iTWO WORLD 2018 Sustainable Technology for Modular Construction and Prefabrication Dipl. Ing. Anne Jacobs Head, Industry Team Construction Asia Pacific
iTWO WORLD 2018
Sustainable Technology for Modular Construction and Prefabrication
Dipl. Ing. Anne Jacobs
Head, Industry Team Construction Asia Pacific
BASF – we create chemistry
Our chemistry is used in almost all industries
We combine economic success, social responsibility and environmental protection
Sales 2017: €64,457 million
EBIT 2017: €8,522 million
Employees (as of December 31, 2017): 115,490
6 Verbund sites and 347 other production sites
Over 10,000 employees for R&D with over 1,000 based in Asia Pacific
regional D
global R
global D
Chigasaki(Admixtures)
Research and Innovation in Construction Chemicals
Chigasaki
Shanghai
We innovate to create value throughout
the life cycle of buildings
Construction phase
Higher productivity, faster progress, lower overall costs,
lower consumption of natural resources,
better energy efficiency,
improved health protection & safety
Use phase
Extended service life, lower life cycle costs,
better performance and functionality,
improved safety & comfort
Research and innovation enabling sustainable construction
-5.9
9.3 °C
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-2
0
2
4
6
8
FLIR Systems
Environmental Challenges for the Construction Industry
Causes
10 %of the world’s
emission of fine
dust
Contributes to
30 %
of the global
greenhouse
gas emissions
Concrete: most widely used
man-made material
(1m3 /Pers/annum)
Consumes up to
40 %of the worlds
energy
The Construction Chemicals Portfolio
Wall Systems / EIFSTile Fixing Systems
Flooring SystemsPerformance
GroutsWaterproofing &
Sealants
Expansion Control Systems
Cement AdditivesUnderground Construction
Concrete Repair & Protection Systems
Admixtures
Solutions for Flooring
Heavy Duty Flooring
Food Industry Flooring
Industrial, residential and
commercial flooring
Highly durable
Fast and easy application
Low maintenance
Food and beverages safety
Installing heavy-duty floors faster
09.11.20188
Ucrete® Fast – is a new version of heavy-duty Ucrete industrial floors
with installation time reduced from 48 hrs to less than 12 hrs
Innovation to strengthen leading position
Ucrete® industrial flooring solutions have been offering market leading performance for over 40 years
Speed of installation is a key recent market requirement esp. in the food industry
The fast cure cycles are enabled by new solutions for ensuring reaction stability and ways of maintaining sufficient open time to install the material
Advantages
Recycled supplementary cementitious materials (fly ash, slag), non-cementitious fillers
Installation in working factories esp. in the food industry without production downtime,
e.g. overnight
Same chemical and physical properties as the standard material when cured
MasterTop 1327-20dB:
Resin flooring system that combines design with noise reduction
“There is basically no
comparison to any
other flooring system.”
Tom Haarsaker,
Manager, Minor Industriplast AS
Quantified Sustainable Benefits
7% Lower
life cycle costs
20 dBReduced
impact noise
50
yearsExpected
service life
Solutions for Cement: Additives
Grinding Aids
Performance Enhancer
Lower cost, higher efficiency and
high quality of cement
production
Reduction of CO2 emissions
Green Sense Concrete
Smart Dynamic Concrete
Optimization
Plasticizer
Fibers
Faster production
Enhanced properties (strength,
durability, cost, workability,..)
Reducing CO2
Solutions for High Performance Concrete: Admixtures
Fiber reinforced concrete optimisation for easier placing and
performing solutions
MasterFiber® is the BASF fiber range developed for concrete
reinforcement
Synthetic fibres with optimized chemical composition and surface
properties to provide:
better dispersion,
easier concrete handling
higher bond to the concrete matrix
for improved ductility.
Advantages
Final concrete properties like cracking behaviour, corrosion are
enhanced.
Possibility to reduce the concrete thickness
Substitution of steel mesh
Sustainable alternative to steel reinforcement
“MasterFiber has
enabled us to save both
production time and
materials.”
Abel Medel,
Technical Manager at Uniblok, Toledo
Quantified Sustainable Benefits
Using MasterFiber, Uniblok achieved significant Quantified Sustainable Benefits. The
facts:
10%MORE EFFICIENT
PRODUCTION PROCESSES
The amount of steel is limited to the
technical optimum using the existing steel
mesh section and the complementary
contribution of PP fibers in tensile strength
and crack width reduction. This saves
steel and energy. Less steel saves time
and money.
LOWER GLOBAL
WARMING POTENTIAL
Less steel weight significantly reduces
CO2 emissions. Similar benefit can be
observed for the other environmental
impact categories like POCP
(Photochemical Ozone Creation
Potential), AP (Acidification Potential)
and Total Resource Depletion, which are
all reduced between 20% and 25%.
LESS STEEL
BY WEIGHT
Up to 20% less steel is needed
while providing the required
strength properties with improved
crack behavior.
20% 21%10% More
efficient production
processes
20%Less
steel by weight
21% Lower
Global Warming
Potential (GWP)
What is Green Sense® Concrete?
09.11.201816
The Green Sense® Concrete technology offers a unique performance
package that optimizes concrete mixtures with regard to environmental
friendliness, performance and production costs.
Our solutions: MasterGlenium®
Advantages
Formulations of concrete mixtures that contain a high proportion of
recycled materials
Decrease of carbon footprint and environmental impact of buildings
Extended lifecycles of buildings
6% of the worlds CO2 emissions are released from the cement
production. Alternative Materials for Concrete Reduce this Impact.
