, but can also be circular.
Master in Construction and Rehabilitation

The minimum size is 300 mm to accommodate


the beam – column connection and ensure a
fire resistance of 2 hours.
Buildings Construction

They can reach a height of 12 m to 15 m.

Some examples of
prefabricated
columns
PREFABRICATED BUILDING STRUCTURES 14/119
2. PRECAST STRUCTURAL
ELEMENTS
2.2. Columns
DECivil
GESTEC
In Portuguese
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 15/119


2. PRECAST STRUCTURAL
ELEMENTS
Description: 2.3. Beams
DECivil
GESTEC Precast beams of constant inertia can overcome spans of:
- 4 to 8 m in reinforced concrete;
Master in Construction and Rehabilitation

- 4 to 25 m in prestressed concrete.
NOTE: reference values
Buildings Construction

Some examples of
precast beam
sections
PREFABRICATED BUILDING STRUCTURES 16/119
2. PRECAST STRUCTURAL
ELEMENTS
2.3. Beams
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

In Portuguese

PREFABRICATED BUILDING STRUCTURES 17/119


2. PRECAST STRUCTURAL
ELEMENTS
2.4. Roof beams
DECivil
Description:
GESTEC
Precast roof beams are elements
with a variable inertia that can
Master in Construction and Rehabilitation

overcome spans of:


- 4 to 12 m in reinforced concrete;
- 4 to 50 m in prestressed concrete.
Buildings Construction

NOTE: reference values

Sample sketch of a precast


roof beam

PREFABRICATED BUILDING STRUCTURES 18/119


2. PRECAST STRUCTURAL
ELEMENTS
2.5. Slabs
DECivil Description :
GESTEC
The main types of precast
slabs are:
Master in Construction and Rehabilitation

• Prestressed concrete
beams;
Buildings Construction

• Hollow core slabs;

• TT (or double tee) slabs;

• Floor plates.

PREFABRICATED BUILDING STRUCTURES 19/119


2. PRECAST STRUCTURAL
Minos slabs ELEMENTS
2.5. Slabs
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

In Portuguese

PREFABRICATED BUILDING STRUCTURES 20/119


2. PRECAST STRUCTURAL
ELEMENTS
2.6. Stairs
DECivil Description:
GESTEC
Precast stairs are elements that can
overcome spans up to 7 m. There are
Master in Construction and Rehabilitation

two types of flights of stairs: the


intermediate and the initial / final.
Buildings Construction

Example of precast
stairs

PREFABRICATED BUILDING STRUCTURES 21/119


2. PRECAST STRUCTURAL
ELEMENTS
2.7. Panels
DECivil Description:
GESTEC
Precast panels are
parallelepipedic elements
Master in Construction and Rehabilitation

which can be up to 12 m in
height and 3 m in width, or
vice versa.
Buildings Construction

Vertical panel

PREFABRICATED BUILDING STRUCTURES 22/119


GFRC PANEL
DECivil
GESTEC
Glass fibre reinforced
concrete
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 23/119


2. PRECAST STRUCTURAL
ELEMENTS
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 24/119


2. PRECAST STRUCTURAL
ELEMENTS
2.8. Fully prefabricated buildings
DECivil
GESTEC
Master in Construction and Rehabilitation

LinhaMais Rusticasa Neapo


Buildings Construction

www.graniminho.com

www.tsf.sapo.pt www.portugalemgrande.pt
PREFABRICATED BUILDING STRUCTURES 25/119
DECivil
GESTEC
Master in Construction and Rehabilitation

3. NON-TRADITIONAL
FLOOR SYSTEMS
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 26/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.1. Advantages and disadvantages
DECivil
PRECAST vs. CAST “in situ”
GESTEC
FLOOR SYSTEMS
Master in Construction and Rehabilitation

HIGHER SPEED OF LESS MORE ECONOMIC


EXECUTION WORKMANSHIP
Buildings Construction

LOWER
HIGHER THERMAL
DISTURBANCE OF
INSULATION
THE PUBLIC SPACE
(in lightweight slabs)

LESS SELF-
ABSENCE OF
WEIGHT
FORMWORK
(in lightweight
slabs)

PREFABRICATED BUILDING STRUCTURES 27/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.1. Advantages and disadvantages
DECivil
PRECAST vs. CAST “in situ”
GESTEC
FLOOR SYSTEMS
Master in Construction and Rehabilitation

WORSE ACOUSTIC WORSE SEISMIC


INSULATION WORSE FIRE
PERFORMANCE
(in lightweight slabs) PERFORMANCE
Buildings Construction

REPEATABILITY SLABS WITH A


OF THE SPANS RECTANGULAR
SHAPE

LOCATION OF NEED FOR


THE SITE IN LIFTING
RELATION TO THE ACCESS TO THE EQUIPMENT
PLANT SITE

PREFABRICATED BUILDING STRUCTURES 28/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.2. Types
DECivil
BEAM-AND-BLOCK
GESTEC These floor systems are made of precast concrete (reinforced or
prestressed) beams, where vault bricks/hollow blocks are laid,
providing the lightening of the floor.
Master in Construction and Rehabilitation

• WITH NORMAL CONCRETE HOLLOW BLOCKS;


• WITH FIRED-CLAY HOLLOW BLOCKS;
• WITH LIGHTWEIGHT CONCRETE HOLLOW BLOCKS;
Buildings Construction

• WITH LIGHTWEIGHT CONCRETE SOLID BLOCKS.

• REINFORCED CONCRETE Complementary concrete/ cast “in


situ” structural topping (with
secondary/distribution
reinforcement)

Beams
Blocks
PREFABRICATED BUILDING STRUCTURES 29/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.2. Types
DECivil
BEAM-AND-BLOCK
GESTEC

• PRESTRESSED CONCRETE
Master in Construction and Rehabilitation

In Portuguese
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 30/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.2. Types
DECivil
HOLLOW CORE SLABS
GESTEC These floor systems are made of precast hollow core slabs, with
constant thickness ranging between 12 and 50 cm, overcome large
spans and can support significant loads (in reinforced and, especially,
Master in Construction and Rehabilitation

in prestressed concrete ).
•PRESTRESSED CERAMIC
Buildings Construction

Estremoz
secondary
•REINFORCED CONCRETE school

31/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.2. Types
DECivil
HOLLOW CORE SLABS
GESTEC These floor systems are made of precast hollow core slabs, with
constant thickness ranging between 12 and 50 cm, overcome large
spans and can support significant loads (in reinforced and, especially,
Master in Construction and Rehabilitation

in prestressed concrete ).

