- Precast solution of the structure (splitting the structure, grouping the elements, creating joints) - Important steps of engineering (from shopdrawing.

GROUPAMA Football Stadium, Budapest Design and other engineering work for

the precast concrete structure

-Precast solution of the structure (splitting the structure, grouping the elements, creating joints)

-Important steps of engineering (from shopdrawing design to complete the structure)

Created by: Pal Zsolt Miklan

Difficulties of completing the precast concrete structure

The stadium is for 24000 visitorThe total time for the project is 1,5 year

- No stadium projects done in the past 30 years- Unique elements are not familiar with prefabrication- Required to ensure the whole bearing capacity- No formwork in storage for such elements- More accuracy (steel like) required- High surface quality recommended- Form and reinforcement more complex- Extra needs for built-in accessoires- Competitive (low) price- Very short deadline 1 + 6 months

Scheduling in 2013 (0. March: contracting, preparations, organize meetings, data supply) 1. April: meetings, shopdrawing design, start production of first elements 2. May: meetings, shopdrawing design, production, starting installation 3-7. June-October: shopdrawing design, production, continuous installation till end

Criterias of completion for shopdrawing design(Engineering in the shopdrawing design)

• Well designed and detailed data supply

• 3D modelling (connecting different structural parts)

• Continuous cooperation, direct design connection

• Fast reaction for modifications, conformation

• Organization, multi-level scheduling

• Fast control, flexible approval system

Estimated amounts due to construction plans:Volume of precast strucutre: ~ 5200 m3

Quantity of precast elements: ~3300 pcsShopdrawings and plans: ~500 pcs

Dividing the precast structure and grouping the elements(Engineering in the shopdrawing design)

1. Frame elements(Main structural frames, bracings)

Columns

Main supporting beams

Ring beams, parapet walls

Layout plan of frame elements

Dividing the precast structure and grouping the elements(Engineering is shopdrawing design)

2. Floor and area elements(visitor’s area, corridors and steps)

Elements for the visitor’s area

Steps and podiums

Floor elements

Layout plan of floor elements

Scheduling the design and production of precast elements(Engineering in the production procedure)

Viewpoints of scheduling (balancing) the shopdrawing design of precast elements

According to function (grouping) and formwork needs:- In a group the elements can be produced easily without any or with small changes --- continuous planning and production- The groups are very different (different function-different geometry) --- parallel planning and production

According to quantity:- In case of large quantity (area elements) production needs to be started very soon --- early and fast designing- Not urgent elements with less quantity (podiums) have time to be produced --- late designing

According to the complexity:- Difficult elements (main column, supporting beam) requires weeks for preparation --- approved drawings needs to be released for formwork preparation, built-in particals needs to be collected for ordering in early time

According to installation order:- Main elements of the load bearing frames (columns, main beams) need to be installed first- Floor and stepping elements can be installed after the main frames are ready to receive

SPECIFIC CONTRADICTIONS:• Accomplish the continuous and the parallel design work with providing a balance• Designing the frame elements - need for early installation versus complex shape means difficulty in production• The huge quantity and formwork need of floor elements and steps versus the late installation time

Solution for designing and producing the precast elements(Engineering in the production procedure)

Design and production of complex elements– Main column and main supporting beam

Actually designed quantities: Total volume of all precast elements: 5406 m3

Total quantity of all installed elements: 3690 pc Shopdrawing quantity: 648 type of elements, formwork+reinforcement+accessories: 1120 pc

Formwork plan of 3200 signed column Formwork plan of 4000 signed beam

Solution for designing and producing the precast elements(Engineering in the production procedure)

Design and production of complex elements – Main column and main supporting beam

Actually produced quantities: All reinforcement steel built into the elements: 875.720 kg All built-in steel parts and accessories: 6974 pc

Reinforcement plan of 3200 signed column Reinforcement plan of 4000 signed beam

Solution of designing and producing the precast elements(Engineering in the production procedure)

Production of complex elements – Main column and main supporting beam

Designer’s responsibility:- Releasing understandable shopdrawings- Taking part in scheduling the production- Supporting the design of new formworks- Close cooperation with the production management- Applying proposals for optimalization- Emphasizing the limit of measurement tolerances- Monitoring of production and produced elements

Placing and installing the precast structure and elements(Engineering in the structural installation procedure)

Usual connection of precast elements:

• Footing beam – short column connected by screwed (Peikko column shoe)• Main column fixed into a monolitic socket (rough surface needed)• Column – beam and beam – beam connection by screwed (Peikko) • Column – beam and beam – beam connection by consols and rebars• Wall elements connection with bolts or fixed by monolitic joints• Elements of visitor’s area are supported by rubber stripe fixed by shear pin• Step and podium elements fixed by sticking and shear pin• Floor panels sitting on rubber stripe and collaborating with monolitic plate• Precast concrete – steel structure connections always screwed

Axonometrical section

Placing and installing the precast structure(Engineering in the structural installation procedure)

The begining (2013 May – June)

Placing and installing the precast structure (Engineering in the structural installation procedure)

Middle time (2013 July – Augustus)

Placing and installing the precast structure(Engineering in the structural installation procedure)Close to the end (2013 September – October)

Placing and installing the precast structure(Engineering in the structural installation procedure)Finishing (2013 November)

Placing and installing the precast structure(Engineering in the structural installation procedure)Precast is completed (2013 December)

Thank you for your attention!