Consolis Technical Guide & Product Manual

Consolis Technical guide & product manual
CONSOLIS IN BRIEF
Consolis is the largest manufacturer of prefabricated concrete elements in Europe. The company has more than 50 factories and operates in 11 countries: Finland, Sweden, Norway, Germany, the Netherlands, Estonia, Russia, Latvia, Lithuania, the Czech Republic and Poland. Consolis produces a wide range of prefabricated concrete products such as floors, structures and walls. These products are used in the construction of buildings. Consolis also makes products for infrastructure, such as railway sleepers and structures for bridges and tunnels. In addition Consolis provides services ranging from planning to erection of its products. Through its market leadership and international presence, Consolis offers customers the benefits of: the latest solutions and technology transfer within the Group unique benchmarking possibilities pan-European purchasing power extensive design and engineering resources production capacity sufficient to deal with the largest projects. Consolis works actively with environmental issues associated with construction. By prefabrication Consolis can reduce environmental burden both during the construction period and the total building life cycle. In 2003 Consolis had net sales of EUR 620 million and employed 5,000 employees at the year end. Consolis was formed in December 1997 following the merger of Partek Precast Concrete and the Swedish company Strngbetong. Consolis major shareholders are the Swedish private equity fund Industri Kapital, KONE and various Finnish insurance companies. Management also has a shareholding in Consolis.
Elematic Parma Strngbetong Spenncon Consolis Headquarters / Consolis Technology
E-Betoonelement
Parastek Consolis Latvija
Betonika
DW Beton Spanbeton VBI Consolis Polska
Dywidag Prefa Lys
CONTENTS
1
1.1 1.2 1.3 1.4
General
Consolis potential Quality guarantee Prefabrication, when and why Standards and technical guidelines Concrete quality Fire resistance Performance curves Notations
5.2 5.3 5.4 5.5 5.6
Purlins Rectangular beams L-beams & inverted T-beams SI-beams I-beams
8.7 8.8 8.9
Balconies and terraces Grey walls Acotec walls
9
9.1
Bashallen
System description TT-roof slabs Faades Details and connections
1.5 1.6 1.7 1.8
6
6.1 6.2 6.3 6.4
Hollow core slabs

Standard profiles Characteristics Performance curves Structural topping Precamber Diaphragm action Concentrated loading Openings Connections Match plates Production tolerances Handling and transport Erection
9.2 9.3 9.4
10
10.1 10.2 10.3
Faades
Sandwich faades Cladding panels Special architectural elements Details and connections
2
2.1
Frame structures
Low-rise utility buildings
2.1.1 2.1.2
6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13
Single-storey buildings Low-rise buildings with intermediate floors Horizontal stability
10.4
2.1.3 2.2
Multi-storey buildings
2.2.1 2.2.2 2.2.3
11
Stability Diaphragm action Modular design
Infrastructural projects
Precast bridges Culverts Railway products
11.3.1 11.3.2 11.3.3
11.1 11.2
7 3
3.1 3.2 3.3 3.4 3.5 3.6
Double-T-slabs
Standard profiles Characteristics TT-2400 Characteristics TT-3000 Performance curves TT-2400 Performance curves TT-3000 Connections Holes and voids Production tolerances Handling and transport
11.3
Columns
Characteristics Corbels Performance curves Connections Tolerances Betemi columns
7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8
Railway sleepers Railway crossings Railway platforms
12
Special products
12.1
Water treatment systems Agricultural products Other special products
12.2 12.3
Pocket foundations Beams

General
5.1.1 5.1.2 5.1.3 5.1.4
7.9
5
5.1
8
8.1 8.2 8.3 8.4 8.5 8.6
Residential buildings
Architectural freedom Structural systems Sound insulation Bathroom floors Foundation units Stairs
13
Addresses
Types Supports Inserts Lifting and temporary storage Production tolerances
5.1.5
1.
General
GENERAL
The aim of the Group is to offer its customers the most advantageous comprehensive solutions for various types of buildings and infrastructure projects, based on precast concrete products together with related services.
2
1.1 CONSOLIS POTENTIAL

The Consolis Group is Europe's leading manufacturer of precast concrete elements. active in prefabrication for more than 70 years annual production : floors frames faades 5000 workers and employees 250 engineers for the design of the precast structures, working with sophisticated CAD systems and calculation programs. R&D Unit with testing laboratory and staff of 25 people To work with Consolis means to get the best solutions for your projects, in a qualitative, environmentally friendly and price efficient way. 7.000.000 m 140.000 m 600.000 m
3 2
The strength of the Group relies on a large staff of design engineers and a research laboratory to raise the quality of end products and the efficiency of the construction process by continually developing and applying state of the art technologies.
more than 50 production plants in 11 European countries
1.2 QUALITY GUARANTEE

Consolis precast products are synonymous with high quality. Every product mentioned in this technical guide is certified by a notified national body. Conforming to the international standard ISO 9001 (CEN 29001), the quality assurance of design and manufacture is based on the principle of self control and is certified by a third party. Consolis' internal quality control service is continuously checking the concrete strength, positioning of the reinforcement and inserts, dimensions of the units and finishing for every product. All data is registered in files and is available to customers and certification bodies.
Apartment building
Office building
Industrial building
Sport complex
1.3 PREFABRICATION: WHEN AND WHY

ious purposes is not a new method. On the contrary, it has been used since the beginning of the twentieth century. Prefabrication technology has continually been refined and developed since then. Compared with traditional construction methods or other building materials, prefabrication, as a construction method, and concrete, as a material, have a number of positive features. It is an industrialized way of construction, with the inherent advantages of: High capacity - enabling the realization of important projects Factory made products Shorter construction time - less than half of conventional cast in-situ construction It offers the customer the performance to fulfill all requirements Continuing erection in Winter time until -20C Quality surveillance system
Opportunities for good architecture Fire resistant material Healthy buildings Reduced energy consumption through the ability to store heat in the concrete mass Environmentally friendly way of building, with optimum use of materials, recycling of waste products, less noise and dust etc. Cost effective solutions
When to use precast concrete

Most buildings are suitable for construction in precast concrete. Buildings with an orthogonal plan are, of course, ideal for precasting because they exhibit a degree of regularity and repetition in their structural grid, spans, member size, etc. Irregular ground layouts are, on many occasions, equally suitable for precasting. Modern precast concrete buildings can be designed safely and economically with a variety of plans and with considerable variation in treatment of the elevations to heights up to twenty floors and more. With the introduction of high strength concrete, already currently used in Consolis' business units, the sizes of load bearing columns can be reduced to less than half of the section needed in conventional concrete structures. Precast concrete offers considerable scope for improving structural efficiency. Longer spans and shallower construction depths can be obtained by using prestressed concrete for beams and floors. For industrial and commercial halls, roof spans can be up to 40 m and even more. For parking garages, precast concrete enables occupiers to put more cars on the same construction space because of the large span possibilities and slender column sections. In office buildings, the modern trend is to create large open spaces, which can be split with partitions. This not only offers flexibility in the building but also extends its life because of the easier adaptability. In this way, the building retains its commercial value over a longer period.
Long line prestressing beds
General
To prefabricate - to precast - concrete components for var-
Independent of adverse weather conditions
1.4 STANDARDS AND TECHNICAL GUIDELINES
General
The calculation of the performance curves given in this Technical Guide are based on the following European Standards and Technical Guidelines: CEN European Committee for Standardization, EN 1992-1-1 Eurocode 2: Design of concrete structures Part 1: General rules and rules for buildings. CEN European Committee for Standardization, EN 1992-1-2 "Eurocode 2: Design of concrete structures - Part 1.2 General rules - Structural fire design. CEN European Committee for Standardization, CEN/TC 229 Precast concrete product standards.
FIP Commission on Prefabrication, "FIP Recommendations Precast Prestressed Hollow Core Floors", Thomas Telford Ltd, London 1988. FIP Commission on Prefabrication, "Planning and design handbook on precast building structures", - SETO Ltd, London 1994. fib Commission on Prefabrication, Guide to good practice "Special design recommendations for precast prestressed hollow core floors", fib bulletin 6.
1.5 CONCRETE QUALITY

The concrete is usually made with normal aggregates and grey Portland cement. For faade units, special aggregates and white Portland cement with colour pigments may be used. Depending on the application of the products, the following concrete strength classes are used: The elements are designed for an exposure class corres Characterictic strength C 40 (Characteristic cylinder strength fck = 40 MPa, cube strength fck = 50 MPa, according to Eurocode 2): Prestressed beams, columns, TT-slabs, prestressed hollow core units, Characterictic strength C 35 (Cylinder strength 35 MPa, cube strength 45 MPa): Products in reinforced concrete. ponding to moderate exposed environmental conditions (moderate humidity, normal frost-thaw). Design for more severe exposure classes - like, for example, in swimming pools - is possible. Special units, for example columns or beams, can be made in high strength concrete, grade C80 (Cylinder strength 80 MPa, cube strength 95 MPa). The application may be indicated to limit the weight or the construction depth of the units.
Shear test on hollow core slab
Workability test fresh concrete
1.6 FIRE RESISTANCE

Precast building structures in reinforced and prestressed concrete normally assume a fire resistance of 60 to 120 minutes and more. For industrial buildings, the normal required fire resistance of 30 to 60 minutes is met by all types of precast components without any special measure. For other types of buildings, a fire resistance of 90 to 120 minutes is obtained by increasing the concrete cover on the reinforcement. The above fire ratings are based on the requirements set forth in Eurocode 2, Part 1-2 "Structural fire resistance" and confirmed by a large number of fire tests on precast concrete units in fire laboratories all over Europe.
1.7 PERFORMANCE CURVES