• PRESTRESSED CONCRETE
Buildings Construction

NOTE: There are prestressed concrete hollow core slabs with a thickness higher
than 50 cm.
PREFABRICATED BUILDING STRUCTURES 32/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.2. Types
DECivil
HOLLOW CORE SLABS
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 33/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.2. Types
DECivil FLOOR PLATES
GESTEC
These floor systems consist
of solid slabs made of
Master in Construction and Rehabilitation

reinforced or prestressed
concrete floor plates, which
serve as formwork of a layer
of complementary concrete/
Buildings Construction

cast “in situ” structural In Portuguese


topping with a resistant Cross-
function. section
In Portuguese

Lateral
view
In Portuguese

PREFABRICATED BUILDING STRUCTURES 34/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.2. Types
DECivil FLOOR PLATES
GESTEC
Floor plate floor systems are made of:
- floor plates:
Master in Construction and Rehabilitation

- h = 5 to 10 cm, b = 0.7 m to 2.5 m, L (defined by request);


- reinforcement: longitudinal (reinforced or prestressed steel) and transversal;
- lattice girders (“treillis”) for handling and anchorage (connecting
reinforcement);
Buildings Construction

- layer of complementary concrete;


- secondary/distribution reinforcement (in current area);
- upper continuity reinforcement (over the supports).

In Portuguese

PREFABRICATED BUILDING STRUCTURES 35/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.3. Applications
BEAM-AND-BLOCK
DECivil
GESTEC • DWELLINGS
• WAREHOUSES
Master in Construction and Rehabilitation

• ROOF SUPPORTING STRUCTURE


Buildings Construction

PREFABRICATED BUILDING STRUCTURES 36/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.3. Applications
HOLLOW CORE SLABS
DECivil
GESTEC
•INDUSTRIAL AND COMMERCIAL BUILDINGS (CAST IN SITU
AND PRECAST REINFORCED CONCRETE, METALLIC, AND MIXED STRUCTURES)
Master in Construction and Rehabilitation

• RESIDENTIAL BUILDINGS
• PARKING BUILDINGS
Buildings Construction

• FOOTBALL STADIUMS

0.21

0.36

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3. NON-TRADITIONAL FLOOR
SYSTEMS
3.3. Applications
HOLLOW CORE SLABS
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 38/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.3. Applications
DECivil
FLOOR PLATES
GESTEC
• RESIDENTIAL AND COMMERCIAL BUILDINGS
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 39/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.3. Applications
DECivil
FLOOR PLATES
GESTEC
• RESIDENTIAL AND COMMERCIAL BUILDINGS
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 40/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.4. Performance
DECivil
GESTEC STRUCTURAL LOADS SUPPORTED:
SELF-WEIGHT

SAFETY BUILDING ASSEMBLIES


Master in Construction and Rehabilitation

LIVE LOADS

•REDUCED SELF-WEIGHT ALLOWS ACCIDENTAL IMPACTS


UNDER NORMAL USE
THE LIGHTENING OF THE SUPPORT
STRUCTURE INTERNAL STRESSES
Buildings Construction

DILATIONS AND CONTRACTIONS


BEAM-AND-BLOCK (HYDROTHERMAL VARIATION)
• POOR SEISMIC PERFORMANCE
• LOWER HORIZONTAL BRACING
The structural behaviour is similar to a slab with unidirectional steel reinforcement but, for it
to be, it is necessary to ensure and maintain the adherence between the complementary
concrete and the beams.
HOLLOW CORE SLABS
• LIMITATIONS ON THE POSITIONING OF CONCENTRATED SUSPENDED LOADS
• EFFECTIVE BRACING
the structural behaviour is similar to a monolithic slab with unidirectional steel reinforcement,
after a small complementary concrete casting.
PREFABRICATED BUILDING STRUCTURES 41/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.4. Performance
DECivil
GESTEC
FIRE “REGULAMENTO DE SEGURANÇA CONTRA
INCÊNDIOS EM EDIFÍCIOS DE HABITAÇÃO”
RESISTANCE (FIRE SAFETY REGULATION IN RESIDENTIAL
Master in Construction and Rehabilitation

BUILDINGS, in Portuguese)

ENABLE THE ESCAPE / EVACUATION OF THE


OCCUPANTS

STABILITY OF THE FLOOR SYSTEM


Buildings Construction

ELIMINATE THE RISK OF COLLAPSE FOR A


CERTAIN PERIOD OF TIME (30 TO 90 MINUTES)

BEAM-AND-BLOCK
• BEAMS AND FIRED-CLAY BLOCKS ARE FROM M0 CLASS (NON-COMBUSTIBLE)
• WORSE PERFORMANCE THAN TRADITIONAL SOLUTIONS (DUE TO
PRESTRESSED WIRES THAT DO NOT RECOVER THEIR CHARACTERISTICS AFTER BEING
EXPOSED TO HIGH TEMPERATURES, RISK OF BRITTLE FAILURE AND LOWER TCRIT)

HOLLOW CORE SLABS


• WORSE PERFORMANCE THAN TRADITIONAL SOLUTIONS
• 15 cm SLAB, Rf = 76 minutes 20 cm SLAB, Rf = 126 minutes
PREFABRICATED BUILDING STRUCTURES 42/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
PRECAST ELEMENTS 3.4. Performance
DECivil
GESTEC THERMAL
ACOUSTIC
INSULATION
Master in Construction and Rehabilitation

“REGULAMENTO DAS CARACTERÍSTICAS DE INSULATION


DESEMPENHO TÉRMICO DOS EDIFÍCIOS” AIRBORNE AND PERCUSSION
(Regulation of the characteristics of thermal SOUNDS INSULATION
behaviour of buildings, in Portuguese)
Buildings Construction

EFFECTIVE WEAK
BEAM-AND-BLOCK
•BLOCKS FAVOUR THERMAL INSULATION
• FIRED-CLAY AND LIGHTWEIGHT CONCRETE (WITH EXPANDED CLAY)

HOLLOW CORE SLABS


• DEPENDS ON THE TYPE OF COATING
PREFABRICATED BUILDING STRUCTURES 43/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.4. Performance
DECivil
GESTEC
STRUCTURAL FIRE
Master in Construction and Rehabilitation

