ECO-THERM. MOBILE FACTORY Technical information on innovative construction methods

Transcription

1 ECO-THERM MOBILE FACTORY Technical information on innovative construction methods

2 The shuttering system ECO-THERM The energy-efficient construction system that can withstand earthquakes In light of the increasing energy costs, efficient energy systems in buildings of all types gain enormously in importance. FoS has been developing an innovative optimization concept, which will guarantee the next life cycle, which is especially energy-efficient and can withstand earthquakes. The MOBILE FACTORY is used to fabricate shuttering profiles that are linked and mounted to each other. Quickly and easily assembled, the ECO-THERM shuttering elements are used as flexible construction elements. Dr. Stracke & Partner further developed the system in cooperation with the universities of Karlsruhe, Aachen and Istanbul to include earthquake safety and energy-efficiency. The solid construction system ECO-THERM is used all over the world. Made of environmentally-friendly EPS rigid foam, the shuttering elements can be quickly, easily and flexibly utilized on the site. The shuttering elements are assembled to form an insulating wall construction filled with concrete. The shuttering elements of the ECO- THERM construction system that are poured out with concrete are used as walls and ceilings. The FoS AG supplies the roof elements. Sturdy frameworks are thus produced easily, quickly and environmentally sound

3 Monolithic construction method MONOLITHIC inseparable unit consisting of one joint less block. Advantages compared to the conventional construction method ECONOMICAL ECOLOGICAL - INNOVATIVE The shuttering system ECO-THERM has been used in Germany and other countries worldwide to erect different buildings up to a height of 10 floors: hospitals, schools, senior s residences as well as single-family and multi-family houses and commercial properties. The construction system and the construction method comply with the German and European standards DIN 41155, 4109, 4102, 18164, EN ISO The modern and monolithic solid construction system is most effectively and economically applied wherever it is important to save energy and to build in a speedy manner. The increase in disasters around the globe calls for engineering skills and a construction system that can withstand earthquakes. The ECO- THERM shuttering system makes it possible to realize earthquake-safety and energy efficiency in a simple fashion. In their application, the elements are extremely flexible and allow for the smallest long measure tolerances so that individual planning can be realized. The integration of physical and supporting characteristics of the elements and materials to be processed allow for a conventional and complicated construction method that offers a high degree of rationalization in the handling of the construction elements and the building of the structures. - High heat insulation U-values ranging from 0.29 to High savings in energy costs for heating and cooling of up to 70% - No heat and cold bridges to the next floor due to a combination of insulating material and concrete over the entire area - Requires no expensive special components for header, back fillet and slab-edge form - Quality tested construction materials - Diffusible mason work - High sound insulation factor due to reinforced concrete > 54 db - Economical thanks to an extremely short construction period thus lower financing costs and early utilization of property - Construction does not depend on weather; construction possible even during winter - Balanced and comfortable living climate in summer and winter - Clean construction site - No cutting work for installations, thus no construction waste and plastering-in - Verifiable reduction of ecological damage - Substantial reduction of CO2 emissions thanks to a lower heat requirement - Durability approved for a building height of up to 25 m (approx. 10 floors) - Fire safety per DIN Easy processing on site without heavy construction equipment. 3

4 Technical data The statical analysis of the concrete core is performed per the standards of the concrete and reinforced concrete construction. A special approval of the ECO-THERM shuttering system is not required as the rigid foam elements are included in the group of standardized construction materials. Details on the shuttering system: Fire wall category F90 Wall thickness 25 cm 14,2 cm U-value 0,29 Insulation 5,4+5,4 cm Sound reduction index R W > 54db DIN 4109 Wall thickness 31,25 cm 14,2 cm U-value 0,19 Insulation 5,4+11,65 cm Sound reduction index R W > 54db DIN 4109 Wall thickness 37,5 cm 14,2 cm U-value 0,14 Insulation 5,4+17,9 cm Sound reduction index R W > 54db DIN 4109 Parameters for a 30 cm wall - Wall thickness 30 cm without plaster - Wall weight approx. 340 kg/sqm plastered on both sides - Concrete quantity 122 l/sqm-wall - Fire resistance approved for a building height of up to 25 m (approx. 10 floors) - Drop point no condensation of water vapor with contracting and expanding wall - Sound insulation 46 db for a 25-cm thick wall with outer plastering coat of 0.3 cm and inner board plate 1.25 cm thick. Production costs of the elements Status 05/2009: - Width 25 cm - Length 120 cm - Height 25 cm elements per sqm wall - Production costs for producing 1 sqm wall approx. 6 Euro The element replaces steel sheets, supplementary insulating functions and makes up parts of the wall. Wall thickness 50 cm 14,2 cm U-value 0,1 Insulation 5,4+30,4 cm Sound reduction index R W > 54db DIN