The performance curves in this guide give indicative values for the maximum admissible applicable permanent and variable load versus span. They can be used for marketing and preliminary dimensioning of the precast members, but not for the final design. They are calculated according to the requirements of the Eurocodes. The self-weight of the components has already been taken into account. The curves are calculated for a proportioning of 50% permanent and 50% variable loading. Please contact our technical staff for other load combinations. Detailed calculations are carried out for each project at the design stage. The indicated performances correspond with the maximum allowable prestressing force per unit. For the final design, the exact prestressing force is determined for the given loading condition, and will not always correspond with the maximum possible prestressing. Checks for adaptations of existing constructions at a later stage should always refer to the final design documents and drawings. Consolis will advise on request.
1.8 NOTATIONS
a b bw d h support length total width cross section web width camber height cross-section partial length warping characteristic variable loading characteristic compressive cylinder strength of concrete at 28 days cd C H L Md Mu design compressive stress in the concrete allowable stress strength class of concrete (expressed as cylinder strength of concrete at 28 days) horizontal force length precast unit design value of bending moment ultimate bending moment N Nd Nu R axial force design value of axial force ultimate axial force standard fire resistance
Hall for prefabrication of hollow core slabs
l
u qk fck
General
2.
Frame and skeletal structures
FRAME AND SKELETAL STRUCTURES
2.1 LOW-RISE UTILITY BUILDINGS

2.1.1 Single-storey buildings
Normally, the skeleton of a single-storey industrial building is composed of a series of basic portal frames. Each frame comprises two columns with moment-fixed connections at the foundations and a pin-joined roof beam. The latter can be with either a sloped pane or a straight profile. The building is normally stabilized by the cantilever action of the columns. The horizontal load action on the gable walls can be distributed to all columns by the diaphragm action of the roof. The distance between the portal frames is governed by the span of the roof and the faade construction.
Industrial hall during construction
Skeletal structural systems are very suitable for buildings which need a high degree of flexibility, because of the possibility of using large spans and to achieve open spaces without internal walls. This is very important in industrial buildings, shopping halls, parking structures and sporting facilities, and also in large office buildings.
The roof can be made with prestressed hollow core elements or with light TT-units or steel sheet deck. The distance between the portal frames is governed by the span of the roof and faade construction - normally between 6 and 9 m for hollow core roof slabs and from 9 to 12 m for light TT-roof units. When steel sheet deck is used, the distance between the portal frames can be larger - up to 12 m and even 16 m- because of the lighter weight of the roof. Secondary beams are generally needed to support the steel sheet deck.
Building structure with sloped I-profile beams and TT-roof slabs
Another solution for large halls is to use large span roof units supported on rows of columns and straight beams. The roof units are saddle TT-slabs or light TT-roof units. The span of the roof units can be up to 32 m. For straight
TT-units, the roof slope is obtained by alternating the height of the supporting beam rows. At the faades, the walls. roof slabs can be supported on beams, or on load bearing
Saddle TT-roof slabs on load-bearing sandwich walls
Straight light TT roof slabs on longitudinal portal frames
2.1.2 Low-rise buildings with intermediate floors
In buildings basically constructed as single-storey structures, it may be necessary to insert intermediate floors in some parts or in the whole building. This is commonly achieved by adding a partly separate beam/column assembly to carry the intermediate floor slabs. The loads on the floors are generally much larger than on the roof. Consequently, the spans will normally be shorter. Span A - as indicated on the Figure - will normally be between 6 m and 18 m, depending upon the live loads and the type of floor slab selected. A good module for span B is 7.20 m to 9.60 m.
A
2.1.3 Horizontal stability

Low-rise skeleton structures are normally stabilized through the cantilever action of the columns. The precast columns are fixed into the foundations with moment-resisting connections. This is easily achievable in good ground or with pile foundations. There are three basic solutions: bolted connections, projecting reinforcement and pockets. In the bolted connection, the column baseplate is fixed to the
Bolted connection
foundation bars with nuts. With projecting reinforcement, projecting bars from the foundation or from the column are fixed into grouted openings in the columns or in the foundation respectively. In the case of pockets, the column is fixed into the pocket with grout or concrete.
Projecting reinforcement
Pocket foundation
Precast frame for papermill
The cantilever action of the columns is used to stabilize low-rise buildings with to about 3 floor levels. The columns are normally continuous for the full height of the structure. Horizontal forces acting on the building are transferred through the faade to the internal frame structure. Other horizontal actions - for example from overhead cranes - are taken up directly by the columns. It is important to spread the acting forces over all the columns in the building to avoid different cross-sections.
Actions and resulting moments/forces on a portal frame structure
Hollow core slabs
Roof beam
Horizontal stiffness
Faade
Horizontal forces parallel to the beams are distributed directly through the beams of the same row, whereas forces in the transverse direction are transferred through the in-plane action of the roof. For buildings with high slender columns, the horizontal stiffness of the structure can be secured by diagonal bracing between the columns of the external bays with the help of steel rods, angles or
Column
concrete beams.
Expansion joints
Socle
The design and detailing of frame structures takes into account the dimensional dilatations due to temperature changes, shrinkage and creep. Expansion joints are chosen in conjunction with the length and the cross-section of the columns. Generally, the distance between expansion joints
Pocket foundation
is not larger than 60 m. They are realized either by using double columns or special bearing pads.
beam-column systems, up
2.2 MULTI-STOREY BUILDINGS
Multi-storey precast concrete frames are constructed with columns and beams of different shapes and sizes, stair and elevator shafts and floor slabs. The joints between the floor elements are executed in such a way that concentrated loads are distributed over the whole floor. This system is widely used for multi-storey buildings.
The structural frame is commonly composed of rectangular columns of one or more storeys height (up to four storeys). The beams are normally rectangular, L-shaped or inverted T-beams. They are single span or cantilever beams, simply supported and pin-connected to the columns. Hollow core floor slabs are by far the most common type of floor slabs in this type of structure.
2.2.1 Stability
For buildings up to 3 or 4 storeys, horizontal stability may be provided by the cantilever action of the columns. They are normally continuous for the full height of the structure. However, for multi-storey skeleton stuctures, braced systems are the most effective solution, irrespective of the number of storeys. The horizontal stiffness is provided by staircases, elevator shafts and shear walls. In this way, connection details and the design and construction of foundations are greatly simplified. Central cores can be cast in-situ or precast.
Example of precast central core
Building with central core and hidden beam-column connections
2.2.2 Diaphragm action

In precast multi-storey buildings, horizontal loads from wind or other actions are usually transmitted to the stabilizing elements by the diaphragm action of the roofs and floors. The precast concrete floors or roofs are designed to function as deep horizontal beams. The structural central core, shear wall or other stabilizing components act as supports for these analogous beams with the lateral loads being transmitted to them. The tensile, compressive and shear forces are resisted by peripheral tie reinforcement of the floor, and grouted longitudinal joints.
2.2.3 Modular design

Modulation is an important economic factor in the design and construction of precast buildings, both for the structural parts and the finishing. The use of modular planning is not a limitation on the freedom of planning as it is only a tool to achieve systematic work and economy and to simplify connections and detailing. Precast concrete floors are extremely versatile and can accommodate almost any arrangement of support walls or beams. There are, however, certain guidelines on the proportioning of a building in plan which can be usefully employed to simplify the construction. The width of the When exact modulation is not possible, it may be necessary to produce a special unit cast to a smaller width or cut to the desired width from a standard module. Changes in floor level across a building can also be readily accommodated, for example by split-level bearings on a single beam or the use of twinned beams at different levels. When a building tapers in plan, the precast units are produced with non-square ends. The angle should not be more than 45. At the apex of a tapered floor area, it may be appropriate to cover this area with in-situ concrete when the span falls below 2 m. precast floor units is modulated on 1200 and 2400 mm. When planning a building it is advisable to modulate dimensions to suit the element widths. In a simple structure, all the floor elements should preferably span in the same direction, simplifying the layout and, in the case of prestressed elements, limiting the number of camber clashes within a bay.
Example of modulated floor layout and location of components
3.
COLUMNS
Precast columns are manufactured in a variety of sizes, shapes and lengths. The concrete surface is smooth and the edges are chamfered. Columns generally require a minimum cross-sectional dimension of 300 x 300 mm, not only for reasons of manipulation but also to accommodate
300 400 500
Columns
the column-beam connections. The 300 mm dimension provides a two-hour fire resistance, making it suitable for a wide range of buildings. Columns with a maximum length of 20 m to 24 m can be manufactured and erected in one piece, i.e. without splicing, although a common practice is to work also with single-storey columns.
3.1 CHARACTERISTICS
3.1.1 Rectangular columns
Profile 300/300 300/400 400/400 400/500 500/500 500/600 600/600 h mm 300 300 400 400 500 500 600 b mm 300 400 400 500 500 600 600 Weight kN/m 2.20 2.94 3.92 4.90 6.12 7.35 8.82
300 b 300 h
3.1.2 Round columns
Profile round columns 300 400 500 600
Diameter mm 300 400 500 600
Weight kN/m 1.73 3.08 4.81 6.92
3.2 CORBELS
Precast columns may be provided with single or multiple corbels to support floor or roof beams, girders for overhead cranes, etc. The corbels are either completely under the beam or within the overall depth of it. This may occur, for example, where it is unacceptable for the connection to project below ceilings or into service zones. Standard dimensions for normal corbels are given in the table. The indicated values for the allowable support load "N" are characteristic values without partial safety margins.
b h
h
300 105 kN 145 kN 140 kN
400 145 kN 205 kN 265 kN
500 185 kN 260 kN 335 kN
300 400 500
b b
300 300
Hidden corbels
The BSF system consists of a hidden steel insert in the beam-to-column connection, enabling a beam support without underlying corbel. A sliding plate fits into a rectangular slot in the beam. A notch at the end of the plate fits over a lip at the bottom of a steel box cast into the column. The system can be used for both rectangular and round columns. The types of corbels and corresponding bearing capacities are given in the table.
Plate type height/ thickness 150/20 200/20 200/30 200/40 200/50 250/50
Allowable load in kN 200 300 450 600 700 950
Minimum beam dimensions mm Height 200 200 300 400 400 400 Width 400 500 500 600 700 900
BSF application
Columns
3.3 PERFORMANCE CURVES