SAFETY RESISTANCE
THERMAL ACOUSTIC
Buildings Construction

INSULATION INSULATION

SOLID FLOOR PLATES


• PERFORMANCE SIMILAR TO CAST IN SITU SOLID SLABS (WITH
UNIDIRECTIONAL STEEL REINFORCEMENT )

LIGHTWEIGHT FLOOR PLATES (NOT USUAL)


• PERFORMANCE DEPENDS ON THE TYPE OF LIGHTENING
PREFABRICATED BUILDING STRUCTURES 44/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 45/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
3.5.1. PRESTRESSED BEAMS – PRODUCTION PROCESS
Master in Construction and Rehabilitation

• CASTING BEDS
LENGTH - 100 m
EXITS - TOPS AND SIDES
CONCRETE PLANT
Buildings Construction

(plan view)

PREFABRICATED BUILDING STRUCTURES 46/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
• CLEANING OF CASTING BEDS 3.5. Execution
DECivil CLEAN DIRT
GESTEC AUTOMATIC: MACHINE WITH ROTATING BRUSHES
MANUAL: USE OF HOSE AND BROOM
Master in Construction and Rehabilitation

• APPLICATION OF RELEASE AGENT


AVOID THE ADHERENCE OF CONCRETE TO THE BED
AUTOMATIC: SPREADER DEVICE (MACHINE)
MANUAL: WATERING CAN
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 47/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
• PLACEMENT OF STEEL WIRES
DECivil
WIRES ARE STORED IN COILS
GESTEC
EXTENDED MANUALLY
FIXED AT THE ENDS
MOORING STRUCTURE
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 48/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation

• PRESTRESS APPLICATION
USING A HYDRAULIC JACK
PROTECTION PANEL
MANOMETER – ADEQUATE PRESSURE (STEEL WIRE)
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 49/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
• CASTING
DECivil
MACHINE WITH THE MOLD OF THE BEAMS
GESTEC
RECEIVE CONCRETE ON THE UPPER PART
WIRE-GUIDES (ON THE FRONT OF THE MACHINE)
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 50/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC • AGGREGATES (STORAGE AND DOSAGE)
SEPARATED SILOS ACCORDING TO THE SIZING
CONVEYOR BELTS
Master in Construction and Rehabilitation

CONCRETE PLANT
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 51/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil • CURING
GESTEC RESISTANCE REQUIRED TO CONCRETE
NATURAL – ATMOSPHERIC MOISTURE
ACCELERATED – HEATED STEAM
Master in Construction and Rehabilitation

USE OF ADEQUATE ADDITIVES (CONCRETE)

• PRESTRESS TRANSMISSION (RELEASE OF


WIRES)
FROM STEEL WIRES TO CONCRETE (2 PROCESSES)
- GRADUAL LOOSENING - RELEASE
Buildings Construction

- WIRE CUTTING

PREFABRICATED BUILDING STRUCTURES 52/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC • CUTTING OF THE BEAMS
CUTTING MACHINE WITH GRINDING WHEEL
PREVIOUSLY DEFINED LENGTHS
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 53/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
• LIFTING AND TRANSPORT 3.5. Execution
DECivil IDENTIFIED (PRODUCTION DATE AND DIMENSION)
GESTEC BRIDGING CRANE WITH FIXING CLIPS
TRANSPORT BY FORKLIFTS
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 54/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
• STORAGE AND DISPATCH 3.5. Execution
DECivil SEPARATED IN GROUPS
GESTEC
STACKED AND SUPPORTED BY WOOD RAFTERS
KEPT IN CASTING POSITION
SHIPMENT AND TRANSPORT TO A CONSTRUCTION SITE - FORKLIFT
Master in Construction and Rehabilitation
Buildings Construction

0.14

PREFABRICATED BUILDING STRUCTURES 55/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil PRODUCTION DEFECTS
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

• COMPRESSIVE STRENGTH (CONCRETE)


INSUFFICIENT STRENGTH

• PRESTRESS IN THE BEAMS


DEFICIENT TRANSMISSION
EXCESSIVE PRESTRESS LOSSES (SLIPPAGE OF THE WIRES)

• WIRE POSITIONING
PRESTRESSING WIRES POSITIONING
ABSENCE OF ADEQUATE COVER
PREFABRICATED BUILDING STRUCTURES 56/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
• OTHER
TREAD THE BEAM (WHEN WITHOUT CONSISTENCY) • BEAM REUSE
GESTEC
DROP THE BEAM / FORKLIFT FENCE POSTS
FAILURE IN CASTING (CONCRETE) FILLINGS BELOW FOUNDATIONS
Master in Construction and Rehabilitation

WATERJET THAT DEFORMS THE BEAM


FAILURE IN CONCRETE SUPPLY
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 57/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
3.5.2. CONCRETE HOLLOW BLOCKS - PRODUCTION
PROCESS
NOTE: FIRED-CLAY HOLLOW BLOCKS ARE THE MOST USED IN THIS FLOOR SYSTEM
Master in Construction and Rehabilitation

• CLEANING OF THE PLATES


AVOID CONCRETE ADHESION
WASTE CLEANING
Buildings Construction

• STATIC MACHINE
PLACEMENT OF THE MOLD IN THE PLATES
CONCRETE POURING INSIDE THE MOLDS
BLOCK VIBRATION
MANUAL INSPECTION
STORAGE IN A HUMID AREA
STACKING AND WRAPPING UP WITH PLASTIC

PREFABRICATED BUILDING STRUCTURES 58/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil • STATIC MACHINE
GESTEC
Master in Construction and Rehabilitation

• MOBILE MACHINE
OUTDOOR PRODUCTION
AUTOMATIC MACHINE (CASTING AND
VIBRATION)
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 59/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
A 3.5. Execution
Barreira A
DECivil 3.5.3. FIRED-CLAY HOLLOW BLOCKS -
Fábrica PRODUCTION PROCESS
GESTEC
Master in Construction and Rehabilitation

Montes
BB

Doseador Doseador A – Raw materials exploitation


B – Raw materials storage
C – Pre-preparation of clay
A - Exploração de Matérias Primas
Buildings Construction