5 Size of the shuttering elements ECO-THERM Normal Element Thick Wall Element Inner Wall Element Measure Wall surface Length Height 0.30 qm per element 120 cm 25 cm Width 25 cm 30 cm 15 cm Thickness insulating material 1*505 mm 1*10 cm + 1* 5 cm 2*4 cm Linear measure 15 cm smallest linear measure tolerance 5 cm Concrete Type B25 or B15 with a grain size of up to 16 mm K2 plastic consistency (38-40 cm slump) Quantity approx. 136 ltr. per sqm wall approx. 65 ltr./sqm wall K-value 0.25 (W/qm K) 0.20 (W/qm K) Fire resistance category acc. to DIN / enclosure of space F90 / stability F120 General you can produce 6.25 sqm wall per hour 3.3 elements are required per sqm wall ECO-THERM Measure Length Height Width Insulation thickness Ceiling Element 56 cm 25 cm 18 cm max. 18 cm Concrete K-value Fire resistance class General Type Quantity B25 with a grain size of up to 8 mm K2 plastic consistency (at least 50 cm slump) Approx ltr. per running mtr (W/qm K) acc. to DIN / enclosure of space F90 / stability F120 Girders made of concrete steel IV Bst 500/550 with a small own load, span up to 8 m, with secondary reinforcement of up to 12 m Steel plate girders with small own weight, span up to 12 m with secondary reinforcement up to 18 m The load bearing capacity of this ceiling construction is approx. 5.5 KN/qm When using a floating screed, this ceiling construction can attain a fire resistance category of F90 Footstep sound insulation with floating screed complies with DIN 4109 ECO-THERM Measure Roof area Length Height Width Thickness of insulation material K-value Roof Eement 0.36 qm per element 123 cm 33 cm 17 cm max. 17 cm 0.20 (W/qm K) 5

6 Mobile Factory The 40 feet container Technology The MOBILE FACTORY has been developed by rebuilding a 40 feet container. All required assemblies for the fabrication of ECO-THERM shuttering profiles are integrated together with technical modifications inside the container. A second container is used to reclaim tools and the polystyrene raw material. The system units are linked and mounted to each other. The forming tool equipment can be different depending on the requirement. Each unit CSC tested and certified (regulations for the construction and the design of container) is completely self-sufficient and includes the following assemblies and components. 1. Machine MSC V 75/ Forming tool for two types of shuttering 3. Compact pre-foaming unit 4. Pneumatic vacuum station for raw material 5. Scale 6. Filtering device 7. Transport bubble 8. Interim storage unit 9. Pipelines 10. Steam boiler 11. Water softening module 12. Water service module 13. Pressure-reducing valve 14. Compressor USP unique selling proposition The development was to install all required components to produce shuttering elements into the smallest possible space. This required technical modifications of components because of structural heights and widths. The complete unit offers 30 sqm of room. The advantage of this unit and this is a USP is its mobility. The ECO-THERM shuttering elements can be fabricated on construction sites all over the world. All assembly work can be omitted. The production can start as soon as the production media such as heating oil (diesel), water and power have been connected. This unit allows the user to be mobile and flexible. The MOBILE FACTORY requires a conventional truck for transportation. 6

7 Output of the MOBILE FACTORY The output of the factory is as follows: The basis for the construction of objects is shown by an example calculation with a usable surface of 100 sqm. According to the experience of the TH Berlin (Prof. Dr. Ing. G. Nedeljkov), which studied this construction system intensively, the ratio between wall surface and usable surface is 1.8: sqm of wall surface are produced for a usable surface of 100 sqm. 1 sqm wall surface = 3.3 standard profile. Empirical values for the production of the walls: 1 man/hr. = 6.25 sqm wall. Production data: Output of 2 standard elements in 2 minutes = 60 elements per hour. The 3 shift operation / 24 hours and 290 days produces 24*290*60* = approx. 418,000 ECO-THERM standard elements per year. This corresponds to a wall surface of approx. 126,550 sqm or a usable area of approx. 70,300 sqm. The profiles can be formed differently. Round facades are easily produced with prepared tools. Roof elements are used for an energy savings potential for the residents of these buildings (up to 70%). They are mounted on the prepared roof beam on which the roof tiles are placed. The minimum roof slope is 30. Wall construction Extra work no longer necessary with this ECO- THERM shuttering system: - Support - Jamp wall - Headers - Ring beam - Ceiling finishes Examples for outer walls A outer wall 25 cm Polystyrene insulation outside 5.4 cm 14.2 cm Polystyrene insulation inside 5.4 cm Total thickness 28.0 cm Insulation thickness 10.8 cm U-value 0,29 W/sqmK B outer wall 37 cm Polystyrene insulation outside 17.9 cm 14.2 cm Polystyrene insulation inside 5.4 cm Total thickness 40.5 cm Insulation thickness 3.3 cm U-value 0.15 W/sqmK C outer wall 50 cm Polystyrene insulation outside 30.4 cm 14.2 cm Polystyrene insulation inside 5.4 cm Total thickness 53.0 cm Insulation thickness 35.8 cm U-value 0.10 W/qmK 7

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