The following figures give the performance curves of columns under axial loading combined with bending moments. The calculations are made for modulated cross-sections, from 3Mx3M (300x300mm ) to 6Mx6M for rectangular columns
2
and 3M to 6M for round columns. The indicated values for Nd and Md are design values at ultimate limit state, which means that the permanent and variable actions are multiplied by the appropriate safety margins.
Columns
15000 14000 13000 12000 11000 10000

Nd (kN)
600x600 600x500
8000 7000 6000 5000 4000 3000 2000 1000 0 0 100 200 300 400 500 600
400x300 300x300 400x400 500x500 500x400
700 800 900 1000 1100 1200 1300 1400 1500

Md (kNm)
Performance curves for rectangular columns
11000 10000 9000 8000 7000

Nd (kN)
600
6000 5000 4000 3000 2000 1000 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
300 400 500
Md (kNm)
Performance curves for round columns
3.4 CONNECTIONS
Precast columns are fixed to the foundations with pockets, projecting reinforcing bars or holding down bolts. The first solution is mainly used for foundations on good soil; the second and third in the case of foundation piles.
Grout filling or alternative polyurethane filling Corner pockets with anchor bars welded to plate
Doweled connection with bolting
Column splicing with baseplate and bolts
Bolted connection through continuous beam
Injection with shrinkage free grout Joint fill with grout or concrete Projecting reinforcement in grouted tube
Corner pockets with anchor bars welded to plate
Foundation pocket
Grouted connection
Bolted connection with baseplate
Columns
Column-to-column splices
Column-to-column splices are made either by bolting mechanical connectors anchored in the separate precast components or by the continuity of the reinforcement through a grouted joint.
Columns
Nut and washer Baseplate
Leveling shims
3.5 TOLERANCES
1. Length (L): 2 3 4 5 6 7 8 9 Cross-section (b, h, d): Curvature (a): Orthogonality cross-section (p): Orthogonality end face (s): Position corbel: (l k): Dimensions corbel (l k , bk, hk): Orthogonality corbel face (r): transversal: depth: 10 Position holes, voids:
1)
10mm or L/1000 10mm
1)
10 mm or L / 750 5mm 5mm 8mm 8mm 5mm 10mm 5mm 20 mm
1)
r hk p h a L b
Position inserts (t): longitudinal: 15mm
d Whichever is the larger tl tt
tl
3.6 BETEMI COLUMNS

3.6.1 System
Betemi circular columns are produced automatically by shotcreting technique. The surface can be in grey troweled concrete or polished. It is possible to produce a variety of surface textures by using coloured concrete and different types of aggregates. In the latter case, only the final coat has to be of this more expensive material. Grey concrete can be used in the inner part. Load-bearing or decorative columns are the main applications. The columns are generally one storey high. Their maximum height is 4 m and the maximum diameter 1.2 m. Also conical shapes can be produced.
Balcony supporting decorative comumns
3.6.2 Applications
Cast in-situ concrete
Load-bearing columns
3.6.3 Connections
Connections are easy to make in Betemi columns. Two methods can be applied: Steel pocket cast into the column for bolted connections Protruding bars anchored in the column core with cast in-situ concrete.
Column reinforcement welded to steel corners
Columns
4.
POCKET FOUNDATIONS
h
Precast pocket foundations realize the site-work faster and cheaper. Indeed, site-cast pockets need a rather complex moulding and reinforcement, and the working conditions are more unfavourable. Consolis has developed a series of pocket foundations for different column sizes. The precast pocket foundations may only be used in conditions of firm and level ground. The pockets are positioned by means of leveling bolts. The baseplate is cast on site. The whole unit can also be precast.
Pocket foundations
Characteristics
a mm 700 800 800 1000 1000 1100 1100 b mm 700 700 800 900 1000 1000 1100 c mm 150 150 150 200 200 200 200 h mm 550 700 700 850 850 1000 1000 Max. column section 300/300 300/400 400/400 400/500 500/500 500/600 600/600
Foundation pockets on stockyard Infill grout
In situ or precast footing
Precast columns during erection
5.
BEAMS
5.1 GENERAL
5.1.1 Types
Overview of the types of prestressed beams for different applications
Purlins: trapezoidal secondary roof beams
R-beams: rectangular roof or floor beams for moderate spans
RF-beams: rectangular floor beams for composite action with floor slabs
RT-beams: inverted T-beams for floors of middle to large spans
RL-beams: L-beams for edge floors
I-beams: for roofs and large floor-beam spans
SI-beams: roof beams with sloped pans for large spans
The cross-section of the beams is standardized. The prestressing force and the beam length is adapted to each specific project. The units are provided with details and
inserts for connections and other specific purposes - for example, for fixings, openings, etc.
Beams
5.1.2 Supports
Large precast elements are normally supported on elastomeric supporting pads in neoprene rubber to ensure a good distribution of the stresses over the contact area. The effective bearing length is determined by the ultimate bearing stress in both the abutting components and the bearing pad, plus allowances for tolerances and spalling risk at the edges. The maximum allowable stress on neoprene pads in the serviceability limit state is normally: For non-reinforced elastomeric pads: For reinforced elastomeric pads: = 6 N/mm
2 2
The pads should be placed at some distance from the support edge as load transfer at the edge may result in damage. The pad should allow for beam deflection so that direct contact between the beam and the support edge is avoided.
= 12 N/mm
5.1.3 Inserts
Inserts are details embedded in a precast unit for the Steel plates, profiles and steel angles Rolled channel Openings, etc. The possible location and load capacity of inserts depends on several parameters and will be dealt with on request by Consolis.
Beams
purpose of fixings, connections to other components, etc. There are many types of inserts, including: Projecting bars Anchor rails Threaded dowels or bolts
5.1.4 Lifting and temporary storage

Lifting points are chosen to minimize deflections. The lifting angle for the slings should not be less than 60 without spreader beam and 30 with spreader beam. Intermediate storage should preferably be on the normal support points. Temporary bracing of slender roof beams may be necessary until the secondary beams or roof slabs are erected and fixed.
5.1.5 Production tolerances

1. Length (L): 2. Cross-section (h,b): 3. Side camber (a): 4. Warping (u): 5. Verticality end face (v): 6. Cantilever end (lh , li ): 7. Orthogonality end face: 8. Camber (d): 9 Position inserts: (t) longitudinal: transversal: depth: 10 Position holes, voids (t):
1)
15 mm or L/1000 10 mm 10 mm or L/500 10 mm or L/1000 10 mm 10 mm 5 mm 10 mm or L /500 15 mm 10 mm 5 mm 20 mm

1) 1)
1)
L t t d
l l
i
1)
b1 b2
a u h2 h1
whichever is the larger
5.2 PURLINS
Purlins are used as secondary beams for roof structures with light roof cladding. The distance between the portal frames is maximum 12 to 16 m. The units are in prestressed concrete. The fire resistance is normally 60 minutes. The standard cross-section is shown in the figure below.
276
400
l
L
152
Purlins are mainly used in industrial storage buildings where light roof coverings such as steel sheet decking, corrugated slabs, cellular concrete slabs, etc. are used. The span of these elements is generally limited to about 3 bridge the distance between the portal frames. The latter can be at larger distances, up to 12 and even 16 m. In this way large open halls can be constructed in an economical way. to 5 m and secondary prestressed beams are needed to
Portal frame with secondary beams and light roof caldding
Purlins
5.2.1 Performance curves RP purlins

20 18 16
Allowable loading in kN/m
14 12 10 8 6 4 2 0 7,0 7,5 8,0 8,5 9,0 9,5 10,0 10,5 11,0 11,5 12,0
12,5
12,5
Purlins
Span l in m
The allowable loading is the sum of the weight of the roof cladding and the variable load (snow and life load), excluding the self-weight of the purlin.
5.2.2 Connections
The elements are connected to the supporting beam with protruding bars and cast in-situ concrete. For light roof structures where diaphragm action can not be achieved by the roof structure itself, the distribution of horizontal forces on the gable walls, over the external and internal columns, can be secured by diagonal bracing between the beams of the external bays, with the help of steel rods or angles.
Steel deck Insulation Roofing
Protruding reinforcement
Neoprene supporting pads
5.3 RECTANGULAR BEAMS

Rectangular beams are mainly used for roof structures, and also for floors with composite action. They are usually in prestressed concrete, although classical reinforced concrete is possible. Standard sections are shown in the table below.
l
L
Standard profiles and weight per m length

b mm h mm 400 500 550 600 650 700 800 900 1000 300 kN/m 2.94 3.67 4.04 4.41 4.78 5.14 5.88 4.90 5.39 5.88 6.37 6.86 7.84 8.82 6.74 10.55 7.96 8.58 9.80 11.03 12.25 9.56 10.29 11.76 13.23 14.70 400 kN/m 500 kN/m 600 kN/m
Compression flange
Composite floor beams

R-beams may be designed composite with the floor to enhance the flexural and shear capacity, fire resistance and stiffness. The main advantage of a composite beam structure is that it permits less structural depth for a given load-bearing capacity.The breadth of the compression flange can be increased to the maximum permitted value, as in monolithic construction. For composite action with hollow core floors, the collaborating section is through the unfilled hollow core. This comprises only the top and bottom flanges of the slab. Detailed information about the load-bearing capacity is available from the technical department.
Rectangular beams
5.3.1 Performance curves R-beams

160 150 140 130
130 110 100 90 80 70

0 40 0/ 50
60 0/ 40 0
10 90 00 80 0/ /5 40 0/ 70 00 4 0 0/ 0 0 40 0
60 50 40 30 20
40 0/ 30 0
Rectangular beams
10
11
12
13
14
15
16
17
18
19
20
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the selfweight of the unit. For example, the allowable loading of a beam supporting a floor, should be calculated as the sum of the self-weight and the permanent and imposed loading of the floor, without partial safety margins, and without the self-weight of the beam.
5.3.2 Connections
nut washer
slot threaded bar neoprene pad
5.4 L-BEAMS & INVERTED T-BEAMS