Desterroador Amassador Secador D – Preparation of clay de Matérias Primas


B - Armazenamento
FF C - Pré-preparação do Barro
E – Block molding (extrusion)
D - Preparação do Barro
E - Moldagem de Abobadilhas por Extrusão
F – Block drying
F - Secagem de Abobadilhas
Desintegrador Laminador
G – Block firing
G - Cozedura de Abobadilhas
D
D
H - Embalagem e Armazenamento de Abobadilhas
H – Packaging and storage of the blocks
Laminador Forno
GG

Amassador Fieira
EE

Apodrecedor Armazém
CC HH

In Portuguese Clientes

PREFABRICATED BUILDING STRUCTURES 60/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
A) EXPLOITATION 3.5. Execution
DECivil METAL
3) SCREEN FEEDER 4) DISAGGREGATION
GESTEC DETECTOR
Master in Construction and Rehabilitation
Buildings Construction

C) CLAY PRE-PREPARATION
1) CLAY PIT

2) STOCKPILE

5) GRINDING 6) LAMINATOR

7) KNEADER 8) ROTTING PROCESS


B) STORAGE PREFABRICATED BUILDING STRUCTURES 61/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
D) CLAY PREPARATION 3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation

9) FEEDER 10) MIXER 11) LAMINATOR


Buildings Construction

E) MOLDING

EXTRUDER MOLD CUTTING MACHINE

F) DRYING G) FIRING E) PACKAGING 62/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
PRODUCTION DEFECTS OF FIRED-CLAY HOLLOW
BLOCKS
• craters due to carbonates;
Master in Construction and Rehabilitation

• lamination;
• cracks from the onset of drying, of heating and firing (kiln area);
• reduction stains;
Buildings Construction

• drying, firing and storage efflorescences;


• other defects / non-conformities:
- dimensional deviations of the pieces (≤ 5mm);
- expansion due to high humidity (≤ 0.65 mm);
- insufficient flexural strength (≤ 1 kN).

PREFABRICATED BUILDING STRUCTURES 63/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
3.5.4. BEAM-AND-BLOCK - ASSEMBLY
GESTEC
FLOOR COMPOSITIONS
Master in Construction and Rehabilitation

• BEAMS
CLASS C35/45 CONCRETE (EN 206-1)
STEEL WIRES CLASSES Y1670C and Y1770C

• HOLLOW BLOCKS
Buildings Construction

LATERAL NIBS – SUPPORTED BY THE FLANGES (BEAM)


FIRED-CLAY, LIGHTWEIGHT AGGREGATES (EXPANDED CLAY) OR CONCRETE BLOCKS

• COMPLEMENTARY CONCRETE
CLASS C20/25 CONCRETE (EN 206-1)
COMPLEMENTARY
STEEL WIRES CONCRETE BEAM HOLLOW BLOCKS

PREFABRICATED BUILDING STRUCTURES 64/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution

In Portuguese
In Portuguese
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 65/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction


0.16

PREFABRICATED BUILDING STRUCTURES 66/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 67/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
3.5.5. BEAMS – ON-SITE INSTALLATION
• RECEPTION OF MATERIALS
Master in Construction and Rehabilitation

STORAGE IN AN APPROPRIATE AREA


Buildings Construction

• LEVELLING OF SUPPORTS
FOR LAYING THE BEAMS

• ASSEMBLY OF PROVISIONAL SHORING


INTERMEDIATE SUPPORT OF THE BEAMS

PREFABRICATED BUILDING STRUCTURES 68/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC • FORMWORK ASSEMBLY
OF MAIN BEAMS (WHEN CASTED SIMULTANEOUSLY WITH THE PRECAST BEAMS)
AND OF SOLID AREAS
Master in Construction and Rehabilitation

• PLACEMENT OF THE BEAMS


Buildings Construction

IN PARALLEL
SPACING BETWEEN – WIDTH OF THE BLOCKS

PREFABRICATED BUILDING STRUCTURES 69/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC • HOLLOW BLOCK PLACEMENT
BETWEEN THE BEAMS – SUPPORTED BY THE FLANGES
Master in Construction and Rehabilitation
Buildings Construction


0.17 0.23  0.35

PREFABRICATED BUILDING STRUCTURES 70/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC • SECONDARY/DISTRIBUTION REINFORCEMENT
REINFORCEMENT PLACEMENT IN TRANSVERSAL SOLID BRACINGS
WELDED STEEL MESH (CONTINUOUS) PLACEMENT
Master in Construction and Rehabilitation
Buildings Construction

0.18

• PLACEMENT OF WOODEN WALKWAYS


WORKERS AND CONCRETE CIRCULATION

PREFABRICATED BUILDING STRUCTURES 71/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
• ABUNDANT WATERING
TO IMPROVE ADHESION STRENGTH (COMPLEMENTARY CONCRETE)
Master in Construction and Rehabilitation

• CASTING AND REGULARISATION (COMPLEMENTARY CONCRETE)


POURING AND COMPACTION
Buildings Construction

0.45 0.17 
0.21 
0.27

• MAINTENANCE OF CONCRETE MOISTURE CONTENT


DURING THE EARLY DAYS OF HARDENING

PREFABRICATED BUILDING STRUCTURES 72/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
3.5.6. CONSTRUCTIVE DETAILS
GESTEC

• TRANSVERSAL SOLID BRACINGS


SOLID RIBS WITH
Master in Construction and Rehabilitation

i) 10 cm MINIMUM WIDTH
ii) PERPENDICULAR TO THE BEAMS
iii) MAXIMUM 2 m SPACING BETWEEN
iv) REINFORCED WITH 2 STEEL BARS ABOVE THE
BEAMS (2φ12, IN GENERAL)
Buildings Construction

FUNCTION: TRANSVERSAL BRACING OF THE SLABS

PREFABRICATED BUILDING STRUCTURES 73/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
3.5.6. CONSTRUCTIVE DETAILS
GESTEC

• EDGE SUPPORTS
Master in Construction and Rehabilitation

- 10 cm MINIMUM SUPPORTED LENGTH – PRECAST BEAM LENGTH OVER


SUPPORTING BEAM
- SOLID AREAS (40 cm) WITH MINIMUM TOP REINFORCEMENT – PROVIDE SOME
RESISTANCE TO M- (CRACKING CONTROL)
Buildings Construction

