Presented at the ADEB Conference.

1. Prefab
Challenges and opportunities
for the contractor
ir. B. PARMENTIER
Division Structures

2. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Inspiring China ?
(see next slide)

3. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
China inspiring…
 30 storeys
 17000 m²
 200 workers
 …
completed in
2 weeks !!

4. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Context
Prefab systems
Energetic transition
Renovation push
The future ?
© slimrenoveren.nl

5. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
1 Context

6. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
We need cost-efficient, performant buildings
YEAR
Salaries
House prices
Renting prices
Consumption prices

7. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
7/16
2 Prefab Systems

8. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Prefab in multiple expressions
Different construction materials
Steel Concrete Masonry Timber
Different methods
1D / 2D 3D (full module)

9. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Prefab : general benefits v. 1.0
Quality
Security
Speed
Environment
Cheap
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5

10. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Quality (labels)
Security
Speed
Environment
Cheap
1
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5
Examples :
- concrete cover reduction
- safety factor reduction
concrete : 1,50 > 1,40
rebar : 1,15 > 1,10
Prefab : general benefits v. 1.0

11. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Quality
Security (better)
Speed
Environment
Cheap
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5
Prefab : general benefits v. 1.0

12. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Prefab companies inform about safe handling etc.
See also BBRI RAP n°10
Prefab : general benefits v. 1.0
Quality
Security
Speed
Environment
Cheap
1
2
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5

13. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Prefab : general benefits v. 1.0
Quality
Security
Speed
Environment
Cheap
1
2
3
4
5

14. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
 Materials
 Production process
 Connection techniques
 Site organisation
Global study !!
Prefab : general benefits v. 1.0
Quality
Security
Speed
Environment
Cheap
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Bio-versneller – Zwijnaarde (Sum.be / Denys / Ergon)
12500 m² - 5 storeys

15. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
 Materials : optimum ?
Example for bridge girders :
Normal strength concrete (NSC) vs.
High performance fibre concrete (HPFC) vs.
Ultra high performance concrete (UHPC)
Concrete compressive stress [MPa]
Deformation [µS]
150
90
50
Prefab : general benefits v. 1.0
Quality
Security
Speed
Environment
Cheap
1
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NSC
HPFC-50
HPFC-90
UHPC

16. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Prefab : general benefits v. 1.0
Quality
Security
Speed
Environment
Cheap
1
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Braike et al (2006)
Example for bridge girders : NSC  HPFC90
Number of beams : 6  4 beams
Height of the beams : 1600  1200 mm
Less prestress losses (more efficient)
Lighter (easier for handling)
 Materials : optimum ?

17. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Site
Organisation
 Enough storage areas
 Job site layout and enough place for
deliveries of precast elements
 Appoint responsibles
 Toolbox meetings with workers
 Transport between precast hall and job site
 Transport on job site
 Check crane capacity
 Safety
 By design
 By practice
Prefab : general benefits v. 1.0
Quality
Security
Speed
Environment
Cheap
1
2
3
4
5

18. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Prefab : version 2.0
+ Architecture + Flexibility + Energy

19. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Leonardo Bridge (Sweden/2002) : 40m central span – Total length : 40m
Arch. : Vebjørn Sand & Selberg
Architecture
This is prefab . . .

20. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Préfab’ : la version 2.0 ?
Architecture
Flexibilité
Energie
6
7
8
Flexibility
This is prefab . . .

21. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Flexibility
New powerful connexion systems . . .

22. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Flexibility
Sometimes simple systems are the best ones . . .

23. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
23/16
3 Towards the energy
transition…

24. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
EU Objectives…20-20-20
Reduction of Energy consumption in the
Construction : potentially 40% !
 Construction details (connexions, etc.)
 Integration (insulation, techniques,…)
Some examples :
BBRI Smart Geotherm project
BIM
Study Mc Kinsey
R. Thomaes (FEB-VBO)
% +Renewable energy
% less greenhouse gas emissions
% +Energy efficiency

25. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Construction details
Solutions for joinery : the independant frame

26. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Integration
Nearly zero energy building in 2021
EPBD-recast may 2010
Ground
geothermal
Building structure
concrete activation
Buffers
water, PCM,
http://www.smartgeotherm.be/

27. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Shallow geothermal energy systems
Energy piles (Structure + Energy)
+3°C every 100m in the ground… brings heat to the building.

28. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Concrete core activation
Slabs …integrating pipes
Heating (~24-30°C)
Cooling (~16°C)
® Climadeck
® Airdeck

29. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Variations with timber
The Vaxjo Project (Sweden, 7 storeys)
500 mm

30. BIM : the tool for integration

31. BIM : the tool for integration

32. BIM : the tool for integration

33. BIM : the tool for integration

34. BIM : the tool for integration

35. BIM : the tool for integration

36. BIM : the tool for integration

37. BIM : the tool for integration

38. BIM : the tool for integration

39. BIM : the tool for integration

40. BIM : the tool for integration

41. BIM : the tool for integration

42. Objectifs
Applications1 Context 2 Prefab systems 3 Energy transition 4 Renovation push 5 The future ?
42/16
4 The renovation push

43. Objectifs
Applications1 Context 2 Prefab systems 3 Energy transition 4 Renovation push 5 The future ?
Renovation market
Not residential
 ~ 4650 new constructions
 ~ 5160 refurbishments
PEconomie – Verslag Bouw 2013

44. Objectifs
Applications1 Context 2 Prefab systems 3 Energy transition 4 Renovation push 5 The future ?
Lab of Renovation, Michael de Bouw
Yves Vanhellemont
Prefab & Renovation : Brussels case-studies

45. Objectifs
Applications1 Context 2 Prefab systems 3 Energy transition 4 Renovation push 5 The future ?
Prefab & Renovation
5 facade systems compared…
 Thick [35 .. 67] cm
 Equalizing surface
 Accessibility techniques
 Stability (heavier) ?
 Passive possible (< 15 kWh/m²/j)
 No necessery moving
 1 to 5 days
http://www.brusselsretrofitxl.be/projects/aim-es/
Lab of Renovation, Michael de Bouw
Yves Vanhellemont

46. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
46/16
5 The future (?)

47. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Jobsite of the 21th century
The vision around 1910…

48. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
The future (?)
Innovative materials
 Structural Insulated Panels (SIP)
 UHPC / FRC / SCC (Spcial concretes)
 Phase Changing materials (PCM)
 Bio-insulation
 …
Innovative structures
 Fully integrated structural systems (modules)
 …
Contour crafting – 3D Printing - BIM
 Partly of fully automated tasks

49. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Innovative materials (SCC, UHPC, CLT,…)
UHPC (Ultra High Performance Concrete)
 Truss footbridge (Alicante - 40m span)
J.A. Lopez et al. (2012)
49/60

50. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
UHPC (Ultra High Performance Concrete)
 Truss footbridge (Alicante - 40m span)
J.A. Lopez et al. (2012)
50/60
Innovative materials (SCC, UHPC, CLT,…)

51. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Japan : ~ 90 single task construction robots
Robotics

52. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Contour Crafting (see video next slide)

53. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Multi-disciplinary job

54. 1 Context 2 Prefab Systems 3 Energy transition 4 Renovation push 5 The future ?
Lab. Structures
bp@bbri.be