L-beams and inverted T-beams are typical floor beams because of the reduced overall structural depth. The beams are in prestressed or reinforced concrete. Standard Consolis cross-sections are shown in the table below. The boot width is governed by the adequate floor slab bearing distance.
400 200 500 200
200, 265, 320, 400
l
L max. 900
100, 200, 300, 400
200
200, 265, 320, 400
l
L max. 700
100, 200, 300, 400
Changes in floor level may be accommodated by either an L-beam or by building up one side of an inverted T-beam, as shown in the figure. If the change of floor level exceeds about 750 mm, a better solution is to use two L beams back to back and separated by a small gap for easier site fixing.
L-beams & inverted T-beams
5.4.1 Performance curves L-beams & inverted T-beams

160 150 150 140
130 110 100

00 /9 00 0 /5 90 0* 0/ 70 50 / 00 0* /8 60 0 00 /4 90 0 / 0* 0 00 /8 60 /5 00 0* /4 50 0* 50
90 80 70 60 50 40 30
40 0* /3 00 /7 00
20 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Span l in m
5.4.2 Beam width

The width of L-beams and inverted T-beams may be confined within the width of the column or may project forward to the column. The latter solution allows the floor units to remain plain edged. In this case, the floor modulation becomes independent of the column spacing and is thus simplified. When beams are not wider than the column width, it will be necessary to form notches in the floor units
5.4.3 Connections
The tie reinforcement between the beam and the floor is made with double bars anchored in slots in the flange of the beams.
T12 / T16
T16
5.5 SI-BEAMS
SI-beams with variable height are particularly suited for roofs with large column free spans - for example, in industrial halls. The I-shaped cross section is typical for prestressed beams. The slope of the top face is 1:16. According to Eurocodes, the SI-beam types have a fire resistance up to 120 minutes. Standard cross-sections are show in the table below.
slope 1/16
f e h bw d c
l
L
Profile SI 900/500 SI 1050/500 SI 1200/500 SI 1350/500 SI 1500/500 SI 1650/500 SI 1800/500 SI 1950/500
h 900 1050 1200 1350 1500 1650 1800 1950
b 500 500 500 500 500 500 500 500
c 150 150 150 150 150 150 150 150
d 190 190 190 190 190 190 190 190
e 95 95 95 95 95 95 95 95
f 150 150 150 150 150 150 150 150
bw 120 120 120 120 120 120 120 120
Lmin 6000 6000 8000 10000 12000 14000 15000 16000
Lmax 12000 12000 16000 20000 25000 28000 30000 32000
5.5.2 Connections
neoprene pad
SI-Beams
5.5.1 Characteristics
5.5.3 Performance curves SI-beams

160 150 140 130
00 27 SI 550 2 00 SI 24 50 SI 22 0 0 SI 21 SI 50 19 0 SI 180 50 16
120 110 100 90 80

SI SI SI 50 13
SI
SI
00 15
70
SI
00 12
60 50 40 30
SI 0 90
50 10
SI-Beams
20 8 10 12 14 16 18 20 22 24 26 28 30 32 34
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the self-weight of the unit.
5.5.4 Weight of the SI-beams

kN
400
SI 2700
350 300 250 200

SI 1350 SI 1500 SI 1800 SI 1650
SI 2550 SI 2400 SI 2250 SI 2100 SI 1950
150 100 50 0 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
SI 1200 SI 1050 SI 900
Beam length L in m
5.6 I-BEAMS
I-beams are used for flat and sloped roof structures and for floor beams with heavy loading and large spans. The beams are in prestressed concrete and the fire resistance is, according to Eurocodes, up to 120 minutes.
f e h bw d c
l
L
Profile I 900/500 I 1200/500 I 1500/500 I 1800/500 h 900 1200 1500 1800 b 500 500 500 500 c 150 150 150 150 d 190 190 190 190 e 95 95 95 95 f 150 150 150 150 bw 120 120 120 120
5.6.2 Connections
neoprene pad
I-Beams
5.6.3 Performance curves I-beams

160 150 140 130
120 110 100

00 I9
I 00 15 I
90 80 70 60 50 40 30
I1 80 0
00 12
I-Beams
20 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Span l in m
The allowable loading is the sum of the permanent and variable loads acting on the beam, excluding the self-weight of the unit.
5.6.4 Weight of the I-beams

kN
400 350 300 250 200 150 100 50

00 I 18 00 I 15 0 I 120
I 900
0 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Beam length L in m
6.
HOLLOW CORE SLABS

depth and capacity, smooth underside and structural efficiency.
Prestressed hollow core slabs are the most widely used type of precast flooring. This success is due to the highly efficient design and production methods, choice of unit
6.1 STANDARD PROFILES

200
6.1.1 Extruded hollow core slab profiles

The nominal width of the units is 1200 mm, inclusive of the longitudinal joint. The various cross sections are given alongside. The edges of the slabs are profiled to ensure an adequate transfer of horizontal and vertical shear between adjacent units. The standard profiles have a fire resistance of 60 to 120 minutes. The latter is obtained by raising the level of the tendons.
125,5
189
265
152
220
The hollow core slabs are manufactured on long-line beds. The units may be manufactured with a thermal insulation layer on the under side - for example, for floors at ground level.
320
The slabs are cut to length using a circular saw. A square end is standard but skew or cranked ends, which are necessary in a non-rectangular framing plan, may be specified. Longitudinal cutting is possible for match plates.
180
280
185,5 1196 mm 4 mm Profile longitudinal joint 1196 mm 1196
275
6.1.2 Slipformed hollow core slab profiles

The nominal width of the units is 1200 mm, inclusive of the longitudinal joint. The various cross sections are given alongside. The edges of the slabs are profiled to ensure an adequate transfer of horizontal and vertical shear between adjacent units. The standard profiles have a fire resistance of 60 to 120 minutes. The latter is obtained by raising the level of the tendons.
Hollow core slabs
400
The hollow core slabs are manufactured on long-line beds. The units may be manufactured with a thermal insulation layer on the under side - for example, for floors at ground level.
The slabs are cut to length using a circular saw. A square end is standard but skew or cranked ends, which are necessary in a non-rectangular framing plan, may be specified. Longitudinal cutting is possible for match plates.
150
100 98,5
250
100 98,5
180
100 98,5
300
186 200
225
100 98,5 400
186
225 1196
Hollow core slabs
1196 mm
4 mm Profile longitudinal joint
1196 mm
6.2 CHARACTERISTICS
Extruded hollow core slabs
Weight b (joints filled) Joint filling 2 (mm) kN/m l/m2 (*) 1196 1196 1196 1196 2,60 3,80 4,10 4,65 7,0 10,0 12,0 17,0
Profile HC-200 HC-265 HC-320 HC-400
h (mm) 200 265 320 400
(*) quantity of grout needed to fill the longitudinal joints

of a floor of a given surface area.
Slipformed hollow core slabs
Profile HC-150 HC-185 HC-200 HC-250 HC-300 HC-400
h (mm) 150 180 200 250 300 400
Weight b (joints filled) Joint filling 2 (mm) kN/m l/m2 (*) 1196 1196 1196 1196 1196 1196 2,57 3,87 3,18 3,85 4,55 5,24 4,7 5,9 6,8 8,9 10,4 14,7
(*) quantity of grout needed to fill the longitudinal joints

of a floor of a given surface area.
6.3 PERFORMANCE CURVES OF HC-SLABS

The curves give the load bearing capacity with a limitation of the deflection under variable loading to 1/800 of the span
Extruded hollow core slabs
14
2
13 12 11
HC
10 9 8 7 6 5 4 3 2 1 4 5
10
11
12
13
14
15
16
17
Span l in m
Hollow core slabs
16 15
H CE
CE H
H CE
E 20 0
5 26
32 0
0 40
Slipformed hollow core slabs
16 15 14 13
2
12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 8 9 10 11 12 13 14 15 16 17
0 20 S HC 80 S1 HC 50 S1 HC
S HC 0 25
S HC 0 30
CS H 0 40
Span l in m
Hollow core slabs
6.4 STRUCTURAL TOPPING

Hollow core floors are normally used without structural topping. However, in the case of seismic action, frequent changes of load or important point loads, a topping may be indicated. The thickness should be at least 40 mm, concrete quality C 30.
6.5 PRECAMBER
Prestressed concrete units are subjected to precamber, depending on the magnitude and centroid of the prestressing force, modulus of rigidity of the cross section and length of the unit. The graph below gives an indication of the minimum and maximum expected average deflection of non-loaded elements after 1 month of storage. Possible tolerances are given in clause 6.11. The design should take account of the precamber in determining the thickness of the topping and screeds and the final levels after finishing - for example, for door thresholds, etc.
mm
40
30 20
10
0 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Span l in m
6.6 DIAPHRAGM ACTION

The diaphragm action of hollow core floors is realized through a good joint design. The peripheral reinforcement plays a determinant role, not only to cope with the tensile forces of the diaphragm action but also to prevent the relative horizontal displacement of the hollow core units, so that the longitudinal joints can take up shear forces. required by Eurocode 2, is shown in the figure below. The positioning and minimum proportioning of ties,
L2 + L3 x 20 kN/m 70 kN 2 A A B B
L3
L2
L1 x 20 kN/m 70 kN 2 C C 70 kN L2 + L3 x 20 kN/m 70 kN 2
L1
L1 x 20 kN/m 70 kN 2
20 kN/m
Hollow core slabs
6.7 CONCENTRATED LOADING