Longitudinal direction Transversal direction

PREFABRICATED BUILDING STRUCTURES 74/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
• CONTINUITY SUPPORTS
1) SOLID LATERAL CONNECTION
Master in Construction and Rehabilitation

(CONNECTION OF THE BEAM WITH CONTIGUOUS


FLOOR)

NOTE: MUST BE SOLID 40 cm FOR EACH SIDE


OF THE SUPPORT (WITH Astop)
Buildings Construction

2) LIGHTWEIGHT LATERAL CONNECTION


(LATERAL END CONNECTION WITH A SUPPORTING
BEAM)

NOTE: SOLUTION TECHNICALLY


WORSE THAN THE PREVIOUS
ONE

PREFABRICATED BUILDING STRUCTURES 75/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
• CONTINUITY SUPPORTS

3) SUPPORT IN A BEAM WITH CONTINUITY


Master in Construction and Rehabilitation

NOTE: MUST BE SOLID 40 cm FOR EACH


SIDE OF THE SUPPORT (WITH Astop)
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 76/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil • LATERAL SUPPORT
GESTEC SOLID AREA IN A LATERAL CONNECTION
THE EXECUTION OF A SOLID AREA WITH TOP (CONNECTION TO THE CAPPING STIRRUP)
REINFORCEMENT IS ADVISABLE (CAPABLE OF
ABSORBING TENSILE STRESSES - CRACKING
Master in Construction and Rehabilitation

CONTROL)
Buildings Construction

LIGHTWEIGHT LATERAL CONNECTION


(END CONNECTION WITH TWO BEAMS)

END CONNECTION WITH A BEAM


AND A WIDER BLOCK

PREFABRICATED BUILDING STRUCTURES 77/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC • PARTITION WALLS
- INCREASE OF THE DISTRIBUTION
REINFORCEMENT
Master in Construction and Rehabilitation

- INSTALLATION OF
SUPPLEMENTARY BEAMS

• SUSPENDED LOADS (EQUIPMENT)


Buildings Construction

- BLOCKS DO NOT HAVE ENOUGH STRENGTH


- SUITABLE ACCESSORIES (IN THE CEILING)

• OPENINGS
- REMOVAL OF ONE OR MORE BLOCKS BETWEEN BEAMS
- TRANSVERSAL BEAMS (CALCULATED)

PREFABRICATED BUILDING STRUCTURES 78/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
• CANTILEVER
SOLID CANTILEVER
Master in Construction and Rehabilitation

WITH BEAMS
INTERRUPTION ON THE
FLOOR
(CANTILEVER PARALLEL TO
Buildings Construction

THE BEAMS)

In Portuguese

CANTILEVER
PERPENDICULAR
TO THE BEAMS
(LATERAL CONNECTION)
In Portuguese

PREFABRICATED BUILDING STRUCTURES 79/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
3.5.7. BEAM-AND-BLOCK COMPARED WITH TRADITIONAL
GESTEC
FLOORS - ADVANTAGES AND DISADVANTAGES
BETTER THERMAL INSULATION
Master in Construction and Rehabilitation

DO NOT REQUIRE THE USE OF A CONTINUOUS FORMWORK


ALLOW THE LIGHTENING OF THE SUPPORT STRUCTURE
FAST AND EASY ASSEMBLY
Buildings Construction

MORE ECONOMIC (WORKMANSHIP AND FORMWORK)

UNIDIRECTIONAL BEHAVIOUR
WORSE ACOUSTIC INSOLATION
POOR SEISMIC PERFORMANCE
LESSER HORIZONTAL BRACING
HETEROGENEOUS CONSTITUTION OF THE FLOORS
SPECIAL ACCESSORIES TO SUSPEND LOADS ON CEILINGS
(ABSENCE OF) RESISTANCE TO NEGATIVE BENDING MOMENTS
WORSE FIRE PERFORMANCE
REQUIRE HIGH QUALITY WATERPROOFING
PREFABRICATED BUILDING STRUCTURES 80/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 81/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC 3.5.8. HOLLOW CORE SLABS – PRODUCTION PROCESS
• CASTING BEDS
Master in Construction and Rehabilitation

• CLEANING OF THE CASTING BEDS


• APPLICATION OF THE RELEASE AGENT
• PLACEMENT OF STEEL STRANDS
• PRESTRESS APPLICATION
Buildings Construction

• CONCRETE PLANT

0.17 
0.14

PREFABRICATED BUILDING STRUCTURES 82/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil • MOLDING
GESTEC
Master in Construction and Rehabilitation


0.10 1.01
Buildings Construction

• CURING
• PRESTRESS TRANSMISSION

PREFABRICATED BUILDING STRUCTURES 83/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
• HOLLOW CORE SLAB CUTTING
Master in Construction and Rehabilitation

• LIFTING AND STORAGE


Buildings Construction

• TRANSPORT AND DISPATCH

PREFABRICATED BUILDING STRUCTURES 84/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil 3.5.9. HOLLOW CORE SLABS - ASSEMBLY
GESTEC
• CONCRETE
PRESTRESSED BY ADHERENT STEEL STRANDS
Master in Construction and Rehabilitation

CLASS C40/50 (EN 206-1)


• STEEL STRANDS
USED ON PRESTRESS
CLASSES Y1770S and Y1860S
• COMPLEMENTARY CONCRETE
Buildings Construction

CASTED OVER THE SLABS


CLASS C20/25 (EN 206-1)
CORES CONCRETE STEEL STRANDS

In Portuguese
PREFABRICATED BUILDING STRUCTURES 85/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil 3.5.10. HOLLOW CORE SLABS – ON-SITE INSTALLATION
GESTEC
• RECEPTION OF MATERIALS
STORAGE IN AN APPROPRIATE AREA
Master in Construction and Rehabilitation

PLACEMENT OF THE SLABS USING CRANES


• LEVELLING OF SUPPORTS
FOR SLAB PLACEMENT 
0.36

• CLEANING AND WATERING OF THE SLABS


Buildings Construction

TO IMPROVE THE CONNECTION WITH CAST IN SITU CONCRETE

• PLACEMENT OF TOP REINFORCEMENT


PRIOR TO COMPLEMENTARY CONCRETE LAYER 
0.36

• CASTING OF TIE JOINTS


WATERING OF CAST IN SITU CONCRETE
CLEANING OF THE UPPER SURFACE
TREATMENT OF BOTTOM JOINTS AND SURFACE

0.40

PREFABRICATED BUILDING STRUCTURES 86/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. execution
DECivil
GESTEC
Master in Construction and Rehabilitation