Alternative fines
Fly ash
By-product from coal power production
Slag
By-product from steel* production
Aggregate fines
By-product from aggregate production
Locally sources alternative materials
Can be added to concrete in controlled amounts to
reduce the cement content and improve some properties
of the concrete.
Alternative Pozzolans Alternative powders
Can be used in the right combinations to reduce
concrete CO2 volume and improve desired
properties.
Green Sense Concrete: No Trade Off! It is Possible to Meet the
Projects Needs and Accreditation Requirements
Smart Dynamic Concrete Ultra High Strength Concrete Architectural Finish
High Durability Extreme Pumping Long workability times
SmallSmall
Large
Compressive strengths
> 120MPa
Low fines (<380kg/m3) SCC
Flow:
580 – 650mm
Superior
colors and
surface
finish.
No
remedial
work
Designing
concrete to
be pumped to
extreme
vertical
heights or
long
distances
Slump
retention
tailored for the
project needs
and
environmental
conditions
Meeting &
Exceeding durability
Life Cycle Analyzer (Tool)
Assess sustainability impact of concrete (for certifications like LEED)
Real-time calculation of different concrete mix-designs
Tailor-made LCA
Fast
Facts
Envir
onm
enta
l Im
pact
Project Reference: One World Trade Center, NYC
Project Overview, GOLD LEED
• 135,000 m3 of Green Sense Concrete
• Developer: Port Authority of NYC & NJ
• Architect: Skidmore Ownings
• Structural Engineer: WSP
• Contractor: Tishman Construction
• Total construction cost: 3.9 bn USD
• Height: 541 m
• 3 billion Litres of Water saved
• 8 Million KWs of Energy saved
• 5445 tons of CO2 saved
• 340 tonnes of Fossil Fuel Savings
Sustainable Solutions:
Accelerating Concrete Hardening
Master X-Seed® -
BASF’s unique patented hardening accelerator speeds up concrete hardening 2 to10 times
at early ages (6-12h)
▪ Accelerates construction in Ready-Mix Concrete
Concrete framing with short production cycles
Faster setting time enables use of power trowels on concrete slabs at a reasonable
short time
High early and 16h strength in winter conditions
▪ High quality concrete
Increased strength development leads to improved safety and predictability of the final
concrete
▪ Material optimization, reduction of CO2 emissions
Highest flexibility in using composite cements and SCM
Admixture solution for sustainable concrete hardening
“In the precast industry,
it is all about
minimizing
the demolding times!”
Thomas Beike,
Managing Director fdu Betonwerke
Quantified Sustainable Benefits
Using the revolutionary admixture Master X-Seed, fdu Betonwerke achieved significant Quantified Sustainable
Benefits, in many of its plants, including:
50%FASTER CONCRETE
HARDENING
Master X-Seed boosts the
hardening process. This leads to
shortened demolding times. Output
of existing plant facilities can
significantly be increased.
REDUCED CO2
FOOTPRINT
A reduction of the CO2
footprint can be achieved
by binder optimization.
LOWER ENERGY
COSTS
High early strength is achieved at
low ambient and heat curing
temperatures reducing the need for
energy intensive supplementary
heating of the molds.
15% 10%
10% Reduced
CO2 footprint
15% Lower
energy costs
50% Faster
concrete hardening
Wall/ Ceiling Systems
Thin
Light-weight
Long Durability
Energy-efficient
Off-site production
Concrete composite elements
Modular Construction Manufacturers need Reliable Materials and
Professional Support for Whole Building Solutions.
Our advantage:
Designed to be lightweight & high
performance
Advantages in acoustic and thermal
mass
Fast production, efficient lines
Modules can be piled up to 4 floors
First projects realized in Europe
BASF Materials
Admixtures
Insulation
Waterproofing
Flooring
Sealants
Grouts
Paints
Adhesives
…
Prefabricated Modular
Construction
Off-site prefabrication
Simple on-site mounting
Long Durability
Flexibility
Reusability
PVCC - Prefabricated Prefinished Volumetric Construction
Currently, we have Installed two Cubes for BASF Temporary Offices.
Our advantage:
Designed to be lightweight & high
performance
Advantages in acoustic and thermal
mass
Fast production, efficient lines
Modules can be piled up to 4 floors
First CPC object realized: hotel in CH
Early Strength Concrete for T301 Depot Buildings
Savings & Benefits Verified by BIM Simulation
Numbers of Columns (Cast-In-Situ) & Beams (Pre-Cast)
Rail and Bus Depot
6182 Columns (too big, too heavy for
precast)
21345 Beams (precast)
Original Plan
Required Strength to install the Pre-Cast
Beams on top of the Column = 40 MPa
In general, it will take about “7 days” …
Our proposal:
2-day early strength 40 MPa
Easy re-use of formwork, early placement
of beams
Cast
-In
-Situ
Column
Pre-Cast
Beam
The BIM Project Simulation is Showing Great Time Savings of Nearly
2 Month Construction Time in Total.
Original Planning:
January 2018
Updated Planning:
January 2018
Original Planning:
November 2018
Updated Planning:
November 2018
Updated Planning:
December 2022
Original Planning:
December 2022
Updated Planning:
December 2023
Original Planning:
December 2023
Original Planning:
Completion 15th Nov 2024
Updated Planning:
Completion 20th Sep 2024
BIM Simulation shows 4 weeks time saving (customer decided to use 3-day early strength instead of standard 7-day)
Pre-Cast Installation in Progress
THANK YOU