Floors composed of prestressed hollow core elements behave almost as monolithic floors for transverse distribution of line or point loads. The loads are transmitted through the profiled longitudinal joints. The transversal distribution should be calculated according to the prescriptions of Eurocode 2 and CEN Product Standard.
6.8 OPENINGS
Holes in hollow core floors are made as indicated in the figure. The dimensions are limited to the values given in the table. Small holes may be formed at the center of the longitudinal voids. The maximum size is limited to the width of the void. Holes are normally made in the fresh concrete during the production process. The edges of the openings are rough. The possible dimensions for openings are given in the table.
l /b
Corner (1) Front (2) Edges (3) Center (4) - round holes - square openings
HC 180 - 300 600/400 600/400 1000/400 Core minus 20mm 1000/400
HC 400 600/300 600/200 1000/300 135 1000/200
4 4
2 1
Hollow core slabs
Larger voids which are wider than the width of the precast units are 'trimmed' using transverse supports such as steel angles or concrete beams. The steel angles can be supplied by Consolis on request.
6.9 CONNECTIONS
6.9.1 Bearing length
The nominal bearing length of simply supported hollow core floor units is given in the table. Neoprene strips ensure a uniform bearing.
Support length a Supporting material Concrete or steel Brick masonry Slab thickness 265 mm 300 mm 265 mm 300 mm Nominal length 70 mm 100 mm 100 mm 120 mm Minimum effective length 50 mm 80 mm 80 mm 100 mm
In-situ concrete tie beam a
6.9.2 Support connections
Tie bar in longitudinal joint Tie bar in transversal joint
Tie bar placed in longitudinal joints through opening in beam Tie bar for diaphragm action Topping Tie bar floor diaphragm Tie steel in joint
Neoprene In-situ concrete Lifting loops or vertical bars used for connection with floor slabs
In-situ concrete
Hollow core slabs
6.9.3 Connections at longitudinal joints

These are provided between the edges of the hollow core floor units and beams or walls running parallel with the floor. Their main function is to transfer horizontal shear, generated in the floor plate by diaphragm action.
Reinforcement
In-situ concrete
6.10 MATCH PLATES

Non-standard plates with a width less than 1200 mm are cut in the green concrete during the casting of the line. The place of the longitudinal cut should correspond to the location of a longitudinal void. Edges cut in fresh concrete are rough. If a straight edge is needed, the slabs are sawed after hardening.
Hollow core slabs
6.11 PRODUCTION TOLERANCES

1. Length (L): 2. Thickness (h): 3. Width (b): whole slab narrow slab: 4. Orthogonality end face (p): 5. Camber before erection (d) :
2)
15 mm or L/1000 5 mm or h/40 + 0 - 6 mm 15 mm 10 mm 6 mm or L /1000 10 mm under a lath of 500 mm

1)
1)
1)
6. Warping: 7. Flatness (y) : 8. Steel inserts, installed in the factory (t): 9. Holes and recesses (t): cut in fresh concrete: cut in hardened concrete:
1) 2)
10 mm or L /1000
3)
20 mm 50 mm
l
L
15 mm
Whichever is the larger Deviated from the calculated deflection (including precamber and calculated deflection under loading circumstances) Valid for slabs h 300 mm p a y
t t t
3)
h b
6.12 HANDLING AND TRANSPORT

Handling, loading and storage arrangements on delivery should be such that the hollow core slabs are not subjected to forces and stresses which have not been catered for in the design. The units should have semi-soft (e.g. wood) bearers placed at the slab ends. Where they are stacked one above the other, the bearers should align over each other. When stacking units on the ground on site, the guidelines will be similar to the above. The ground should be firm and the bearers horizontal, such that no differential settlement may take place and cause spurious forces and stresses in the components. During handling, provisions shall be taken to ensure safe manipulation, for example safety chains under the slab.
1m Safety chain
1m
clamps hanging on a steel spreader beam. The use of a sling alone is strictly forbidden.
Hollow core slabs General
Hollow core slabs are hoisted with specially designed
6.13 ERECTION
The erection of the hollow core floor slabs should be done according to the instructions of the design engineer. If needed, Consolis can second him to supervise the construction methods. Consolis will supply written statements of the principles of site erection, methods of making structural joints and materials specification on request.
Drainage holes
Drainage holes are drilled into the voids at the slab ends to evacuate any rainwater that might penetrate during site erection. After erection, the contractor should check that the holes are open.
Joint infill and concrete screeds

The longitudinal joints between the floor units should be filled using concrete grade C25 to C30, containing an 8 mm maximum size aggregate. The floor units should be moistened prior to placement of in-situ concrete. The joints should be filled carefully since they fulfill a structural function both in the transversal load distribution and the horizontal floor diaphragm action. When a structural screed is to be used, it is advisable to fill the longitudinal
are used to compact the concrete. The screed may be power floated or rough tampered in the usual manner, depending on the type of floor finish. The topping screed should contain a shrinkage reinforcement mesh.
Hollow core slabs
joints immediately prior to the casting of the screed. The workability should give a slump between 50 and 100 mm. The wet concrete should be spread evenly over the floor area as quickly as possible. Mechanical vibrating beams
Fixings
There are several ways of fixing hanging loads to the hollow core floor - for example, special sockets drilled into the voids, anchors placed into the longitudinal joints, etc. Consolis will supply detailed information on request.
7.
DOUBLE-T SLABS
Double-T floor units in prestressed concrete have a ribbed cross-section and a smooth under face. The units are mainly used for greater spans and imposed loading. The units are manufactured with two standard widths: 2400 and 3000 mm. The standard cross-sections are given in the tables. The ends of the units can be notched to reduce the overall structural depth. A structural topping can be used to ensure both vertical shear transfer between adjacent units and horizontal diaphragm action in the floor plate. The standard double-T units have a minimum fire resistance of 60 to 120 minutes. Anchor rails can be cast into the soffits of the webs.
7.1 STANDARD PROFILES

The nominal widths of double-T units are 2400 mm and 3000 mm. However, the units can also be manufactured in a smaller width to meet the requirements of a particular project. The minimum width is 1500 mm.
b2
b1
b2
7.2 CHARACTERISTICS TT-2400

Profile Fire resistance 60 min. TT 2400-500/120 TT 2400-800/120 Fire resistance 90 min. TT 2400-500/150 TT 2400-800/150 Fire resistance 120 min. TT 2400-500/200 TT 2400 -800/200 h mm 500 800 500 800 500 800 b mm 2390 2390 2390 2390 2390 2390 b1 mm 1068 1143 1084 1159 1100 1175 b2 mm 661 623 671 615 645 607 b0 mm 120 120 150 150 200 200 Weight 2 kg/m 261 360 287 405 332 481
TT- slabs
b0
General
7.3 CHARACTERISTICS TT-3000

Profile Fire resistance 60 min. TT 3000-500/120 TT 3000-800/120 Fire resistance 90 min. TT 3000-500/150 TT 3000-800/150 Fire resistance 120 min. TT 3000-500/200 TT 3000-800/200 h mm 500 800 500 800 500 800 b mm 2990 2990 2990 2990 2990 2990 b1 mm 1368 1443 1384 1459 1400 1475 b2 mm 811 773 821 765 795 757 b0 mm 120 120 150 150 200 200 Weight 2 kg/m 232 313 254 349 290 409
TT- slabs
Super market with TT-roof
7.4 PERFORMANCE CURVES TT-2400

40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 5 6 7
TT 2400-500
TT 2400-800
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Span l in m
7.5 PERFORMANCE CURVES TT-3000

40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 5 6 7 8 9
TT 3000-800
TT 3000-500
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Span l in m
TT- slabs
General
7.6 CONNECTIONS
7.6.1 Support connections
Connections between TT floors and supporting beams are made through lapping reinforcement in the structural topping or by bars welded to plates fully anchored in the units.
Connection through structural topping
TT-slabs with slanted ends
Car park
Anchored steel plate
Steel strip Anchored steel plate
7.6.2 Edge connections

Edge connections with walls or faade units, or connections
TT- slabs
between adjacent double-T units are normally realized by lapping reinforcement in the structural topping or by steel strips or bars welded to fully anchored steel angles or plates in the units.
Transversal tie reinforcement
Welded connection
Connection between adjacent units
Welded connection with wall or faade
7.7 HOLES AND VOIDS

Holes may be formed in double-T slabs in the positions shown in the figure. The maximum dimensions are given in the table. It is also possible to form circular holes in the webs to provide a passage for services. The positions and sizes of holes and voids need to be planned in advance because they may affect the load-bearing capacity of the slabs.
b
l
b
l /b
Center Edge Corner
TT-2400 1000/630 1000/320 1000/320
TT-3000 1000/930 1000/460 1000/460
7.8 PRODUCTION TOLERANCES

1. Length (L): 2. Height slab (h), flange thickness (h1): 3. Width web (b0), width slab (b): 4. Warping (a): 5. Flange angle (p): 6. Slanting end (v): 7. Camber before erection (d) :
2)
15 mm or L/1000 10 mm 10 mm 10 mm or L/1000 10 mm 15 mm 30 mm or L/1000 20 mm 30 mm 10 mm
1)
v t2
1)
t1
t3 t4 a L p b h
1)
8. Steel inserts, holes, and voids (t): - top surface: length- and cross wise: - webs: longitudinal and vertical: - depth of steel parts:
1)
Whichever is the larger 2) Deviated from the calculated deflection (including precamber and calculated deflection under loading circumstances)
b0
7.9 HANDLING AND TRANSPORT

The TT-units should always be stacked one above the other and the soft wood bearers placed at the slab ends should also be one above the other. This also applies when loading on the truck.
The units are provided with four cast-in lifting hooks, each over the line of the webs. The slings or chains should be long enough to enable an inclination to the slab of not less than 60.
TT- slabs
tw
General
8.
RESIDENTIAL BUILDINGS
Residential buildings constitute an important activity within the Consolis Group. A construction system has been developed for single family houses, low rise and high-rise apartment buildings. The total structure includes complete outer walls, inner walls, hollowcore flooring, stairway towers and stairs, roof and balconies.
8.1 ARCHITECTURAL FREEDOM