Buildings Construction

0.40

2.52

PREVIOUS PROCEDURES INSTALLATION

PROJECT FOR ON-SITE PLACEMENT AND STORAGE ORGANISATION OF THE CONSTRUCTION


PRECAUTIONS: WORK:
• SLAB CLEANING; • ABSENCE OF FORMWORK;
•HORIZONTAL ARRANGEMENT; • LOW LABOUR NEEDS;
• STACKING LOWER THAN 1.5 m IN HEIGHT; • CRANE – SLAB HANDLING;
• INSTALLATION OF WATERPROOFING • TWO WORKERS ON THE EDGES.
MEMBRANES.
PREFABRICATED BUILDING STRUCTURES 87/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

1.55

LATERAL
SUPPORTS

AFTER HOLLOW CORE SLAB PLACEMENT:


●SURFACE WATERING;
●VERIFY REINFORCEMENT IN THE SUPPORTS;
●COVERING THE CORES OF THE SLABS;
●CAST AND VIBRATE THE JOINTS.
PREFABRICATED BUILDING STRUCTURES 88/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
• ASSEMBLY DETAIL
Master in Construction and Rehabilitation
Buildings Construction

In Portuguese
PREFABRICATED BUILDING STRUCTURES 89/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
• ASSEMBLY DETAIL
Master in Construction and Rehabilitation
Buildings Construction

In Portuguese
PREFABRICATED BUILDING STRUCTURES 90/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil 3.5.11. HOLLOW CORE SLABS – CONSTRUCTIVE
GESTEC
DETAILS
• HIGH VERSATILITY;
Master in Construction and Rehabilitation

• SUPPORTED IN (i) LOAD-BEARING


MASONRY WALLS, OR IN (ii) REINFORCED
CONCRETE OR (iii) METALLIC
BEAMS/STRUCTURES;
Buildings Construction

• SUPPORTED LENGTH ≥ 4 cm;


• OPENINGS - USE OF SPECIAL METALLIC
ACCESSORIES (TRANSFERENCE OF LOADS
TO ADJACENT PANELS);
• WELDED STEEL MESH;
• COMPLEMENTARY CONCRETE  2.11

(COMPRESSION LAYER, MONOLITHISM


BETWEEN PANELS, CONTINUITY BETWEEN
FLOOR SPANS WITH TOP REINFORCEMENT).

PREFABRICATED BUILDING STRUCTURES 91/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
• DISTRIBUTION REINFORCEMENT
PLACED WITHIN THE COMPLEMENTARY CONCRETE LAYER
GESTEC
Master in Construction and Rehabilitation

• SLAB TYING/ ANCHORAGE (SUPPORTS)


Buildings Construction

EDGE OF THE BOARDS WITH 7.5 cm SUPPORTED LENGTH

• SUPPORT REINFORCEMENT
SUPPORT AREA WITH A SALIENCE
OPENINGS FOR THE SUPPORTS (ON SITE)

PREFABRICATED BUILDING STRUCTURES 92/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
•DIRECT SUPPORT
GESTEC
THE EDGE OF THE SLAB RESTS OVER A SUPPORT
Master in Construction and Rehabilitation
Buildings Construction

• INDIRECT SUPPORT
THERE IS NO BASE UNDER THE EDGE OF THE SLAB

PREFABRICATED BUILDING STRUCTURES 93/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
In Portuguese

METALLIC
Master in Construction and Rehabilitation

PROFILE
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 94/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation

DOUBLE SUPPORT
Buildings Construction

PRECAST BEAM

SINGLE SUPPORT
PRECAST BEAM

PREFABRICATED BUILDING STRUCTURES 95/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
• MOUNTINGS TO THE BOTTOM FACE
MADE DURING CONSTRUCTION WORKS
GESTEC
PLACED VERTICALLY WITHIN HOLLOWS
Master in Construction and Rehabilitation

• CUTS
LONGITUDINAL CUT
SLAB SEPARATION
TRANSVERSAL CUT
CORNER CUT
Buildings Construction

• OPENINGS
SUPPORT OF THE SLAB

• CANTILEVER AREA
SOLID SLAB

PREFABRICATED BUILDING STRUCTURES 96/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil 3.5.12. HOLLOW CORE SLABS COMPARED WITH
GESTEC
TRADITIONAL FLOORS
Master in Construction and Rehabilitation

• FASTER EXECUTION; • MODULARITY OF THE STRUCTURE IS


REQUIRED;
• HIGH PRODUCTION CAPACITY
(REPETITION); • POOR ACOUSTIC INSULATION;
Buildings Construction

• ABSENCE OF FORMWORK AND SHORING • WORSE FIRE PERFORMANCE;


• REDUCTION OF THE STRUCTURE SELF-
WEIGHT; • LIMITATIONS TO THE APPLICATION OF
• EFFICIENT THERMAL INSULATION; CONCENTRATED SUSPENDED LOADS;

• SUPERIOR QUALITY CONTROL • HEAVY EQUIPMENT FOR INSTALLATION;


(PREFABRICATION); • NEED FOR ADEQUATE
• GOOD RESISTANCE TO ATMOSPHERIC TRANSPORTATION MEANS;
AGENTS; • EXISTENCE OF APPARENT JOINTS.
• EFFECTIVE BRACING OF THE STRUCTURE.

PREFABRICATED BUILDING STRUCTURES 97/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil 3.5.12. HOLLOW CORE SLABS COMPARED WITH BEAM-
GESTEC
AND-BLOCK FLOOR SYSTEMS
• HOMOGENEOUS BOTTOM SURFACE;
Master in Construction and Rehabilitation

• SELF-SUPPORTING;
• POSSIBILITY OF ABSENCE OF COATINGS
ON THE BOTTOM SURFACE;
• HIGHER RESISTANCE TO
Buildings Construction

CONCENTRATED LOADS;
• FASTER EXECUTION;
• LESS EXPENSIVE HAND LABOUR

• GOOD RESISTANCE TO MECHANIC


ACTIONS AND TO THERMAL VARIATIONS;
• JOINT CRACKING DUE TO DIFFICULTY OF
CONCRETE ENTRANCE;
• LESS THERMAL INSULATION;

• HEAVY WEIGHT EQUIPMENT (CRANE);


• PRICE.
PREFABRICATED BUILDING STRUCTURES 98/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 99/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
3.5.13. PRODUCTION PROCESS
GESTEC
Floor plates are casted in metallic casting beds whose lateral
faces (vertical) define the outline and the height of the
Master in Construction and Rehabilitation

element to be casted.
The walls of the casting beds are made of removable metallic
profiles, and the top profiles have slots to place the
Buildings Construction

longitudinal reinforcement at the right level.