The design of the building is not fixed by rigid concrete elements and almost every building can be adapted to the requirements of the builder or architect. There is no contradiction between architectural elegance and variety on the one hand and increased efficiency on the other. The days are gone when industrialisation meant large numbers of identical units; on the contrary, an efficient production process can be combined with skilled workmanship, which permits an architectural design without extra costs. By using the hollowcore concrete elements with spans up to 12 metres extending across the house, we can obtain floors with very large and unobstructed areas. In other words, a house with the greatest possible range of uses and longest service life. These open areas and the opportunities to easily modify the interior layout can be utilised in several ways. In new production, future residents can also be given opportunities to influence the design of their flats. In a longer perspective, the house can easily be adapted to different situations with different demands. Large rooms can be converted into small ones, and vice versa. A flat could be converted into, for example, a kindergarten, or the whole building, or parts of it, could be converted into offices.
The recently developed jointless faade is composed of internal panels in grey concrete, carrying the hollow core floors, and an insitu external skin in a special decorative concrete mix, reinforced with synthetic fabric. The thermal insulation is either placed on site, or incorporated in the precast panel.
8.2 STRUCTURAL SYSTEMS

Within the Consolis Group, systems for housing and apartment buildings are normally designed as wall-frame structures. The walls support the vertical loads from the floors and the upper structure. They can also perform only as separating walls. Central stair cases and lift shafts are constructed with precast walls As a variant, the vertical structure of the buildings can also be made with skeletal frames and infill walls.
Load bearing cross-wall system with hollow core floors spanning over 10 to 12 m
Lay-out of apartment building with load bearing faades and internal load-bearing cross-walls
Floors are usually made of hollow core elements. The latest tendency is to span the floors over the full width of the apartment. In this way one obtains not only more flexibility for the internal lay-out, but also the possibility to modify it later without major costs. The faades are normally sandwich elements. The inner leaf of the units may be load-bearing. A variant solution is to precast only the inner leaf of the faade and to clad it on site with brick masonry or any other added finishing.
Schematic view of load bearing sandwich faade with window frame. The thermal isolation is continuous over the whole surface to avoid cold bridges.
Residential General buildings
8.3 SOUND INSULATION

Sound is one of the most important quality aspects in multifamily houses, where pleasant sound in one flat may be experienced as disturbing noise in another. One of the requirements of a good house is thus, that it not only prevents "internal" noise caused by impact sounds, music, etc., but also that it effectively dampens external noise from e.g. traffic. The residential system, with its load-bearing outer walls and floors with long spans, creates the conditions for good sound insulation in all respects, covering the entire frequency range registered by the human ear. The installation of a sub-floor on top of the hollowcore floor is a key factor in achieving a good indoors sound insulation - both as regards impact sounds and airborne sounds. A sub-floor can be easily installed as a floating floor, either by means of a concrete screed on a dampening layer or with a cushioned strutted wooden floor. This will cause the floor to float and become fully insulated from the supporting floor elements.
8.4 BATHROOM FLOORS
In Europe, bathroom floors usually have an increased floor screed thickness to install pipes and conduits. A solution with reduced floor thickness in the bathroom enables one to avoid the step between the bathroom and the adjacent floor. The load bearing floor is between 60 mm and 170 mm lower at the bathcell than elsewhere. After installation of the pipes, a structural topping is cast to provide for the needed bearing capacity.
Examples of bathroom slabs
8.5 FOUNDATION UNITS

Special solutions for ground floors with supports have been developed. They can be used for completely precast houses but also for the footing of wooden cottages.
8.6 STAIRS
Precast concrete stairs are very interesting products for domestic and other buildings, because of the quality of finishing and the cost efficiency. Various types of precast stairs are available at Consolis, going from individual steps to straight or helicoidal monobloc units. The first category comprises straight stair units. They are made out of both individual precast flights and landings or The second category comprises monobloc staircases. They can be used either in the stairwells or individually between the different storeys. combined flight and landings. In the latter solution there may be differential levels at floors and half-landings, necessitating a finishing screed or other solution.
Examples of monobloc stair units
Polished precast spiral stair
8.7 BALCONIES AND TERRACES

Balconies in apartment buildings are usually made with special architectural units fixed to the building structure or floor slab, or supported by external columns. To avoid cold bridges, a thermal insulation is placed between the balcony and the inner floor.
Cantilevering balconies with intermediate thermal insulation
Terraces supported on Betemi columns
8.8 GREY WALLS

Precast walls are mainly used in apartment buildings, houses, hotels and similar structures. The bearing walls are generally used in combination with hollow core floors. Other applications are partition walls and elevator and stairwell shafts. Generally, the larger the wall units are, the more economic the project is and the better the site productivity. Of course, limitations can be imposed by the capacity of the site craneage and transport limitations. Precast walls are manufactured on long table or battery moulds. The moulded side is smooth as cast, the top face leveled and floated. Painting or wallpapering is possible after thin plastering. Technical ducts and inserts for electricity are incorporated prior to casting.
Dimensions wall units: maximum length: maximum height: thickness: Fire resistance: 180 minutes (Eurocode 2) 14 m 3.50 m 200 mm
8.8.2 Connections
Vertical wall-to-wall connections are generally designed to transmit shear forces. The vertical joint faces of the panels are profiled. Horizontal joints between walls and floors are either with direct floor support on the walls for mediumrise buildings or with floors supported on corbels, for high rise buildings. It is advisable to concentrate the tie reinforcement in the horizontal joint between the units.
Floor support on wall
Dowel Tie reinforcement
Neoprene
8.9 ACOTEC WALLS

The Acotec wall is a unique solution for non-load bearing internal walls. The elements are usually made of light Leca concrete), a very safe environmentally friendly material without health hazards. Acotec wall elements are hollow cored and produced to room height, max. 3.30 m. The thickness varies between 68 mm and 140 mm. The elements are 600 mm or 300 mm wide. For severe circumstances, as in seismic areas, the elements can be produced with extra reinforcement. weight expanded clay aggregate concrete (also known as
8.9.1 Installation
The main benefit of the Acotec wall element is its easy and light handling at the construction site. A two-man team can easily install Acotec walls with a speed of 6 m
2
per hour. The tongue and groove structure assures a perfect straight wall alignment and the flat surface needs only a thin coating (1-2 mm) without normal plastering. The cores inside the elements can be used for installation of electrical wires and pipes. Cutting and drilling of the product is also easy. Compared to other materials, savings up to 40% on the cost of the installed wall can be made.
8.9.2 Applications
The Acotec walls resist moisture very well, have good fire resistance and durability. A single wall structure has an airborne sound insulation capacity of over 40 dB. Acotec walls have a wide range of applications. In the first place they are used for bathrooms, kitchens, shower rooms, and other areas with a high degree of moisture. Another field of application is for rooms where good sound insulation is needed, for example apartments, hotels, schools, etc. Their high fire resistance makes Acotec walls very suitable for garages, parking buildings, etc. Acotec walls can also be produced with coloured concrete for applications such as fences and boundary walls.
9.
BASHALLEN
9.1 SYSTEM DESCRIPTION
The "Bashallen" system is composed of two modulated components: a saddle roof slab and load-bearing faades in architectural concrete. The solution offers large internal open spaces, with free spans up to 32 m, and a variable length modulated on 2.4 m. The internal height can vary up to 8 m. Intermediate floors may be installed over a part or the whole surface. The aesthetic outlook of the faade has been carefully studied. Rounded corners and cornices in a panoply of surface finishing and colours give the building a prestigious outlook . Thermal capacity and insulation of the complete concrete building ensures a stable indoor climate with low energy consumption.
Bashallen
9.2 TT-ROOF SLAB

The saddle TT-roof slab in prestressed concrete was developed in connection with the "bashallen" system. It is a rational and aesthetic solution for industrial and commercial buildings. The TT-units are characterized by their light weight and large span length. The units are 2.400 mm wide and the slope of the top surface is 1/40. The flanges are waffled to save weight. The fire resistance is 60 minutes. Standard dimensions are given in the table.
Type STTF 240-15/70 STTF 240-15/88
h mm 700 880
b mm 2396 2396
Weight 2 kN/m 2.0 2.1
Max. span m 24.6 32.0
9.3 EXTERIOR WALLS

The sandwich faades in the bashallen concept are composed of an external leaf in architectural concrete, 150 mm insulation and an internal load-bearing concrete leaf. The standard width of the units is 2.40 m and the thickness 300 mm. Openings for windows, doors and gates may be provided. Different surface finishing and colours are possible.
9.4 DETAILS AND CONNECTIONS

The "Bashallen" system comprises a complete set of standard solutions for connections, details and inserts in the units. The webs of the ribbed roof slabs are supported in recesses in the load-bearing faades. All connections between adjacent faade units, roof elements and between faades and roofs are made through welding of plates anchored in the units.
Welded connection between faade and roof units
Welded connection
Pinned connection with foundation
Corner solution
Bashallen
General
10.
FAADES
not always need to have the appearance of concrete. Buildings clad in precast architectural cladding can give the impression of being constructed in brickwork, polished marble or granite. Alternatively, if the architect wishes to maintain the appearance of concrete, the elements can be produced in a vast range of self finishes - an array of profiles and textures which bring out the natural beauty of the aggregates from which the elements are made. As a matter of course, such finishing requires a high level of technology and workmanship, available at, and steadily further developed by Consolis.
Consolis specializes in the production of faade elements in architectural concrete. There are two concepts: sandwich panels and cladding units. The units are generally one storey high and the normal standard widths are 2.40 m, 3.00 m and 3.60 m. The term "architectural concrete" refers to precast units which are intended to contribute to the architectural effect of the faade through finish, shape, colour, texture and quality of fabrication. Precast concrete offers an extremely wide range of visual appearances. Although the basic structural material is concrete, the finished elements do
10.1 SANDWICH FAADES

Sandwich elements consist of two concrete leaves with an insulation layer in between. The external leaf is generally in architectural concrete. The internal leaf is in gray concrete and may be designed as load-bearing or self-bearing. Load-bearing means that it is supporting the floors and the structure above. Self-bearing means that it is only supporting the self-weight of the faade.
Faades
The Consolis Group has developed a new faade panel with an air void between the outer cladding and the insulation, enabling the evaporation of any seeping water or condensation that has penetrated.
10.2 CLADDING PANELS

Simple cladding panels fulfill only an enclosing and decorative function in the faade. The single skin units are used for the facing of walls, columns, spandrel panels, etc. The units can be fixed either separately to the structure or they can be self-bearing. In principle, the architectural design of cladding panels is completely free. In the design process, Consolis early involvement can effect considerable time and cost savings in the contract.
10.3 SPECIAL ARCHITECTURAL ELEMENTS

Architectural concrete is perfectly suited for complicated geometric shapes and forms which would prove prohibitively expensive in traditional methods of construction. Similarly, other features normally requiring the use of site skills become economical and constructionally practical. This is the case for, for examcornices, pediments, etc. Skilful and economical manufacture gives all of the quality associated with natural materials at a fraction of the cost. ple, window surrounds, carved columns,
10.4 DETAILS AND CONNECTIONS

Consolis has developed standard details for connections between faade elements, faades and floors, solutions for corners, etc. Some details are shown below and more information is available from the technical department.
Window opening
Floor - faade connection Connection with side wall Corner solution
Faades
General
11.
INFRASTRUCTURAL PROJECTS
tunnel linings, railway sleepers, concrete piles, water treatment systems, elements for agriculture, etc.
The Consolis Group produces a wide range of precast concrete elements for infrastructural projects such as bridges,
11.1 PRECAST BRIDGES

490 15 990 10
80 n x 1000
Consolis has more than fifty years experience in precast bridge construction. Several systems have been developed of which the most important are solid slab bridges, girder bridges with cast in-situ deck and complete precast box girder bridges.
Precast solid deck bridge system with inverted T-beams placed side by side
11.1.1 Systems
only for collision resistance
Solid slab bridges are constructed with precast units and a cast in-situ topping, acting together as a composite structure. They are used for decks of bridges, viaducts, culverts, tunnel decks, etc. For small spans up to about 8.00 to 13.00 m, solid precast slabs can be used. They are modulated on 1200 mm width, and the thickness varies from 150 to 350 mm. The slabs are positioned side by side and a structural topping varying from 150 to 200 mm is cast on site. In a more advanced solution, the deck is composed of small inverted T-profiles placed side by side, and connected with a cast in-situ topping and infill concrete. Girder bridges are composed of inverted T-beams or I-shaped beams. The inverted T-beams can be placed side by side, to obtain a closed underside with a high resistance to collision by trucks. The elements may also be placed at a distance. The beams are connected by transversal diaphragm beams at each support and also in the span when needed. The deck is cast in-situ. The system is suitable for spans between approximately 15 and 35 m. I-shaped bridge girders are used for bridges up to 55 m span. The weight of the beams may be up to 70 tons. After erection of the beams and casting of the transversal diaphragm beams, the deck slab is cast on site, mostly with concrete shuttering planks positioned on a notch at the top of the beams.
Girder bridge with inverted T-beams placed side by side and in-situ deck slab
Girder bridge with I beams and in-situ deck
In box beam bridges, the elements are placed side by side or at a small distance. After erection the site work is limited to the filling of the longitudinal joints and the transversal post-tensioning of the bridge. The slenderness ratio is in the order of 30; however, spans of 50 m have already been realized with box beams of 1.50 m height. Protruding reinforcement is available in the beams for connections to cast in-situ edge profiles, joint constructions, screeds, etc. Precast bridges are well suited for projects where the realization of classical scaffolding supported on the ground is prohibitively expensive and where the speed of construction is mandatory: watercourses, railways, roads and motorways in use, in order to limit traffic restrictions.
Precast viaduct with box beams
11.1.2 Aesthetic bridges

The aesthetic appearance of a bridge is an essential factor, which has to be taken into account from the beginning of by its overall aspect, in other words, by the first image perceived by an observer situated at a distance. Also details such as the architecture of piers and abutments, the aspect of the surface, shape, colour and proportions of the edges are important Today, precast bridges can be as beautiful and elegant as classical cast in-situ bridges. The slenderness can be low using high strength concrete up to 100 MPa, structural continuity, and the combination of prestressing and post tensioning. Box beam bridges exhibit a slenderness ratio down to 30, which is comparable to classical slab bridges. The bridge can also be executed with special edge profiles or more slender edge beams, especially in the case of box beam bridges. Another novelty concerns curved prestressed box beams. The radius varies from 200 m to as low as 100 m.
type 1 type 2
Metro viaduct with curved box beams.
General
a project. The general silhouette of a bridge is conditioned
11.2 CULVERTS
Culverts are used for underpasses, tunnels, protection against avalances, etc. The system is composed of two or more vault units.
11.3 RAILWAY PRODUCTS

The Consolis Group has a long tradition in railway products. The assortment varies from railway sleepers and foundation systems for railway poles to slab track railway crossings and slabs for railway platforms.
11.3.1 Railway sleepers

In comparison with other precast elements, concrete sleepers are a highly sophisticated product. Concrete sleepers are produced to the highest standards due to the stringent demands of rail owners. The Consolis Group is a pioneer in concrete sleeper production with more than 40 years experience, having developed production and quality assurance systems which have defined the standard for certification in the majority of European countries. Existing quality and production aspects go along with a steady development of new sleepers or sleeper systems. Consolis produces annually more than 2 million railway sleepers in Finland, Norway, the Netherlands, Germany and the Baltics. The product range includes sleepers for slab track systems, standard sleepers, switch sleepers, sleepers for urban railways and under ground systems, rail grids and crane runway sleepers. The monobloc sleepers are prestressed. The units are provided with rail fixing anchors.
Systems such as the Slab Track, ensure the companies of the Consolis Group a secure market both for the present and the future.
11.3.2 Railway crossings

The system is based on a railway track slab of 2.37 m width and 6.00 or 9.00 m length. The elements are used for railway crossings at ground level. The crossing comprises one or more elements connected to each other. Curved tracks are also possible. Two grooves at the top of the slab enable the placement of the rails. The fixing is done with a cast elastomere encasing. The erection of the units is very fast. Experience shows that the system is very stable and completely free of maintenance for decades.
11.3.3 Railway platforms

Modern railway platforms are constructed with large platform slabs in precast reinforced concrete. The principal exigences are a slipp-free surface, dimensional accuracy and high durability. The units are 3.00 m wide and the length is variable. The top surface is sandblasted and slightly sloped for the evacuation of rain water. Longitudinal grooves are provided near the edge to conduct visually handicaped people. There is also a wide rabbet with safety mark.
General
12.
SPECIAL PRODUCTS
The Consolis Group manufactures special products and develops techniques and know-how in the domain of water treatment and specific structures for agriculture. In addition to this, exclusive products and projects are regularly realised for specific applications such as monuments and other one-off projects. They are merely the fruit of imagination and creativity in the collaboration between architects and our technical staff.
12.1 WATER TREATMENT SYSTEMS

Increasing the purification performance and maintaining the rhythm of the natural water cycle (extraction - consumption - collection - purification - recycling) are two of the main tasks confronting sewage treatment systems. Companies of the Consolis Group have been active in this specialised field for decades and have developed a range of products incorporating all the available technical knowhow in the sewage treatment sector.
d1 100 t
Pipe of 3.2 m diameter for transportation of fresh and waste-water
e1 / e2
d2
e3
d3
Water supplying and sewerage Large wastewater collection pipes up to 4 m diameter are used in these systems. Consolis also manufactures high precision reinforced concrete segmental rings for large sewerage conduits, as well as complete shaft and pipe systems with diameters of 300 mm to 4000 mm. Waste-water purification The systems developed by Consolis optimise waste-water purification by using different processes, such as: Rainwater / waste-water collection tanks from 2.5 to 100 m , to store domestic and commercial sewage. Multichamber sedimentation and digestion tanks for mechanical waste-water purification, for small applications
3
Biological waste-water treatment system (4-10 inhabitant equivalent)
Special products
Multichamber septic tank with floating filter and anaerobic final treatment, also for one-family houses and small apartment buildings. Biological sewage treatment plants for domestic wastewater. The application ranges from local communities, residential estates, schools, hotels, camping sites, commercial enterprises, and barracks.
Big separator tank
Aqua protection The Consolis Group also offers suitable water protection systems for a wide range of types of waste-water. The various separator systems are designed to purify and/or protect water from pollution by oils, petrol, greases and other harmful substances. The systems work on the principle of coalescence, gravity and filtration, as well as the separation of sedimentary constituent parts.
Petrol separator tank
12.2 AGRICULTURAL PRODUCTS

Storage tanks Circular precast concrete tanks are used for the storage of animal slurry, liquid manure and other types of liquids. The stucture is composed of vertical wall segments and the bottom slab is cast in-situ. Prestressing tendons are placed in a horizontal plane along the circumference of the tank. They may pass through ducts within the wall elements, each crossing the vertical joints. After tensioning of the cables, the ducts are filled with grout. Another option is to apply external prestressing cables. The diameter of the tanks is between 10 and 30 m Therefore the capacity of the tank is between 150 and 6000 m . On most farms the average capacity is approximately one thousand cubic meter.
3
Storage tanks for manure, under construction.
Retaining elements for storage Open silos for the storage of animal food, dung, etc. The structure comprises a cast in-situ bottom slab and precast retaining walls. The silos are modulated on the standard width of the elements.
Floor slats for live stock Floors for animal stables are built with floor slats, provided with longitudinal slits for the evacuation of manure. The width of the slits differs depending on the animals.
Special products
General
and the height of the wall structure 2.00 to 6.00 m.
12.3 OTHER SPECIAL PRODUCTS