Metallic casting bed for the molding of floor plates


PREFABRICATED BUILDING STRUCTURES 100/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
PRESTRESSED FLOOR PLATES PRODUCTION PROCESS

- placement of separators;
Master in Construction and Rehabilitation

- placement of prestressing steel;

- placement of transversal reinforcement;


Buildings Construction

- prestress application;

- casting, pouring and compaction of


concrete;

- scratching (during the curing);

- floor plates cutting (orders).


Floor plate scratching
process
PREFABRICATED BUILDING STRUCTURES 101/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC 3.5.14. FLOOR PLATES - ASSEMBLY
Reinforced floor plates
Master in Construction and Rehabilitation

- Class C20/25 concrete (EN 206-1);


- Class 500 plain welded steel mesh;
- Class 400 ribbed steel bars as the main reinforcement;
Buildings Construction

- Class 400 plain bars in the “treillis” anchorage reinforcement.

Prestressed floor plates


- Class C35/45 concrete (EN 206-1);
- Prestressing steel wires of class Y1770C of low relaxation;
- Plain bars in hanging hooks (4 or 6 hooks per floor plate).

PREFABRICATED BUILDING STRUCTURES 102/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC 3.5.15. FLOOR PLATES - ON-SITE INSTALLATION
The execution of solid slab floors using floor plates should
Master in Construction and Rehabilitation

follow, in common situations, the next procedures:


Buildings Construction

1) Placement and levelling


of the shoring lines next to
the supports and on the
central area of the floor
plates, transversally to these;

Floor plates shoring


PREFABRICATED BUILDING STRUCTURES 103/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC 2) Placement of the floor plates,
juxtaposed, and their adjustment;
Master in Construction and Rehabilitation

3) Installation of necessary
complementary shoring, depending
on the span and on the total
thickness of the slabs and on the
Buildings Construction

live loads resulting from the


Installed floor plates execution;

4) Placing the floor reinforcement over the supports and


reinforcement over the joints between floor plates, to improve their
tying and the performance in case of fire or earthquake;
5) Cleaning and watering of the upper surface of the floor plates
using a water jet, in order to avoid desiccation and to improve the
adhesion to complementary concrete;

PREFABRICATED BUILDING STRUCTURES 104/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC 6) Casting, pouring, regularisation and
compaction of complementary concrete,
ensuring its perfect adherence to the exposed
Master in Construction and Rehabilitation

surfaces of the floor plates and the


maintenance of the required thickness of the
concrete layer above the floor plates;
7) Maintenance of concrete moisture content
Buildings Construction

on-site (curing), during the early days of


hardening, via watering, keeping the casted
Concrete pouring surface moist ;
8) Treatment of the joints and of the bottom
surface of the floor plates depending on the
coating material to be applied, after shoring
removal in accordance with minimum
regulatory periods.

Concrete regularisation PREFABRICATED BUILDING STRUCTURES 105/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
3.5.16. FLOOR PLATES – CONSTRUCTIVE DETAILS
GESTEC

DISTRIBUTION REINFORCEMENT
Master in Construction and Rehabilitation

Floors made with floor plates


must include, within the
complementary layer, a distribution
reinforcement of area not lower than
Buildings Construction

the one referred to in the technical


approval.

FLOOR PLATE ANCHORAGE Floor plates to be casted together with the beam

In the floors casted together with the beams that support them, floor
plates should be supported on the beam’s formwork. Main and
secondary reinforcement should be extended inside the beam, in order
to guarantee an adequate anchorage length.

PREFABRICATED BUILDING STRUCTURES 106/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil SIMPLE SUPPORTS
GESTEC
In simple supports, a reinforcement must be installed next to the
upper face of the floor, made with bars spaced 250 mm maximum
Master in Construction and Rehabilitation

and with a length of L/10, counted from the internal surface of the
floor support. This reinforcement, when there is no bending
moment in the support, must be calculated for a value of 15% of the
Buildings Construction

ultimate resisting moment.

Simple support

PREFABRICATED BUILDING STRUCTURES 107/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil SUPPORTS WITH CONTINUITY
GESTEC
Slabs made with floor plates in which there is continuity over the
supports must be reinforced for design bending moments (M-Ed). The
Master in Construction and Rehabilitation

reinforcement design must follow a similar procedure of the one used


in the design of solid slabs and in accordance with regulation in force.
Buildings Construction

Continuous support
PREFABRICATED BUILDING STRUCTURES 108/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
JOINTS BETWEEN FLOOR PLATES 3.5. Execution
DECivil
GESTEC • aim: transversal anchorage of the floor plates (important also for
seismic action); reduction of the risk of cracking of the bottom
Master in Construction and Rehabilitation

surface of the floors, especially when traditional mortar coatings


are used (in which strips of textile fibre or a metallic mesh should
be applied);
• a reinforcement in orthogonal web must cover the space between
Buildings Construction

the treillis neighbours of the joint;


• area of the reinforcement bars of the joint ≥ distribution
reinforcement;
• maximum spacing of 0.25 m in both directions;

Joints between plates


PREFABRICATED BUILDING STRUCTURES 109/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC
- In lateral vertical faces L reinforcements must be placed next to the
lateral faces of the plate, during the production stage; this
reinforcement is complemented by a continuity reinforcement
Master in Construction and Rehabilitation

installed on-site in order to guarantee the anchorage between floor


plates;
- extra care should be given during shoring installation of floor plate
joints , in order to guarantee the levelling of the bottom face of the
Buildings Construction

floor plates.

In Portuguese
Joint between floor plates with a L reinforcement
PREFABRICATED BUILDING STRUCTURES 110/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC 3.5.17. FLOOR PLATES COMPARED WITH TRADITIONAL
FLOORS - ADVANTAGES AND DISADVANTAGES
Master in Construction and Rehabilitation

Advantages:
- need for a small shoring amount and do not require the use
of a continuous formwork;
- require less hand labour than a traditional concrete slab,
Buildings Construction

simplifying the construction process and making it faster;


- reduce the quantity of reinforcement to be installed on-site;
- Allow a high quality control of the concrete and steel used in
floor plate production;
- guarantee a good bracing for seismic actions.