A number of remarkable monuments have been realised in precast concrete by companies of the Consolis Group. Prefabrication is very well suited for this type of structures because of the mouldability of concrete and the high quality of execution. In addition, a large range of surface textures and finishing is available. A cost effective solution for road acoustic barriers has been developed, using prestressed hollow core elements. The wall structure comprises precast columns clamped into foundation pockets, in which the long hollow core units are fixed. The aesthetic quality of the acoustic barrier in the context of the environment may be obtained by an applied surface finishing in wood, architectural concrete or any other material.
Viking monument at Hjrundfjord near lesund, Norway
Special products
Accoustic barrier with hollow core units
Control tower at Arlanda airport in Sweden, rising 83 metres above the ground. The faade in highly polished architectural precast panels is ornamented with carefully selected quotations from Antoine de Saint-Exupry
FINLAND Consolis Oy Ab yritie 12 b FIN-01510 Vantaa Tel: +358 20 577 577 Fax: +358 20 577 5110 Email: info@consolis.com www.consolis.com President and CEO: Bengt Jansson Consolis Technology Oy Ab yritie 12 b FIN-01510 Vantaa Tel: +358 20 577 577 Fax: +358 20 577 5152 Managing Director: Olli Korander Parma Oy P.O. Box 76 FIN-03101 Nummela Tel: +358 20 577 5500 Fax: +358 20 577 5699 E-mail: info@parma.fi www.parma.fi Managing Director: Hannu Martikainen Parastek Oy P.O. Box 76 FIN-03101 Nummela Tel: +358 20 577 5500 Fax: +358 20 577 5625 Managing Director: Aapo Rahkjrvi Elematic Oy Ab P.O. Box 33 FIN-37801 Toijala Tel: +358 3 549 511 Fax: +358 3 549 5300 Email: info@elematic.com www.elematic.com Managing Director: Leo Sandqvist Rimera Oy Tehtaankatu 3 a FIN-11710 Riihimki Tel: +358 19 720 318 Fax: +358 19 720 636 E-mail: rimera@kolumbus.fi Managing Director: Antti Lahti THE CZECH REPUBLIC Dywidag Prefa Lys nad Labem a.s. Jedlickova 1190 / 1 CZ-289 22 Lys nad Labem Tel: +420 325 510 010 Fax: +420 325 551 326 Email: info@dywidag-prefa.cz www.dywidag-prefa.cz Managing Director: Michal Miksovsky
ESTONIA AS E-Betoonelement Tammi tee 51 EE-76902 Harku Harju maakond Tel: +372 6 712 500 Fax: +372 6 712 555 E-mail: ebe@betoonelement.ee www.betoonelement.ee Managing Director: Jaan Valbet AS Swetrak Tammi tee 51 EE-76902 Harku Harju maakond Tel: +372 6 712 500 Fax: +372 6 712 555 E-mail: taimi@betoonelement.ee Managing Director: Ove Johansson GERMANY DW Beton GmbH Stadthausbrcke 7 D-20355 Hamburg Tel: +49 40 360 9130 Fax: +49 40 3609 1379 Email: info@dw-beton.de www.dw-beton.de Managing Directors: Heikki Haikonen, Thomas Krmer-Wasserka DW Betonrohre GmbH Zinkhttenweg 16 D-41542 Dormagen Tel: +49 2133 2773 Fax: +49 2133 277 545 Email: info@ dw-betonrohre.de www.dw-betonrohre.de Managing Director: Heinz-Toni Dolfen DW Schwellen GmbH Pareyer Strasse 4a D-39317 Gsen Tel: +49 3934 4920 Fax: +49 3934 492 215 Email: info@ dw-schwellen.de www.dw-schwellen.de Managing Director: Heinz-Hermann Schulte-Loh DW Systembau GmbH An der B 19 D-98639 Walldorf / Meiningen Tel: +49 36 93 8830 Fax: +49 36 93 883 314 Managing Director: Heinz-Hermann Schulte-Loh
VERBIN Baufertigteile GmbH P.O. Box 170341 D-47183 Duisburg Tel: 0800 181 5939* Fax: 0800 181 5938* *(In Germany only. From abroad please call VBI BV.) E-mail: verbin@verbin.de www.verbin.de Managing Director: Lambert Teunissen Elematic GmbH Kleebergstrasse 1 D-63667 Nidda Tel: +49 6043 961 80 Fax: +49 6043 6218 E-mail: info@elematic-gmbh.com Managing Director: Simo Lperi LATVIA SIA Consolis Latvija Katlakalna iela 1, 4 floor LV-1073 Riga Tel: +371 7 138 777 Fax: +371 7 138 778 E-mail: office@consolis.lv www.consolis.lv Managing Director: Vladimirs Chamans LITHUANIA UAB Betonika Naglio 4 A LT-3014 Kaunas Tel: +370 37 400 100 Fax: +370 37 400 111 E-mail: info@betonika.lt www. betonika.lt Managing Director: Vytautas Niedvaras THE NETHERLANDS Spanbeton BV P.O. Box 5 NL-2396 ZG KOUDEKERK AAN DEN RIJN Tel: +31 71 341 9115 Fax: +31 71 341 2101 (office) E-mail: info@spanbeton.nl www. spanbeton.nl Managing Director: Lambert Teunissen VBI Verenigde Bouwprodukten Industrie BV P.O. Box 31 NL-6850 AA Huissen Tel: +31 26 379 7979 Fax: +31 26 379 7950 E-mail: vbi@vbi.nl www.vbi.nl Managing Director: Lambert Teunissen
Leenstra Machine- en Staalbouw BV P.O. Box 9 NL-9200 AA Drachten Tel: +31 512 589 700 Fax: +31 512 510 708 E-mail: info@leenstra.nl www.leenstra.nl Managing Director: Paul Schut NORWAY Spenncon AS Industriveien 2 N-1337 Sandvika Tel: +47 67 573 900 Fax: +47 67 573 901 Email: post@spenncon.no www.spenncon.no Managing Director: Terje Shoel POLAND Consolis Polska Sp. z o.o. ul. Przemyslowa 40 PL-97-350 Gorzkowice Tel: +48 44 732 7300 Fax: +48 44 732 7301 E-mail: office@consolis.pl www.consolis.pl Managing Director: Piotr Biskup RUSSIA ZAO Parastek Beton 3. Silikatny proezd, 10 123308 Moscow, Russia Tel: +7 095 742 5911 Tel: +7 095 742 5912 Fax: +7 095 946 2680 www.parastekbeton.ru Managing Director: Olli Ruutikainen SWEDEN Strngbetong AB P.O. Box 858 S-131 25 Nacka Tel: +46 8 615 8200 Fax: +46 8 615 8260 www.strangbetong.se Managing Director: Johnny Sthl USA Elematic Inc. 21795 Doral Road Waukesha, WI 53186, USA Tel: +1 262 798 9777 Fax: +1 262 798 9776 E-mail: info@elematic-inc.com Local Manager: Matt Cherba
Frame structures
www.consolis.com
Columns
Pocket foundations
Beams
Hollowcore slabs
Double-T slabs
Bashallen
Faades

Consolis Technical Guide &amp; Product Manual

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Consolis Technical Guide &amp; Product Manual

Caricato da

Copyright:

Formati disponibili

Consolis Technical guide & product manual

Elematic Parma Strngbetong Spenncon Consolis Headquarters / Consolis Technology

Parastek Consolis Latvija

DW Beton Spanbeton VBI Consolis Polska

Dywidag Prefa Lys

5.2 5.3 5.4 5.5 5.6

Purlins Rectangular beams L-beams & inverted T-beams SI-beams I-beams

8.7 8.8 8.9

Balconies and terraces Grey walls Acotec walls

1.5 1.6 1.7 1.8

Hollow core slabs

9.2 9.3 9.4

6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13

Single-storey buildings Low-rise buildings with intermediate floors Horizontal stability

Stability Diaphragm action Modular design

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

Railway sleepers Railway crossings Railway platforms

Water treatment systems Agricultural products Other special products

Pocket foundations Beams

Types Supports Inserts Lifting and temporary storage Production tolerances

1.1 CONSOLIS POTENTIAL

more than 50 production plants in 11 European countries

1.2 QUALITY GUARANTEE

1.3 PREFABRICATION: WHEN AND WHY

When to use precast concrete

Long line prestressing beds

To prefabricate - to precast - concrete components for var-

Independent of adverse weather conditions

1.4 STANDARDS AND TECHNICAL GUIDELINES

1.5 CONCRETE QUALITY

Shear test on hollow core slab

Workability test fresh concrete

1.6 FIRE RESISTANCE

1.7 PERFORMANCE CURVES

FRAME AND SKELETAL STRUCTURES

2.1 LOW-RISE UTILITY BUILDINGS

Industrial hall during construction

Building structure with sloped I-profile beams and TT-roof slabs

Saddle TT-roof slabs on load-bearing sandwich walls

Straight light TT roof slabs on longitudinal portal frames

Frame and skeletal structures

2.1.2 Low-rise buildings with intermediate floors

Frame and skeletal structures

2.1.3 Horizontal stability

Precast frame for papermill

Hollow core slabs

Frame and skeletal structures

2.2 MULTI-STOREY BUILDINGS

Frame and skeletal structures

Example of precast central core

Building with central core and hidden beam-column connections

2.2.2 Diaphragm action

2.2.3 Modular design

Example of modulated floor layout and location of components

Frame and skeletal structures

3.1.2 Round columns

Profile round columns 300 400 500 600

Diameter mm 300 400 500 600

Weight kN/m 1.73 3.08 4.81 6.92

300 105 kN 145 kN 140 kN

400 145 kN 205 kN 265 kN

500 185 kN 260 kN 335 kN

300 400 500

Allowable load in kN 200 300 450 600 700 950

Consolis Technical Guide & Product Manual

Consolis Technical Guide & Product Manual