PREFABRICATED BUILDING STRUCTURES 111/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.5. Execution
DECivil
GESTEC Disadvantages:
- need to provide adequate equipment for floor plate
Master in Construction and Rehabilitation

handling;
- problems may arise at the interface of complementary
concrete / floor plate, due to possible mechanical actions,
vibrations or effects from accentuated thermal variations;
Buildings Construction

- its execution requires particular care to ensure the


connection between the floor plate and the complementary
concrete;
- possible cracking in the areas of connection between floor
plates, when there are continuous ceiling coatings;
- the profitability of the solution is associated to span
repetitions.

PREFABRICATED BUILDING STRUCTURES 112/119


3. NON-TRADITIONAL FLOOR
SYSTEMS
3.6. Quality control
DECivil
GESTEC
ON-SITE RECEPTION: VERIFICATIONS

• PRODUCER BRAND
Master in Construction and Rehabilitation

TECHNICAL CHARACTERISTICS SHEETS

• MATERIAL CORRESPONDS TO THE PROJECT


ORDER FORMS

• DIMENSION OF THE ELEMENTS


Buildings Construction

REINFORCEMENT POSITION
• ROUGHNESS
IN LATERAL AND TOP SURFACES – CONCRETE ADHERENCE
• TOLERANCES
DEVIATIONS THAT MAY BE ACCEPTABLE (MARGIN OF ERROR)

BEAMS HOLLOW

LENGTH 20 mm
CORE SLABS
20 mm
REJECT
•CRACKING PENETRATING TO
WIDTH 5 mm 15 mm
THE INTERIOR
THICKNESS 5 mm • VOIDS IN CONCRETE
PREFABRICATED BUILDING STRUCTURES 113/119
3. NON-TRADITIONAL FLOOR
SYSTEMS
3.6. Quality control
DECivil FLOOR PLATES
GESTEC

- floor plates must not present concrete cracks or flaws;


Master in Construction and Rehabilitation

- the surface of contact between the floor plates and the


complementary concrete should present roughness;
- the difference of length of the floor plate regarding the order
should not exceed 20 mm;
Buildings Construction

- the cross section should not vary by more than 5 mm regarding


the order;
- main reinforcement should not deviate more than 3 mm vertically,
and 5 mm horizontally, in relation to the expected position;
- the lateral curvature of the floor plate should not exceed L/500 or
10 mm;
- prestressed floor plates should not present a camber higher than
L/300, for normal support conditions and when subjected to their
self-weight.

PREFABRICATED BUILDING STRUCTURES 114/119


DECivil
GESTEC
Master in Construction and Rehabilitation

4. REFERENCES
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 115/119


4. REFERENCES
“Ligações de Estruturas Prefabricadas de “Design of Multi-storey Precast Building
Betão” Structures”
Santos, S. Pompeu FIP recommendations - Thomas Telford
DECivil LNEC, 1985 Londres, 1994
GESTEC
“Ligações entre Elementos Prefabricados de “FIB Congress 1994 - Part C: Prefabrication”
Betão” Fédération Internationale de la Précontrainte
Londres, 1982
Master in Construction and Rehabilitation

Santos Silva, A.
IST, 1998
“Draft Guide for Design of Precast Wall
“Solução Prefabricada para um Edifício de Connections”
Grandes Vãos” Comité Euro-Internacional du Béton
Lúcio, V; Santiago, A. Lausanne, 1988
Buildings Construction

Congresso de Betão Estrutural 96


Lisboa, 1996 “Le Guide di modulo - Le costruzioni
prefabbricate”
“Aspectos práticos da prefabricação de Maria Piagnataro e Ettore Zambelli
paredes em painéis pesados” F.B.M - Milano
Branco, J. P. 1ª Edizione 1986
Edição do LNEC
“Prefabrication with concrete”
Catálogos de empresas Bruggling, A. S. G.;Huygue, G. F.
A. A. Balkema, Rotterdam 1991
 Civibral;
 Concremat; “Manual de la Construcción Prefabricada”
 Martifer; Koncz, T.
 Pavicentro; Editorial Blume
 Prainsa. Barcelona, 1968

PREFABRICATED BUILDING STRUCTURES 116/119


4. REFERENCES
• BRITO, Jorge de - Folhas de apoio à disciplina Tecnologia da Construção de
Edifícios 2002/2003
DECivil
GESTEC • PAVICENTRO - Catálogo Técnico, CD-ROM (imagens, filmes e ficheiros DXF)

• Documento de Homologação, LNEC - DH574 “PREMOLDE-LAP: Pavimentos


Master in Construction and Rehabilitation

aligeirados de pranchas prefabricadas de betão pré-esforçado” - Lisboa, 1999

• SECIL-PRÉBETÃO - Catálogos de Apresentação

• PAVIPREL - Catálogos de Apresentação


Buildings Construction

• PREFABRICADOS CASTELO - Catálogo Técnico, CD-ROM (imagens, filmes


e ficheiros DXF)

• ASSAP
• MAPREL - Painéis alveolares em lajes de edifícios, Porto, 1997 (Dossier Técnico)

• Regulamento de Estruturas de Betão Armado e Pré esforçado,


Decreto-Lei n.º 349-C/83, de 30 de Julho

• SOLOARQUITECTURA – Manual AIDEPLA, imagens e filmes (Espanha)

PREFABRICATED BUILDING STRUCTURES 117/119


4. REFERENCES

• GRUPPO CENTRO NORD - Manual e imagens


DECivil
GESTEC • LNEC - A qualidade em Pavimentos com Elementos Prefabricados, Lisboa 1983

• LNEC - Vãos Máximos de Lajes com Vigotas, Lisboa 1991


Master in Construction and Rehabilitation
Buildings Construction

PREFABRICATED BUILDING STRUCTURES 118/119


DECivil
GESTEC
Master in Construction and Rehabilitation
Buildings Construction

Trabalho realizado com o apoio do Programa


Operacional Sociedade da Informação - POSI
PREFABRICATED BUILDING STRUCTURES 119/119

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